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Bowflex Max Trainer SE Service Manual

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Table of Contents

Section Code
Section
1
1
1
1
1
1
1
1
1
1
1
Bluetooth
1
1
1
1
1
Part Replacement
2
Replace the Cable, DC to Hub
3
(Servo, Resistance and Speed)
4
5
6
7
8
9
10
11
BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.
com | outside U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex, JRNY, and the BowFlex logo are trademarks owned or licensed by
BowFlex Inc., registered or otherwise protected by common law in the United States and other nations. |
SION ONLY
8031181.101523.A
™
Service Manual
®
SE/SEi machines
™
Page Number
2
3
4
5
6
6
6
7
7
7
7
9
11
12
13
17
18
32
47
50
56
67
82
88
93
97
ORIGINAL DOCUMENT - ENGLISH VER-
1
Service Manual
8031180.101523.A

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Summary of Contents for Bowflex Max Trainer SE

  • Page 1: Table Of Contents

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex. com | outside U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex, JRNY, and the BowFlex logo are trademarks owned or licensed by ORIGINAL DOCUMENT - ENGLISH VER- BowFlex Inc., registered or otherwise protected by common law in the United States and other nations.

  • Page 2: Bowflex Max Trainer

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | outside U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex, JRNY, and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., ORIGINAL DOCUMENT - ENGLISH VERSION ONLY registered or otherwise protected by common law in the United States and other nations.

  • Page 3: Safety Warning Labels And Serial Number

    Important Safety Instructions Serial Number Label WARNING! Read, understand and obey all warnings on this machine. Keep children and pets away. Not intended for use by anyone under 14 years of age. Refer to the Owner’s Manual for additional warnings and safety information.

  • Page 4: Specifications

    The rubber machine mat provides a non-slip, rubber surface which limits static discharge and reduces the possibility of display errors. If possible, put your BowFlex™ Max Trainer™ Machine Mat in your selected workout area before you begin assembly.

  • Page 5: Moving / Leveling The Machine

    Adjustments 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 fit and able to move the machine safely. 1. Grasp the back of the Stabilizer to carefully tilt the machine forward onto the transport rollers.

  • Page 6: Demonstration Mode

    Demo Mode, Changing Units, and Muting the Console Demonstration Mode During Demonstration Mode, the Console will cycle through messages prompting to connect to the JRNY™ app, and display sample workout information. The machine ships with Demonstration Mode inactive. To activate the Demonstration Mode: With the machine activated, push and hold the hidden button beside the JRNY QR code on the Console for 3 seconds.

  • Page 7: Connect Your Device To Jrny App

    If you have a JRNY™ membership*, it can be accessed through your display the Bluetooth® Heart Rate Detected icon. device when synced to the console of this BowFlex™ machine. With If you have a pacemaker or other implanted electronic that JRNY™ membership, you receive guided workouts adapted device, consult your doctor before using a Bluetooth®...
  • Page 8 Heart Rate The most efficient procedure to burn fat during exercise is to start FAT-BURNING TARGET HEART RATE at a slow pace and gradually increase your intensity until your heart rate reaches between 60 – 85% of your maximum heart rate. Continue at that pace, keeping your heart rate in that target zone for over 20 minutes.

  • Page 9: Console Setup Mode

    Console Setup Mode Console Setup Mode – System Menu The Console Setup Mode allows you to set units of measurement to either Imperial or metric, adjust screen brightness, view maintenance statistics (such as Run Time hours and software version – for service technician use only), or reset the Console. 1.
  • Page 10 Console Setup Mode 27. Push the Enter/Start button to continue to the next menu option. 28. The Console display shows the Reset Console prompt. The default option is NO. Push the Pause/Stop button to exit without starting Reset. Note: The YES option will reset the System Units, Screen Brightness and Demo Mode to default settings. It does not reset the Run Time Hours.

  • Page 11: Maintenance

    When the machine is used in a Studio/Institutional environment, we recommend that the Pedals be replaced every year to maintain maximum user safety and performance. Only use replacement Pedals available from BowFlex. Other brands of Pedals may not be designed for this product, and can cause danger to users and bystanders, and will void the warranty.

