Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2020 Nautilus, Inc.

| Bowflex, the B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. | The Bluetooth® word mark and

logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc. is under license. |

8027711.071522.B

Bowflex

Heart Rate Armband

Noises - Metallic Grinding or Scraping

Noises - Rubbing / Belt

Noises - Clicking, Clunking or Knocking

Noises - Squeaking, Squealing or Chirping

Heart Rate Issues

Max Total

16/40

™

Service Manual

Page Number

106

108

113

119

122

124

129

134

136

140

148

ORIGINAL DOCUMENT - ENGLISH VERSION ONLY

Service Manual

8027706.071522.B

Table of Contents

Summary of Contents for Bowflex Max Total 16/40

Page 1: Table Of Contents
Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2020 Nautilus, Inc. | Bowflex, the B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. | The Bluetooth® word mark and ORIGINAL DOCUMENT - ENGLISH VERSION ONLY logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc.
Page 2 Warnings on this machine. Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2019 Nautilus, Inc. | Bowflex, the B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. App Store is a service mark of Apple Inc. The Bluetooth® word ORIGINAL DOCUMENT - ENGLISH VERSION ONLY mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc.
Page 3: Safety Warning Labels And Serial Number
SAFETY WARNING LABELS AND SERIAL NUMBER Console Serial Number Label WARNING! • Injury or death is possible if caution is not used while using this machine. • Keep children and pets away. • Read and follow all warnings on this machine. •...
Page 4: Specifications
SPECIFICATIONS Maximum User Weight: 136 kg ( 300 lbs.) Total Surface Area (footprint) of equipment: 9648.8 cm (1494.5 in 166 cm Maximum Pedal Height: 48.5 cm ( 19.1 inches ) (65.7 in) Machine Weight: approx. 70.5 kg (155.4 lbs.) Power Requirements: (AC Adaptor) Input Voltage: 100-240V AC, 50-60Hz, 1.5A 125 cm Output Voltage: 12V DC, 5A 78.2 cm (49.3 in) (30.8 in)
Page 5: Moving / Leveling The Machine
Moving the Machine The machine may be moved by one or more persons depending on their physical abilities and capacities. Make sure that you and others are all physically fi t and able to move the machine safely. Grasp the Main Bar of the Static Handlebar Assembly to carefully tilt the machine toward you onto the transport rollers.
Page 6: Bluetooth ® Heart Rate Armband
Simply download the JRNY™ app to your device for access to your JRNY™ membership. 1. Download the app, named “Bowflex™ JRNY™ App “. The app is available on Google Play™ and the App Store. Note: For a complete list of supported devices, review the app on the App Store or Google Play™.
Page 7 During your workout, the Heart Rate Armband may take up to 60 seconds to connect. When connected, the Bluetooth Heart ® Rate Device icon will be displayed along with your heart rate. Note: The Armband can only be connected once to an active workout. If the On/Off LED button is pushed after being connected, the workout must be restarted.
Page 8: Maintenance
MAINTENANCE Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is required to do the necessary tasks. Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure that regular maintenance is done.
Page 9: Maintenance Parts Exploded View
Maintenance Parts Console Assembly Pedal Shroud, Right Static Handlebars Cap Foot Pad Power Inlet Console Rear Cover Foot Pad Insert Shroud, Right Fan Upper Wiring Harness/Resistance Leveler Rail Assembly Cable/Heart Rate Cable Static Handlebar Stabilizer AC Adapter Upper Shroud Transport Wheel Stabilizer Shroud, Right Shroud, Left Stabilizer Shroud, Left...
Page 10 Arm Drive Assembly Crank Arm, Left Drive Pulley, Upper Drive Belt Tensioner Fan Assembly Speed Sensor Disc Brake Fan Belt Drive Pulley, Lower Crank Arm, Right Upper Body Sensor...
Page 11: Troubleshooting - Sections
TROUBLESHOOTING Troubleshooting - Sections A. No Power / Display Will Not Turn On B. Machine Goes to Sleep While in Use C. Resistance Does Not Respond D. Machine Seized Up E. Machine Slips During Use F. Rollers and Pedals G. Noises - Main H.
Page 12: No Power / Display Will Not Turn On
No Power / Display Will Not Turn On Unplug the power adapter from both ends. Replace the Power Is the end of the BEGIN HERE Inspect the entire cord for any visible Adapter and Power adapter cord broken? wires, cuts, breaks or crimps. Inlet Plug.
Page 13: Machine Goes To Sleep While In Use
Machine Goes to Sleep While in Use Remove console from console mast. Unplug I/O cables and inspect for damage. Reconnect cables. Each Cable connector (3-pin, 4-pin, 5-pin and 12-pin) has a BEGIN HERE corresponding end connector with that many openings. Be sure to orient the cables properly (as shown), and to fully connect the cable connectors.
Page 14: Resistance Does Not Respond
Resistance Does Not Respond Remove console from console mast. Unplug I/O cables and inspect for damage. Reconnect cables. Is the red light Each Cable connector (3-pin, 4-pin, 5-pin and 12-pin) has a around the BEGIN HERE corresponding end connector with that many openings. Be Resistance Knob sure to orient the cables properly (as shown), and to fully connect lit?
Page 15: Machine Seized Up
Machine Seized Up Attempt to rotate the Crank Arms by hand. The Pedals may also be “bottomed out”. Are the Crank Arms BEGIN HERE Safely grasp the Static Handlebars and apply your weight opposite each other to the heel of the higher foot. While still grasping the Static 180*? Handlebar, lean back slightly applying more weight onto the heel.
Page 16: Machine Slips During Use