  • Page 12: Maintenance Parts Exploded View

    Maintenance Dynamic Handlebar, Left Pedal Platform Speed Sensor Magnet Top Shroud Pedal Radial Disc Ring Shroud Brake Assembly Console Assembly Roller Disc Brake Media Rack Rail Assembly Stationary Magnet Carriage Handlebars Shroud, Rear Drive Belt, Lower Dynamic Handlebar, Right Stabilizer Drive Pulley, Lower Transport Wheel Crank Arm...

  • Page 13: Troubleshooting

    Troubleshooting Condition/Problem Things to Check Solution No display/unit will not Console in sleep mode Push any Console button or move pedals to wake up Console. turn on AC Adapter Check for visual sign that AC Adapter is cracked or otherwise damaged.
  • Page 14 Troubleshooting Condition/Problem Things to Check Solution No speed/RPM reading Check data cable integrity Cable sheath should be intact and undamaged. if partially or fully cut, replace the cable. Check data cable Be sure cable is connected securely. connections Check Speed Sensor (requires Speed sensor should be aligned with magnet and connected to shroud removal) data cable.
  • Page 15 Troubleshooting Condition/Problem Things to Check Solution Console continuously Console is in demonstration Press and hold the hidden button beside the JRNY QR code on the displays sample workout mode Console for 3 seconds. The hidden button is centered in the text to information, with “connect the left of the QR code.
  • Page 16 Troubleshooting Condition/Problem Things to Check Solution Squeak noise Roller wheels Clean the rails and surface of the rollers with a damp cloth. Apply silicone lubricant to a dry cloth and wipe the rails to eliminate roller noise. Clunk or thump sound per Hardware Tightly secure all hardware on the Pedals, Legs and Handlebar Arms pedal rotation/foot pedals...

  • Page 17: 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 When disposing of old parts, obey the applicable local and provincial requirements.
  • Page 18 BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 19 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 20 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly. Remove the Leg Assembly from the Frame Assembly. 5. Using a Short #2 Phillips screwdriver, remove the 5 screws (indicated by ovals) that secure the Decorative Shroud to the Structural Shroud.
  • Page 21 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 22 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 23 8. Remove the Right Decorative Shroud. 9. Repeat the last 6 Steps to remove the Left Decorative Shroud. 10. Remove the Console Cable from the Console, and undo the Cable Restraining Strap. Console NOTICE: Do not cut or pinch the cable. Console Restraining Strap...
  • Page 24 11. Remove the 3 Plugs (2 indicated here from the Handlebar Assembly. Handlebar Assembly 12. Using a 5mm hex wrench, remove the hardware that was under the Plugs from the Handlebar Assembly. 13. Slide the Handlebar Assembly, with the Console and Media Rack, from the Frame Assembly.
  • Page 25 16. Remove the Crank Cover Insert to expose the Crank Cover hardware. Crank Cover Insert Crank Cover 17. Using a #2 Phillips screwdriver, remove the hardware (indicated by ovals) from the Crank Cover. Remove the Crank Cover and place outside of the work area.
  • Page 26 Right Left Structural Structural Shroud Shroud Number of screws: Left Shroud = 12 Right Shroud = 6 18. Using a #2 Phillips screwdriver, remove the indicated hardware from the Structural Shrouds. Note: To assist with re-assembly, the key to the type of screw and where it is used is provided.
  • Page 27 Printed Circuit Printed Circuit Board Assembly Board Assembly (PCBA) (PCBA) 19. Remove the DC Power to PCBA Cable from the PCBA. Note: Be sure to note how the cable attaches for re- assembly. If the Cable Connector is secured by a small amount of glue, use a pair of small nose pliers to grab Printed Circuit and remove the glue.
  • Page 28 ELECTRICAL WIRING ROUTE DETAIL - DC Power to PCBA Cable CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A...
  • Page 29 20. The DC Power to PCBA Cable routes to the Power Inlet. Using a 15mm open faced wrench, remove the securing washer from the Power Inlet. NOTICE: Do not cut or pinch the cables. 21. Attach the new DC Power to PCBA Cable to the Frame.
  • Page 30 24. Re-install all remaining parts that were removed in Right reverse order. Console Structural Cable Shroud When replacing the Structural Shrouds, be sure that the Main Mast Cable is routed through the opening between the Structural Shrouds, and that the Grommet is outside of the Shrouds. Once they have been attached, slide the Grommet down into the Grommet opening between the Structural Shrouds.
  • Page 31 When re-installing the Rear Shroud to the Frame Assembly, place the upper part of the Rear Shroud onto the Frame Assembly. Then pivot it downward into place. There are 6 tabs that will secure it. 25. 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 32: Replace The Cable, Split