Machine Slips During Use Refer to the “Replace The Drive Belt” procedure. BEGIN HERE Follow the directions until it tells you to loosen the Drive Belt Tensioner Screw. Loosen the screw, and adjust the Drive Belt Tensioner, so that it puts more tension on the drive belt.
Page 17: Rollers And Pedals
Rollers and Pedals Is a clicking or rubbing noise being Wave Washers The noise is a normal function, caused by contact BEGIN HERE installed between and is not harmful to the between the roller Pedals and Crank machine. wheel and the roller Arms.
Page 18: Noises - Main
Noise Issues - Main What type of noise is BEGIN HERE Metallic Grinding or Rubbing Clicking, Clunking, or Squeaking, Squealing Rattling Around Inside Scraping Knocking or Chirping From Bottom of Machine Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- ing: Noise Issues -...
Page 19: Noises - Metallic Grinding Or Scraping
Noise Issues - Metallic Grinding or Scraping BEGIN HERE Remove the user right side lower round cover (4 screws). Replace the Brake Are the magnets Have the Assembly making contact with magnets broken off the the metallic brake red plastic arm? disc? Carefully operate machine and Follow the “Adjust the Brake...
Page 20: Noises - Rubbing / Belt
Noise Issues - Rubbing / Belt If unsure, remove the tall plastic rear cover. Use the machine while Which side is the noise listening carefully. BEGIN HERE coming from, the left or If the machine is not making any right side? noise, check both belts starting with the user left side.
Page 21: Noises - Clicking, Clunking Or Knocking
Noise Issues - Clicking, Clunking, or Knocking Remove the tall plastic rear cover. Tighten the 4 bolts that hold the top part of the rail BEGIN HERE NOTE: If the noise is assembly to the frame. Then coming from the fan area, tighten the 4 large bolts on the jump ahead to the FAN base assembly.
Page 22: Noises - Squeaking, Squealing Or Chirping
Noise Issues - Squeaking, Squealing or Chirping Remove the rubber end cap, Re-attach the end caps where the pedal arm connects Does the noise loosely. If they are BEGIN HERE to the crank arm, on both sides persist? pushed on too tight, they of the machine.
Page 23: Contact Heart Rate Issues
Contact Heart Rate Issues Ensure hands are centered on BEGIN HERE the Heart Rate (HR) sensors with equal pressure, and as little movement as possible without touching the metal frame. Explain that the HR may spike initially at a high rate, when ﬁrﬆ touching the contact plates.
Page 24: Bluetooth Heart Rate Issues
Bluetooth Heart Rate Issues ® Make sure the machine has the BEGIN HERE latest ﬁrmware by having an active Wiﬁ connection to the console. Make sure you are using a Bluetooth Heart Rate (HR) ® Strap. Follow the manufactur- er’s inﬆructions for use. Be sure that Bluetooth ®...
Page 25: Upper (Drive) Pulley
Upper (Drive) Pulley Begin by inspecting around the machine for any hardware that may Crank Puller: have fallen out of the machine. A Crank Puller is required to Next remove the rear shroud, and inspect the upper, or drive, pulley. A replace the drive pulley.
Page 26: Power Off And Restart The Machine
Power Off and Restart the Machine Note: W hen active, the Bowflex™ machine checks for software updates and installs them. If the machine is de-activated for a period of time, it may try to install updates when restarted. 1. To power off the machine, log the user out from the Console. 2. Unplug the power cord from the machine. To prevent unsupervised operation of the machine always disconnect the power cord from the wall outlet and machine power input.
Page 27: Replacement Procedure Skill Level
REPLACEMENT PROCEDURE SKILL LEVEL Level I : Low - very little mechanical knowledge or exposure. Level II : Intermediate - some experience with mechanical procedures Level III : Advanced - knowledgeable about mechanical procedures To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet before cleaning, maintaining or repairing this machine.
Page 28 Replacement Procedure Adjust the Brake Assembly on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023622.071522.D This document provides instructions for the adjustment of the Brake Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 29 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. When the machine has completed the adjustments to the resistance, unplug the AC Adapter from the wall outlet and machine. 3.
Page 30 6. At the maximum resistance setting, the outer edge of the Brake Magnet should line up with the outer edge of the Brake Disc. Brake Magnet Brake Disc Brake Disc Brake Magnet Brake Disc Brake Assembly...
Page 31 7. If the Brake Assembly needs to be adjusted, use a 8mm open ended Adjustment Barrel wrench to loosen the Brake Cable Securing Nut. Turn the Adjustment Bar- rel by hand until the magnet is placed correctly. 8. Carefully rotate the Brake Disc. If the Brake Disc does not rub against Brake Cable Securing Nut the Brake Magnet, skip to step 11.
Page 32 Note: The Brake Disc may appear to have a slight “wobble”. This is nor- mal and will not affect machine function. 11. Installation is the reverse procedure. 12. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled.
Page 33: Adjust The Leg Assembly Alignment
Service Procedure Adjust the Leg Assembly Alignment on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025271.071522.C This document provides instructions for the adjustment of the Leg Assembly Alignment on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / NOTICE: Max Trainer™ M9. The Rollers on the Leg Assemblies may be slightly “off”, or not fully centered onto the Rail Assembly. This procedure may assist with this condition.