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 33 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 34 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly. Remove the Leg Assembly from the Frame Assembly. 5. Using a Short #2 Phillips screwdriver, remove the 5 screws (indicated by ovals) that secure the Decorative Shroud to the Structural Shroud.
  • Page 35 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 36 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 37 8. Remove the Right Decorative Shroud. 9. Repeat the last 6 Steps to remove the Left Decorative Shroud. 10. Remove the Console Cable from the Console, and undo the Cable Restraining Strap. Console NOTICE: Do not cut or pinch the cable. Console Restraining Strap...
  • Page 38 11. Remove the 3 Plugs (2 indicated here from the Handlebar Assembly. Handlebar Assembly 12. Using a 5mm hex wrench, remove the hardware that was under the Plugs from the Handlebar Assembly. 13. Slide the Handlebar Assembly, with the Console and Media Rack, from the Frame Assembly.
  • Page 39 16. Remove the Crank Cover Insert to expose the Crank Cover hardware. Crank Cover Insert Crank Cover 17. Using a #2 Phillips screwdriver, remove the hardware (indicated by ovals) from the Crank Cover. Remove the Crank Cover and place outside of the work area.
  • Page 40 Right Left Structural Structural Shroud Shroud Number of screws: Left Shroud = 12 Right Shroud = 6 18. Using a #2 Phillips screwdriver, remove the indicated hardware from the Structural Shrouds. Note: To assist with re-assembly, the key to the type of screw and where it is used is provided.
  • Page 41 Printed Circuit Printed Circuit Board Assembly Board Assembly (PCBA) (PCBA) 19. Remove the Split Cable from the PCBA. Note: Be sure to note where all cables attach for re- assembly. If the Cable Connector is secured by a small amount of glue, use a pair of small nose pliers to grab and remove the glue.
  • Page 42 ELECTRICAL WIRING ROUTE DETAIL - Split Cable Assembly CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A 2 WIRE...
  • Page 43 21. Disconnect the Split Cable - Resistance PCB Arm from the Resistance PCB. 22. Remove the old Split Cable - Resistance PCB Arm from the two securing clips on the Frame, and route the new Split Cable - Resistance PCB Arm to the Resistance PCB.
  • Page 44 24. Disconnect the Cable Connector between the Split Cable- Servo Arm and the Servo Motor. Split Cable - Servo Arm NOTICE: Do not cut or pinch the cables. Cable Connector 25. Route the new Split Cable - Servo Arm to the Cable Connector to the Servo Motor, and connect them.
  • Page 45 30. Re-install all remaining parts that were removed in Right reverse order. Console Structural Cable Shroud When replacing the Structural Shrouds, be sure that the Main Mast Cable is routed through the opening between the Structural Shrouds, and that the Grommet is outside of the Shrouds. Once they have been attached, slide the Grommet down into the Grommet opening between the Structural Shrouds.
  • Page 46 When re-installing the Rear Shroud to the Frame Assembly, place the upper part of the Rear Shroud onto the Frame Assembly. Then pivot it downward into place. There are 6 tabs that will secure it. 31. 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 47: Replace The Console Assembly

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 48 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Media Rack 2. Using a 4mm hex wrench, remove the hardware (indicated by ovals) from the Media Rack. 3. Slide the Media Rack from the Handlebar Assembly. 4.
  • Page 49 6. Slide the new Console onto the Handlebar Assembly until the Securing Tab is engaged. NOTICE: Do not cut or pinch the cable. 7. The Cable Connector has a tab that can only be connected to the Console in one orientation. Connect the Console Cable to the new Console in the proper orientation.