Page 34 If the Rollers seem to be “off” and not fully tracked on the Rail Assembly, this procedure may assist. Roller riding slightly outward or “off” of the Rail Assembly 1. Unplug the AC Power Adapter from the machine. Rail Assembly 2. Using a #2 Phillips screwdriver, remove the 1 indicated screw from the Rear Shroud.
Page 35 4. Using a 6mm hex wrench, slightly loosen the indicated bolts that secure the Rail Assembly to the Frame Assembly. Do not fully remove the hardware. Rail Assembly 5. Using a 8mm hex wrench, slightly loosen the indicated bolts that secure the Rail Assembly to the Base Assembly. Do not fully remove the hardware. 6.
Page 36: Modify The Resistance Knob Cable
Replacement Procedure Modify the Resistance Knob Cable on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025591.071522.C This document provides instructions to modify the Resistance Knob Cable on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max Trainer™ NOTICE: Note: Only perform this procedure if directly instructed to do it by Customer Service or your local distributor.
Page 37 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Rear Console Cover from the Console Assembly. 3. Using a #2 Phillips screwdriver, remove the screws (indicated by ovals) Console Assembly from the Console Assembly. 4. Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections. Note: Do not crimp any of the Console Cables.
Page 38 Console Mast Resistance Knob Cable (5-pin) 6. Locate the Resistance Knob Cable which has the 5-pin Wire Connector coming from the Console Mast. This Cable will have Red, Yellow, Black, Green and White Wires inside of it. Resistance Knob Cable White Wire 5-pin Wire Connector 7.
Page 39 8. Dispose of the removed piece of White Wire. 9. Re-assemble the machine in the reverse order of when the parts were removed. Note: Do not cut or crimp the Cables. Each Cable connector (3-pin, 4-pin, 5-pin and 14-pin) has a cor- responding end connector with that many openings. Be sure to fully connect the cable connectors. When attaching the Console Assembly, do not fully tighten the hardware until all hardware has been hand tightened.
Page 40 Replacement Procedure Replace the Brake Assembly on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023623.071522.D This document provides instructions for the replacement of the Brake Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9 If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 41 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. Unplug the AC Adapter from the wall outlet and machine. 3. Remove the Right Stabilizer Shroud from the machine. Right Stabilizer Shroud 4. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws...
Page 42 6. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the Brake Disc. 7. Carefully remove the Brake Disc from the machine. Brake Disc Brake Assembly Brake Assembly Magnets 8. Place a piece of tape (as a marker) on the Brake Cable immediate- ly above the Brake Arm. During re-assembly, the tape will be a guide for the placement of the new Brake Arm on the Brake Cable.
Page 43 9. While applying upward pressure to the Brake Arm, remove the hardware that secures the Brake Cable to the Brake Arm with a 2.5mm hex wrench. Once loose, gradually lower the Brake Arm. Note: Be aware that the Spring will pull the Brake Arm once released.
Page 44 16. If the Brake Assembly needs to be adjusted, use a 8mm open ended wrench to loosen the Brake Cable Securing Nut. Turn the Adjustment Bar- rel by hand until the magnet is placed correctly. Adjustment Barrel 17. Carefully rotate the Brake Disc. If the Brake Disc does not rub against the Brake Magnet, skip to step 20.
Page 45 Note: The Brake Disc may appear to have a slight “wobble”. This is nor- mal and will not affect machine function. 20. Installation is the reverse procedure. 21. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled.
Page 46: Replace The Console Assembly
Replacement Procedure Replace the Console Assembly on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023484.071522.D This document provides instructions for the replacement of the Console Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 47 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Rear Console Cover from the Console Assembly. 3. Using a #2 Phillips screwdriver, remove the screws (indicated by ovals) Console Assembly from the Console Assembly. 4. Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections. Note: Do not crimp any of the Console Cables.
Page 48 7. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 49: Replace The Console Rear Panel
Replacement Procedure Replace the Console Rear Panel on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023486.071522.C This document provides instructions for the replacement of the Console Rear Panel on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 50 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Rear Console Cover from the Console Assembly. 3. Using a #2 Phillips screwdriver, remove the screws (indicated by ovals) Console Assembly from the Console Assembly. 4. Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections. Note: Do not crimp any of the Console Cables.
Page 51 6. To protect the Console display from scratches, gently place the Console Assembly face down on a towel or piece of cardboard. 7. Using a #2 Phillips screwdriver, remove the screws (indicated by arrows) from the back of the Console Assembly. 8. Carefully tilt the Console Rear Panel outward off of the Console Assembly, exposing the USB Cable connected to the Console Front Panel. Note: Do not crimp any of the Cables.
Page 52 13. Using a #2 Phillips screwdriver, attach the new Console Rear Panel to the Console Front Panel. 14. Installation is the reverse procedure. Note: Do not cut or crimp the Cables. Each Cable connector (3-pin, 4-pin, 5-pin and 12- pin) has a corresponding end connector with that many openings. Be sure to fully connect the cable connectors. 15. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled.
Page 53: Replace The Crank Arm, Left
Replacement Procedure Replace the Left Crank Arm on the ™ ™ Skill Level: III Bowflex Max Total machine and Max Total 16/40 ™ ™ ™ 8023488.071522.D This document provides instructions for the replacement of the Left Crank Arm on the Bowflex™ Max Total™ machine and Max Total™ 16/40. NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 54 Note: Your machine may not match the images provided exactly. 1. Remove the indicated Cap from the left side of the machine. 2. Using a 6mm hex wrench, remove the hardware exposed from below the Cap. 3. Lift the Foot Pedal and slide the Leg Assembly straight off the ma- Leg Assembly chine. Be sure to pull straight out, or the Leg Assembly may be difficult to remove.
Page 55 8. Using a #2 Phillips screwdriver, remove the 2 indicated screws from the Left Crank Cover. Note: The Left Crank Cover screws may have been over-tightened when installed. Try not to strip the screws when removing them. Crank Cover 9. Remove the Left Crank Cover from the machine. 10. Using a 9/16” or 14mm socket and wrench, remove the indicated nut from the Crank Assembly. 11.
Page 56 12. Carefully thread the Crank Puller into the Left Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 13. Using an adjustable wrench, turn the inner portion (the Bolt) of the Crank Puller clockwise. The Crank Arm will slide off as it is tightened. Note: Be aware that the Crank Arm will be loose and will need to be sup- ported.
Page 57: Replace The Crank Arm, Right
Replacement Procedure Replace the Right Crank Arm on the ™ ™ Skill Level: III Bowflex Max Total machine and Max Total 16/40 ™ ™ ™ 8023489.071522.D This document provides instructions for the replacement of the Right Crank Arm on the Bowflex™ Max Total™ machine and Max Total™ 16/40 NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 58 Note: Your machine may not match the images provided exactly. 1. Remove the Cap from the right side of the machine. 2. Using a 6mm hex wrench, remove the hardware exposed from below the Cap. 3. Lift the Foot Pedal and slide the Leg Assembly straight off the ma- chine. Be sure to pull straight out, or the Leg Assembly may be difficult to Leg Assembly remove.
Page 59 8. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated Upper Shroud on one side) from the Upper Shroud. 9. Using a #2 Phillips screwdriver, remove the 2 indicated screws from the Crank Cover. Note: The Crank Cover screws may have been over-tightened when installed. Try not to strip the screws when removing them. 10. Remove the Crank Cover from the machine. Crank Cover 11.
Page 60 13. Using a 9/16” or 14mm socket and wrench, remove the indicated nut from the Crank Assembly. 14. Adjust the Crank Puller until the end of the Bolt is inside the Nut (as Bolt shown). 15. Carefully thread the Crank Puller into the Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 16. Using an adjustable wrench, turn the inner portion (the Bolt) of the Crank Puller clockwise.
Page 61 17. Remove the Crank Puller from the Crank Arm. Codewheel 18. Slide the new Right Crank Arm Assembly onto the machine. Note: Be sure not to damage or break the Codewheel on the new Right Crank New Right Crank Arm Arm or the one still remaining on the machine.
Page 62: Replace The Drive Belt
Replacement Procedure Replace the Drive Belt on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023624.071522.D This document provides instructions for the replacement of the Drive Belt on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max Trainer™ NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 63 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Left Upper Handlebar 3. Using a 6mm hex wrench, remove the indicated hardware from the Up- per Handlebars and place them out of the work area. Note: Be aware that the Upper Handlebars must be supported when removing the hardware.
Page 64 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw. While pushing up on the tab, remove the Right Fan Cover from the assembly.
Page 65 11. Using a #2 Phillips screwdriver, remove the indicated screw from the Rear Shroud. 12. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 66 21. Using a #2 Phillips screwdriver, remove the screws from the Left Shroud. ( 9 screws on the Left Shroud) Remove the upper screws labeled ‘ * ’ last. Right Side Left Side 22. Using a 4mm hex wrench, remove the screw indicated by “A” from the Drive Belt Tensioner Arm. 23. Using a 8mm hex wrench, loosen the screw indicated by “B” until the Drive Belt is free enough to be removed from the Drive Pulley.
Page 67: Replace The Drive Pulley
Replacement Procedure Replace the Drive Pulley on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025270.071522.C This document provides instructions for the replacement of the Drive Pulley on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 68 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar and place it out of the work area. Note: Be aware that the Upper Handlebar must be supported when removing the hardware.
Page 69 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw. While pushing up on the tab, remove the Right Fan Cover from the assembly.
Page 70 10. Using a #2 Phillips screwdriver, remove the indicated screw from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 71 19. Using a 9/16” or 14mm socket and wrench, remove the nut from the Left Crank Assembly. Left Crank Assembly 20. Adjust the Crank Puller until the end of the Bolt is inside the Bolt Nut (as shown). 21. Carefully thread the Crank Puller into the Left Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted.