  • Page 50: Replace The Decorative Shrouds

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 51 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 52 Note: The following images show the removal of the Right Decorative Shroud. The procedure is the same for the Left Decorative Shroud. 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly.
  • Page 53 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 54 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 55 8. Remove the old Decorative Shroud. To attach the new Decorative Shroud, reverse the order of removal. 9. Re-install all remaining parts that were removed in reverse order. When re-installing the Rear Shroud to the Frame Assembly, place the upper part of the Rear Shroud onto the Frame Assembly.

  • Page 56: Replace The Main Mast Cable

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 57 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 58 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly. Remove the Leg Assembly from the Frame Assembly. 5. Using a Short #2 Phillips screwdriver, remove the 5 screws (indicated by ovals) that secure the Decorative Shroud to the Structural Shroud.
  • Page 59 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 60 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 61 8. Remove the Crank Cover Insert to expose the Crank Cover hardware. Crank Cover Insert Crank Cover 9. Using a #2 Phillips screwdriver, remove the hardware (indicated by ovals) from the Crank Cover. Remove the Crank Cover and place outside of the work area.
  • Page 62 10. Remove the Console Cable from the Console, and undo the Cable Restraining Strap. Console NOTICE: Do not cut or pinch the cable. Console Restraining Strap Console Cable Console Connector Console Cable...
  • Page 63 11. Using a #2 Phillips screwdriver, remove the indicated hardware from the Structural Shrouds. Note: To assist with re-assembly, the key to the type of screw and where it is used is provided. 12. Flex the Left Structural Shroud outward just enough to release the old Main Mast Cable from Main Mast the opening, and place the new Main Mast Cable...
  • Page 64 13. The Main Cable routes downward along the Frame, secured by three Zip-Ties, where it connects to the Printed Circuit Board Assembly (PCBA). Zip-Tie Route the new Main Cable along the old Cable through the Frame, being sure not to cut or pinch the Cable.
  • Page 65 16. Re-install all remaining parts that were removed in reverse order. Main Mast Cable Slide the Grommet down into the opening between the Structural Shrouds. Note: Do not cut or pinch the Console Cable. Grommet Left Structural Shroud When re-connecting the Cable to the Console, the Cable Connector has a tab that can only be connected to the Console in one orientation.
  • Page 66 When re-installing the Rear Shroud to the Frame Assembly, place the upper part of the Rear Shroud onto the Frame Assembly. Then pivot it downward into place. There are 6 tabs that will secure it. 17. 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 67: Replace The Pcba And Mount