Page 72 24. Using a #2 Phillips screwdriver, remove the screws from the Left Shroud. ( 9 screws on the Left Shroud) Remove the upper screws labeled ‘ * ’ last. Right Side Left Side 25. Using a 4mm hex wrench, remove the screw indicated by “A” from the Drive Belt Tensioner Arm. 26. Using a 10mm wrench, remove the securing nuts (if present) from the back side of the Drive Pulley.
Page 73 32. Installation is the reverse procedure excluding steps with the Crank Puller. The Crank Puller is not required for re-assembly. Note: When replacing the Crank Arm be sure the Right and Left Crank Arms are oriented inline and opposite each other. The Crank Nut should be tightened to a torque value of 29-32.5 ft lbs (or 350- 390 in lbs).
Page 74: Replace The Drive Pulley Hardware
Replace the Hardware of the Drive Pulley on the Replacement Procedure ™ Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ ™ Skill Level: III 8025273.071522.C This document provides instructions for the replacement of the Hardware that attaches the Drive Pulley on the Bowflex™ Max Total™ machine / Max NOTICE: Total™ 16/40 / Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 75 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar and place it out of the work area. Left Upper Handlebar Note: Be aware that the Upper Handlebar must be supported when removing the hardware.
Page 76 7. Using a #2 Phillips screwdriver, remove the 2 indicated screws (by ovals) from the Left Crank Cover. Pivot Arm 8. Remove the Left Crank Cover from the machine. 9. Place a rag or protective material below the Left Connector Arm to protect the Shroud from potential scratches from the Connector Arm.
Page 77 13. Carefully thread the Crank Puller into the Left Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. Left Crank Assembly 14. Using a 16mm wrench, turn the inner portion (the Bolt) of the Crank Puller clockwise. The Left Crank Arm will slide off as it is tightened.
Page 78 19. Installation is the reverse procedure excluding steps with the Crank Puller. The Crank Puller is not required for re-assembly. Note: When replacing the Crank Arm be sure the Right and Left Crank Arms are oriented inline and opposite each other. The Crank Nut should be tightened to a torque value of 29-32.5 ft lbs (or 350-390 in lbs).
Page 79: Replace The Fan Assembly
China | © 2020 Nautilus, Inc. | Bowflex, the B logo, Max Total, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
Page 80 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right and Left Stabilizer Shrouds from the machine. Right Stabilizer Shroud Left Stabilizer Shroud 3. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover.
Page 81 5. Using a #2 Phillips screwdriver, remove the indicated (by oval) screw and only loosen the lowest indicated screw (arrow) from the Left Fan Cover. 6. The Left Fan Cover Assembly has a tab that needs to be pushed upward to clear the loosened screw. While pushing up on the tab, remove the Left Fan Cover Assembly.
Page 82: Replace The Fan Belt
Replacement Procedure Replace the Fan Belt on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023625.071522.D This document provides instructions for the replacement of the Fan Belt on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max Trainer™ NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 83 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 6mm hex wrench, remove the indicated hardware from the Right Upper Handlebar and place it out of the work area. Note: Be aware that the Right Upper Handlebar must be supported when removing the hardware.
Page 84 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw. While pushing up on the tab, remove the Right Fan Cover from the assembly.
Page 85 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 86 19. Using a #2 Phillips screwdriver, remove the screws from the Right Shroud ( 3 screws on the Right Shroud). Remove the upper screws labeled ‘ * ’ last. Right Side 20. Using a #2 Phillips screwdriver, remove the 3 screws (indicated by arrows) from the Brake Disc. 21. Carefully remove the Brake Disc from the machine exposing the lower Fan Belt. Brake Disc Fan Belt...
Page 87 22. Turn the Fan Pulley while forcing the Fan Belt to the outside. Belt will come off of the Fan Pulley. Keep fingers out of any pinch opportunities when removing the Fan Belt. 23. Loop the new Fan Belt around the lower Pulley and start it on the face of the Fan Pulley.
Page 88 26. Grasp the Fan Pulley where the Fan Belt is engaged on it, and forcibly rotate the Fan Pulley until the Fan Belt is fully engaged. Keep fingers out of any pinch opportunities when rotating the Fan Pulley. 27. Cut the Zip-Tie without damaging the new Fan Belt or Fan Pulley. 28.
Page 89: Replace The Fan Pulley
Replacement Procedure Replace the Fan Pulley on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025275.071522.C This document provides instructions for the replacement of the Fan Pulley on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max Trainer™ NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 90 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar and place it out of the work area. Note: Be aware that the Right Upper Handlebar must be supported when removing the hardware.
Page 91 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw. While pushing up on the tab, remove the Right Fan Cover from the assembly.
Page 92 10. Using a #2 Phillips screwdriver, remove the indicated screw from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 93 19. Using a 9/16” or 14mm socket and wrench, remove the nut from the Right Crank Assembly. 20. Adjust the Crank Puller until the end of the Bolt is inside the Nut (as Bolt shown). 21. Carefully thread the Crank Puller into the Right Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 22.