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 68 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 69 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly. Remove the Leg Assembly from the Frame Assembly. 5. Using a Short #2 Phillips screwdriver, remove the 5 screws (indicated by ovals) that secure the Decorative Shroud to the Structural Shroud.
  • Page 70 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 71 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 72 8. Remove the Right Decorative Shroud. 9. Repeat the last 6 Steps to remove the Left Decorative Shroud. 10. Remove the Console Cable from the Console, and undo the Cable Restraining Strap. Console NOTICE: Do not cut or pinch the cable. Console Restraining Strap...
  • Page 73 11. Remove the 3 Plugs (2 indicated here from the Handlebar Assembly. Handlebar Assembly 12. Using a 5mm hex wrench, remove the hardware that was under the Plugs from the Handlebar Assembly. 13. Slide the Handlebar Assembly, with the Console and Media Rack, from the Frame Assembly.
  • Page 74 16. Remove the Crank Cover Insert to expose the Crank Cover hardware. Crank Cover Insert Crank Cover 17. Using a #2 Phillips screwdriver, remove the hardware (indicated by ovals) from the Crank Cover. Remove the Crank Cover and place outside of the work area.
  • Page 75 Right Left Structural Structural Shroud Shroud Number of screws: Left Shroud = 12 Right Shroud = 6 18. Using a #2 Phillips screwdriver, remove the indicated hardware from the Structural Shrouds. Note: To assist with re-assembly, the key to the type of screw and where it is used is provided.
  • Page 76 Printed Circuit Printed Circuit Board Assembly Board Assembly (PCBA) (PCBA) 19. Remove the Cables from the PCBA. Main Mast Cable Note: Be sure to note where all cables attach for re- assembly. If the Cable Connectors are secured by a small amount of glue, use a pair of small nose pliers to grab and remove the glue.
  • Page 77 ELECTRICAL WIRING ROUTE DETAIL - PCBA CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A 2 WIRE HA-2Y...
  • Page 78 23. Re-install all remaining parts that were removed in Right reverse order. Console Structural Cable Shroud When replacing the Structural Shrouds, be sure that the Main Mast Cable is routed through the opening between the Structural Shrouds, and that the Grommet is outside of the Shrouds. Once they have been attached, slide the Grommet down into Grommet the opening between the Structural Shrouds.
  • Page 79 When re-installing the Rear Shroud to the Frame Assembly, place the upper part of the Rear Shroud onto the Frame Assembly. Then pivot it downward into place. There are 6 tabs that will secure it. Calibrating the Resistance: Note: During the calibration process no one should be pedaling the machine. Standing on the pedals is okay dur- ing the calibration process.
  • Page 80 26. The Console display shows the Hardware Variant & Console Firmware Version. Push and hold for 3 seconds the Pause/Stop button to go to the Manufacturing Test Menu. 27. The Console display shows the START TEST SUITE menu option. Push the Down () button 2 times to advance to the AUTO CAL_RESISTANCE (Automated Calibrate Resistance) option.
  • Page 81 30. The console display will change to “CNFRM C4095 AGC xx”. 31. Push the Enter/Start button to confirm and save the resistance calibration values. The display will momentarily change to “SAVING CAL”, then display “AUTO CAL_RESISTANCE”. Calibration is complete. Note: Pushing the Pause/Stop button will abort the calibration process, with the new calibration values not being saved, and the last saved calibration values being restored.

  • Page 82: Replace The Resistance Pcb

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 83 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 84 ELECTRICAL WIRING ROUTE DETAIL - Resistance PCB CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A 2 WIRE...
  • Page 85 3. Disconnect the Cable Connector from the Resistance PCB. Note: Be sure to note how the cable attaches for re- assembly. If the Cable Connectors are secured by a small amount of glue, use a pair of small nose pliers to grab and remove the glue.
  • Page 86 Calibrating the Resistance: Note: During the calibration process no one should be pedaling the machine. Standing on the pedals is okay dur- ing the calibration process. 8. Push the Enter/Start button and hold for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode (System Menu).
  • Page 87 12. The Console display shows the AUTOCAL_ RESISTANCE (Automated Calibrate Resistance) option. Push the Enter/Start button. Note: If the Pause/Stop button is pushed part way through the calibration (exit), the new calibration is not saved. 13. The console will display changing text and numbers for approximately 30 seconds as the servo motor moves.

  • Page 88: Replace The Servo Motor

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 89 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 90 Note: All Shrouds have been removed for clarity. 3. Using an 8mm open ended wrench, loosen the Servo Brake Cable Securing Nut until the Brake Cable can Motor be released from the Servo Motor Arm. Brake Cable Securing Nut Brake Cable Servo Motor 4.
  • Page 91 7. 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 8. If the Brake Assembly needs to be adjusted, use a 8mm open ended wrench to loosen the Brake Cable Securing Nut.
  • Page 92 ELECTRICAL WIRING ROUTE DETAIL - Servo Motor CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A 2 WIRE...