Page 94 24. Using a #2 Phillips screwdriver, remove the screws from the Right Shroud ( 3 screws on the Right Shroud). Remove the upper screws labeled ‘ * ’ last. Right Side 25. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the Brake Disc. 26. Carefully remove the Brake Disc from the machine exposing the lower Fan Belt. Brake Disc Fan Belt Brake...
Page 95 27. Turn the Fan Pulley while forcing the Fan Belt to the outside. Belt will come off of the Fan Pulley. Fan Pulley Keep fingers out of any pinch opportunities when removing the Fan Belt. 28. Using a 10mm wrench, remove the securing nuts (if present) from the back side of the Drive Pulley.
Page 96 33. Secure the Fan Belt to the Fan Pulley with a Heavy Duty Zip-Tie. Be sure to attach the Zip-Tie where the Fan Belt is fully in contact with the Fan Pulley. 34. Grasp the Fan Pulley where the Fan Belt is engaged on it, and forcibly Heavy rotate the Fan Pulley until the Fan Belt is fully engaged. Duty Zip-Tie Keep fingers out of any pinch opportunities when rotating the...
Page 97: Replace The Frame Assembly
™ ™ 8025276.071522.C This document provides instructions for the replacement of the Frame Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / NOTICE: Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 98 Note: Replace any damaged hardware with the new hardware provided with this kit for re-assembly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right and Left Stabilizer Shrouds from the machine. Right Stabilizer Shroud Left Stabilizer Shroud 3.
Page 99 9. Using a 5mm hex wrench, remove the screws (indicated by ovals) from the Static Handlebar Assembly. Static Handlebar Assembly 10. Carefully lift the Static Handlebar Assembly and expose the Cable Connections. Note: Do not crimp any of the Console Cables. This step may require two people.
Page 100 13. Using a 6mm hex wrench, remove the indicated hardware from the Rail Assembly. Be prepared to support the weight of the Rail Assembly. Rail Assembly 14. Using new Hardware Items C, B, and A, attach the Rail Assembly to the new Frame Assembly. Some components of the machine can be heavy or awkward. Use a second person when doing the assembly steps involving these parts.
Page 101 A second person is recommended to stabilize the Frame Assembly. 15. Using an 8mm hex wrench, remove the indicated hardware from the old Frame Assembly. Be prepared to support the Frame Assembly before removing the hardware. The Frame Assembly may be awkward when released from the Stabilizer Assembly.
Page 102 19. Fully tighten the hardware that attaches the Rail Assembly to the new Frame Assembly (from Step 13), and then the hardware just installed to the Stabilizer Assembly. 20. Using a #2 Phillips screwdriver, attach the Upper Shroud to the Frame Assembly. 21. Attach the Rear Shroud and Caps to the Frame Assembly NOTICE: Place the inside hook of the Rear Shroud on the Frame Assem- bly and then pivot it up into place.
Page 103 22. Attach Leg Assemblies to Frame Assembly Be aware that the Legs are connected and when either of these parts move the other does as well.
Page 104 23. Connect the Static Handlebar Assembly to the Frame Assembly Note: When attaching the Static Handlebar Assembly, do not fully tighten the hardware until all hardware has been hand tight- ened. Do not crimp any of the Console Cables.
Page 105 24. Attach the Upper Handlebars to Frame Assembly Be aware that the Pedals and the Upper Handlebars are connected and when either of these parts move the other does as well. Some components of the machine can be heavy or awkward. Use a second person when doing the assembly steps involving these parts.
Page 106: Bowflex ™ Max Total
Replacement Procedure Replace the Handlebar Pivot Assembly on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025277.071522.C This document provides instructions for the replacement of the Handlebar Pivot Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 NOTICE: / Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 107 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar and place it out of the work area. Left Upper Handlebar Note: Be aware that the Upper Handlebar must be supported when removing the hardware.
Page 108: Replace The Mid Mast Cables
Replacement Procedure Replace the Mid Mast Cables on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023493.071522.D This document provides instructions for the replacement of the Cables that are the Mid Mast Cables on the Bowflex™ Max Total™ machine / Max NOTICE: Total™ 16/40 / Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 109 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Rear Console Cover from the Console Assembly. 3. Using a #2 Phillips screwdriver, remove the screws (indicated by ovals) Console Assembly from the Console Assembly. 4. Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections. Note: Do not crimp any of the Console Cables.
Page 110 6. Using a 5mm hex wrench, remove the four screws (indicated by oval) from the Static Handlebar Assembly. Static Handlebar Assembly 7. Carefully lift the Static Handlebar Assembly and expose the Cable Connec- tions. Note: Do not crimp any of the Console Cables. This step may require two people.
Page 111 11. To replace the Upper Body Sensor or the Input/Output (I/O) Cables, attach the ends of the new Cable to the old Cable using a piece of wire or string. Note: Only replace one Cable at a time because of the limited space. 12.