  • Page 93: Replace The Speed Sensor

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 94 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 95 3. Using a #2 Phillips screwdriver, remove the 1 screw (indicated by oval) that attaches the Speed Sensor Mount to the Frame Assembly. 4. Remove the Speed Sensor Assembly from the old Speed Sensor Mount. Speed Sensor NOTICE: Do not cut or pinch the cables. Mount 5.
  • Page 96 ELECTRICAL WIRING ROUTE DETAIL - Speed Sensor CONSOLE ASSEMBLY USB-C RECPT USB-C PLUG SUB ASSY, HANDLEBARS SUB ASSY, ENGINE USB-C PLUG USB-C RECPT VH-2Y 12VDC 3 A 2.0MM PIN 2 WIRE VH-2A C2501-H05 PCBA, BASE HUB (SM-5A) SUB ASSY, SERVO PHD-2X4Y PHD-2X4A 2 WIRE...

  • Page 97: Replace The Structural Shrouds

    BowFlex Inc., www.bowflex.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, cs@bowflex.com | out- side U.S. global.bowflex.com | Printed in China | © 2023 BowFlex Inc. | BowFlex and the BowFlex logo are trademarks owned or licensed by BowFlex Inc., registered or ORIGINAL DOCUMENT - ENGLISH VERSION ONLY otherwise protected by common law in the United States and other nations.
  • Page 98 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. Rear Shroud 2. Grasping the Rear Shroud with the side openings, abruptly pull out and upward to release the Rear Shroud from the Frame Assembly.
  • Page 99 3. Remove the Cap from the hardware that secures the Leg Assembly. 4. Using a 14mm open faced wrench, remove the hardware that attaches the Leg Assembly. Remove the Leg Assembly from the Frame Assembly. 5. Using a Short #2 Phillips screwdriver, remove the 5 screws (indicated by ovals) that secure the Decorative Shroud to the Structural Shroud.
  • Page 100 6. At the top of the curve of the Decorative Shroud, gently pry outward to disengage it from the Structural Shroud. NOTICE: There are two Round Securing Tabs that need to be released. Structural Shroud (inner) Decorative Shroud (outer) Round Securing Tabs Securing Tabs...
  • Page 101 7. From the front of the machine, gently pry the Decorative Shroud outward to release the upper Securing Tab. There are 5 Securing Tabs that secure the Decorative Shroud on the front of the machine. Note: A standard screwdriver covered with cloth or paper can be inserted and twisted between the Deco- rative Shrouds to help release the Securing Tabs.
  • Page 102 8. Remove the Right Decorative Shroud. 9. Repeat the last 6 Steps to remove the Left Decorative Shroud. 10. Remove the Console Cable from the Console, and undo the Cable Restraining Strap. Console NOTICE: Do not cut or pinch the cable. Console Restraining Strap...
  • Page 103 11. Remove the 3 Plugs (2 indicated here from the Handlebar Assembly. Handlebar Assembly 12. Using a 5mm hex wrench, remove the hardware that was under the Plugs from the Handlebar Assembly. 13. Slide the Handlebar Assembly, with the Console and Media Rack, from the Frame Assembly.
  • Page 104 16. Remove the Crank Cover Insert to expose the Crank Cover hardware. Crank Cover Insert Crank Cover 17. Using a #2 Phillips screwdriver, remove the hardware (indicated by ovals) from the Crank Cover. Remove the Crank Cover and place outside of the work area.
  • Page 105 Right Left Structural Structural Shroud Shroud Number of screws: Left Shroud = 12 Right Shroud = 6 18. Using a #2 Phillips screwdriver, remove the indicated hardware from the Structural Shrouds. Note: To assist with re-assembly, the key to the type of screw and where it is used is provided.
  • Page 106 19. Place the new Structural Shrouds in place on Right the Frame. Be sure that the Console Cable (or Structural Console Shroud Cable Main Mast Cable) is routed through the opening between the Structural Shrouds, and that the Grommet is outside of the Shrouds. Note: Do not cut or pinch the Console Cable.
  • Page 107 21. Re-install all remaining parts that were removed in reverse order. When re-connecting the Cable to the Console, the Cable Connector has a tab that can only be connected to the Console in one orientation. Connect the Console Cable to the Console in the proper orientation.

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