Page 112 18. Using a piece of wire or string, attach the new Resistance Cable to the end of old Resistance Cable where it connected to the Resistance Knob. Be sure to con- nect the Cables so that when the new Resistance Cable is routed the connectors will match the old Resistance Cable connectors 19.
Page 113: Replace The Pcba Board
Replacement Procedure Replace the PCBA Board Assembly on the ™ ™ Skill Level: II Bowflex Max Total 16/40 and Max Trainer ™ ™ ™ 8029817.071522.A This document provides instructions for the replacement of the PCBA Board Assembly on the Bowflex™ Max Total™ 16/40 and Max Trainer™ M9 NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 114 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Left Upper Handlebar 2. Using a 6mm hex wrench, remove the indicated hardware from the Right and Left Upper Handlebar and place them out of the work area. Note: Be aware that the Right and Left Upper Handlebar must be sup- Right Upper ported when removing the hardware.
Page 115 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
Page 116 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 117 Right Side Left Side 19. The PCBA Board Assembly is located above the Servo Motor. After noting how the cables connect to the PCBA Board Assem- bly, disconnect the cables from it. Note: Be sure not to crimp or cut any of the cables. PCBA Board Assembly Servo Motor...
Page 118 20. Using a short #2 Phillips screwdriver, remove the 4 screws (indicated with red ovals) that secure the PCBA Board Assembly to the Frame and remove it. Note: Be sure to remove the screws from the PCBA Board As- sembly and not the PCBA Board. PCBA Board Assembly PCBA Board 21. Using a short #2 Phillips screwdriver, attach the new PCBA Board Assembly to the Frame and connect the cables.
Page 119: Replace The Power Inlet
Replacement Procedure Replace the Power Inlet on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025278.071522.C This document provides instructions for the replacement of the Power Inlet on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 120 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. Right Stabilizer Shroud 3. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 4. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
Page 121 Power Cable 5. Disconnect the Power Inlet from the Power Connector behind the Brake Disc. Brake Disc Power Connector 6. Using a 15mm open end wrench, remove the Securing Ring from the outside of the Right Fan Cover. 7. Remove the Power Inlet from the inside of the Right Fan Cover. 8.
Page 122: Replace The Roller Wheel Assembly
Replacement Procedure Replace the Roller Wheel Assembly on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025279.071522.C This document provides instructions for the replacement of the Roller Wheel Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / NOTICE: Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 123 1. Unplug the AC Power Adapter from the machine. 2. Using two 6mm hex wrenches, remove the hardware (indicated by arrows) from the Roller Wheel Assembly. Pedal Arm In order to avoid possible serious injury when removing the Roller Wheel Assembly, be careful to avoid fingers or hands being caught or pinched.
Page 124: Replace The Servo Motor
Replacement Procedure Replace the Servo Motor on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023626.071522.D This document provides instructions for the replacement of the Servo Motor on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 125 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. Unplug the AC Adapter from the wall outlet and machine. 3. Remove the Right Stabilizer Shroud from the machine (if equipped). Right Stabilizer Shroud 4. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws...
Page 126 6. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the Brake Disc. 7. Carefully remove the Brake Disc from the machine. Brake Disc Fan Belt Brake Magnets 8. Using an 8mm open ended wrench, loosen the Brake Cable Adjustment Securing Nut until the Brake Cable can be released from the Servo Barrel Motor Arm.
Page 127 14. At the maximum resistance setting, the outer edge of the Brake Mag- net should line up with the outer edge of the Brake Disc. Brake Magnet Brake Disc Adjustment Barrel 15. If the Brake Assembly needs to be adjusted, use a 8mm open ended wrench to loosen the Brake Cable Securing Nut. Turn the Adjustment Barrel by hand until the magnet is placed correctly.
Page 128 17. The Brake Magnets should be aligned with the Brake Disc and centered around the Brake Disc. If they are not aligned and centered, then the Magnets are adding drag. Brake Disc 18. If the Brake Assembly only needs to be slightly adjusted, loosen the front screw (indicated by double-tailed arrow) that secures the Brake Assembly using a 10mm hex wrench.
Page 129: Replace The Shrouds
Replacement Procedure Replace the Shrouds on the ™ ™ Skill Level: II Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023627.071522.D This document provides instructions for the replacement of the Shrouds on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max Trainer™ NOTICE: If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 130 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Left Upper Handlebar 2. Using a 6mm hex wrench, remove the indicated hardware from the Right and Left Upper Handlebar and place them out of the work area. Note: Be aware that the Right and Left Upper Handlebar must be sup- Right Upper ported when removing the hardware.
Page 131 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
Page 132 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 133 Right Side Left Side 19. Using a #2 Phillips screwdriver, remove the screws from the Right and Left Shrouds. ( 3 screws on the Right Shroud, 9 on the Left Shroud) Remove the upper screws labeled ‘ * ’ last. 20. Carefully remove the Shrouds from the machine. If replacing the Right Fan Cover: A. Using a 14mm open face wrench, remove the Securing Ring from the outside of the Right Fan Cover.
Page 134: Replace The Speed Sensor Assembly
Replacement Procedure Replace the Speed Sensor on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025280.071522.C This document provides instructions for the replacement of the Speed Sensor on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9 If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 135 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. Right Stabilizer Shroud 3. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 4. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
Page 136: Replace The Static Handlebar Assembly
Note: Left Fan Cover is hidden for image clarity. 5. Using a #2 Phillips screwdriver, remove the screw that attaches Fan Disc the Speed Sensor. Note: To assist with re-assembly, note that the new Speed Sensor must be 3mm (1/8”) from the Speed Sensor Magnet on the Fan Disc. Speed Sensor Magnet Speed...
Page 137 Replacement Procedure Replace the Static Handlebar Assembly on the ™ ™ Skill Level: I Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8023487.071522.D This document provides instructions for the replacement of the Static Handlebar Assembly on the Bowflex™ Max Total™ machine / Max Total™ 16/40 NOTICE: / Max Trainer™ M9. If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 138 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Rear Console Cover from the Console Assembly. 3. Using a #2 Phillips screwdriver, remove the screws (indicated by ovals) Console Assembly from the Console Assembly. 4. Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections. Note: Do not crimp any of the Console Cables.
Page 139 6. Using a 5mm hex wrench, remove the four screws (indicated by oval) from the Static Handlebar Assembly. Static Handlebar Assembly 7. Carefully lift the Static Handlebar Assembly and expose the Cable Connec- tions. Note: Do not crimp any of the Console Cables. This step may require two people.
Page 140: Replace The Upper Body Sensor Assembly
Replacement Procedure Replace the Upper Body Sensor Assembly on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 ™ ™ ™ 8025281.071522.C This document provides instructions for the replacement of the Upper Body Sensor Assembly on the Bowflex™ Max Total™ machine / Max Total™ NOTICE: 16/40 If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 141 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Left Upper Handlebar 2. Using a 6mm hex wrench, remove the indicated hardware from the Right and Left Upper Handlebar. Note: Be aware that the Right and Left Upper Handlebar must be sup- Right Upper ported when removing the hardware.
Page 142 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
Page 143 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
Page 144 17. Using a #2 Phillips screwdriver, remove the indicated screws from the Right shroud ( 3 screws on the Right Shroud). Remove the upper screws labeled ‘ * ’ last. 18. Carefully remove the Right Shroud from the machine. Right Side 19. Using a #2 Phillips screwdriver, remove the screws (indicated by ar- rows) that secure the Upper Body Sensor. Allow the Upper Body Sensor to hang on the Cable, away from the Right Crank Arm.
Page 145 20. Using a 9/16” or 14mm socket and wrench, remove the indicated nut from the Crank Assembly. 21. Adjust the Crank Puller until the end of the Bolt is inside the Nut (as shown). Bolt 22. Carefully thread the Crank Puller into the Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 23.
Page 146 25. Using a 2mm hex wrench, loosen the two screws (indicated by ar- rows) that secure the Inner Codewheel Assembly. Upper Body Sensor 26. After noting the orientation of the Inner Codewheel Assembly on the axle, remove the old Inner Codewheel Assembly. Replace with the new Inner Codewheel Assembly so it is in the same orientation.
Page 147 31. Installation is the reverse procedure excluding steps with the Crank Puller. The Crank Puller is not required for re-assembly. Note: When replacing the Right Crank Arm, be sure the Right and Left Crank Arms are oriented inline and opposite each other. The Crank Nut should be tightened to a torque value of 29-32.5 ft lbs (or 350-390 in lbs).
Page 148: Replace The Wiring Harness, Main
Replacement Procedure Replace the Main Wiring Harness on the ™ ™ Skill Level: III Bowflex Max Total machine / Max Total 16/40 / Max Trainer ™ ™ ™ ™ 8025282.071522.C This document provides instructions for the replacement of the Main Wiring Harness on the Bowflex™ Max Total™ machine / Max Total™ 16/40 / Max NOTICE: Trainer™ M9 If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To find your local distributor, go to: www.nautilusinternational.com...
Page 149 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. Right Stabilizer Shroud 3. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover.
Page 150 Note: Shrouds are removed for clarity. 5. Note how the I/O Cable routes through the machine. I/O Cable Route 6. Cut the two lower Zip-Ties without damaging the Cables. 7. Disconnect all the Cables that connect to the lower part of the old I/O Cable.
Page 151 10. Using a 5mm hex wrench, remove the screws (indicated by ovals) from the Static Handlebar Assembly. Static Handlebar Assembly 11. Carefully lift the Console and Static Handlebar Assembly and expose the Cable Connections. Note: Do not crimp any of the Cables. This step may require two people. 12.

Bowflex Max Total 16/40 Service Manual

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