Bowflex Max Trainer M7 Service Manual

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Owner's/assembly manual (60 pages)

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Table of Contents

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Summary of Contents for Bowflex Max Trainer M7

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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 2: Important Safety Instructions
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 3: Safety Warning Labels And Serial Number
SAFETY WARNING LABELS AND SERIAL NUMBER WARNING! 1. Prior to use, read and understand the Owner’s Manual, including all Warnings. 2. Inspect product before use. Do not use if any parts are in need of repair. 3. Keep children and pets away from this machine at all times.
Page 4: Specifications
SPECIFICATIONS Maximum User Weight: 300 lbs. (136 kg) Maximum Pedal Height: 19.1 inches ( 48.5 cm) Power Requirements: Operational Voltage: 9VDC 65.5” Operating Current: 1500 mA (166.4 cm) Heart Rate Chest Strap: 1 CR2032 battery Assembled Weight: approximately 148 lbs (67.1 kg) Regulatory Approvals: A C Power Adapter: U L listed, CSA certified (or equivalent), Rated 120V 60Hz...
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 fit and able to move the machine safely. Grasp the Aero Bars to carefully tilt the machine toward you onto the transport rollers. Be sure not to grab the Media Shelf. Be aware of the Handlebars and the weight of the machine before tilting the machine.
Page 6: Connectivity
CONNECTIVITY Connectivity on your Bowflex Max Trainer machine ® The Bowflex Max Trainer M7 cardio machine is equipped with Bluetooth connectivity and can wirelessly sync with the “Bowflex Max Trainer ” Fit- ® ® ® ness App on supported devices. Fitness App ( “Bowflex Max Trainer 2" ) ® The Bowflex Max Trainer 2 App syncs with your Bowflex Max Trainer M7 to track total calories burned, time, watts, and more. Records and stores ®...
Page 7: 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 8: Maintenance Parts Exploded View
Maintenance Parts...
Page 9 Dynamic Handlebar, Left Stabilizer Handlebar Pivot Assembly Console Assembly (w/Aerobars) Leveler Crank Arm Dynamic Handlebar, Right Pedal Tensioner Crank Cover Foot Pad Drive Pulley, Lower Shroud, Right Roller Fan Belt Disc Brake Shroud, Right Fan Shroud, Left Fan Speed Sensor (behind Fan) Fan Assembly Inserts Fan Assembly Drive Belt...
Page 10: Troubleshooting - Sections
TROUBLESHOOTING Troubleshooting - Sections A. No Power / Display Will Not Turn On B. Buttons Do Not Respond C. Needle Does Not Move or Machine Goes to Sleep While in Use D. Resistance Does Not Respond E. Machine Seized Up F.
Page 11: 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 12: Buttons Do Not Respond
Buttons Do Not Respond Cycle the power off/on. If the BEGIN HERE issue persists continue on with the troubleshooting. Is the display Go toTroubleshooting: completely blank with No Power no lights? Remove the console rear shroud (cover). Unplug and replug all connections into the back of the console.
Page 13: Needle Will Not Move / Machine Goes To Sleep While In Use
Needle will Not Move or Machine Goes to Sleep While in Use Remove the hardware from the right lower round cover. To BEGIN HERE remove the right lower round cover, the power plug inlet wire must be gently released from the inside of the cover.
Page 14: Resistance Does Not Respond
Resistance Does Not Respond Cycle the power off/on. If the issue persists Go to Troubleshoot- Does the console turn continue on with the BEGIN HERE ing: No Power troubleshooting. Remove the right side Go to Troubleshoot- Does the fan turn lower round cover.
Page 15: Machine Seized Up
Machine Seized Up Attempt to rotate the Crank Are the Crank Arms BEGIN HERE Arms by hand. opposite each other 180*? Does the issue Issue resolved. Follow the “Replace the Crank persist? Arms” procedure to remove and reorient one Crank Arm so that they are 180* opposite each other as shown.
Page 16: Console Does Not Light Up Completely
Console Does Not Light Up Completely Peel off the protective plastic BEGIN HERE film on the display. If the plastic film has already been removed and the problem remains, continue with troubleshooting. Go to Troubleshooting: Is the entire display No Power not lighting up? Remove console hood (8 screws) and check all connec-...
Page 17: 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 18: Rollers And Pedals
Rollers and Pedals The noise is a normal function, Is a clicking and is not harmful to the or rubbing noise being machine. Install the Felt Washers caused by contact The clicking noise can be BEGIN HERE supplied in the Roller Wheel between the roller reduced by the installation of Axle Service Kit...
Page 19: Noises - Main
Noise Issues - Main What type of noise is BEGIN HERE Metallic Grinding or Rubbing Clicking, Clunking, or Squeaking, Squeling 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 20: 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 21 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 22: 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 23: Noises - Rubbing / Belt
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 24: Telemetric Heart Rate Issues
Telemetic Heart Rate Issues Move the machine away from Ensure strap is “POLAR” compatible sources of potential electromag- and uncoded. Make sure strap is BEGIN HERE netic interference such as TV, against the bare skin, just below the computers, microwave, cordless chest muscles, and buckle it.
Page 25: 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 26: 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 27: Console Setup Mode
CONSOLE SETUP MODE The Console Setup Mode lets you view maintenance statistics (Total Run Hours and Software Version) or fully reset the Console. Push and hold down the Volume and PAUSE/STOP buttons for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode. Note: Push PAUSE/STOP to exit the Console Setup Mode and return to the Power-Up Mode screen.
Page 28: Console Board Detail
CONSOLE BOARD DETAIL Note: The color of the Board may vary. Speaker Wireless Heart Rate Module Cable Input/Output Cable Bluetooth ® Module Resistance Level Target Burn Rate (Increase) (Increase) [ Zero Insertion Force (ZIF) [ Zero Insertion Force (ZIF) Connector ] Connector ] Contact Heart Rate...
Page 29: 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 and wait 5 minutes before cleaning, maintaining or repairing this machine.
Page 30: Roller Wheel Maintenance Procedure
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 31 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location. 1.
Page 32 3. Using a clean rag or paper towel, clean both the Axle and the Wheel Bearing (including the inner edge). Wipe off any residue or debris. 4. Apply one drop of Multi-purpose Mineral Oil to the inside of the Wheel Bearing (Areas 1 and 2), which is the surface that contacts the Axle.
Page 33: Adjust The Brake Assembly
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 34 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. Remove the Right Stabilizer Shroud from the machine. 4.
Page 35 Power Cable 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 36 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. Brake Cable Securing Nut 8.
Page 37 11. Installation is the reverse procedure. 12. 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 38: Adjust The Leg Assembly Alignment
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 39 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location. If the Rollers seem to be “off”...
Page 40 5. 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. 6. Using a 8mm hex wrench, slightly loosen the indicated bolts that secure the Rail Assembly to the Base Assembly.
Page 41: Reset The Console
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 42 16. The Console displays the RESET CONSOLE NO prompt. 17. Push the Increase button to select the RESET CONSOLE YES prompt. NOTICE: With a reset of the Console, all User Profile settings and previous Workouts will be erased from the Console. This information is not retrievable after a reset. 18. Push ENTER/START button. The Console will reset to factory settings. 19. Turn the machine off when the Console displays the “POWER CYCLE NOW” prompt.
Page 43: Set The Date And Time
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2016 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 44: Replace The Brake Assembly
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 45 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. 4. 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 46 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 Magnets Brake Assembly 8. Place a piece of tape on the Brake Cable immediately above the Brake Arm.
Page 47 11. Using a 10mm hex wrench, remove the screws that connect the Brake Assembly and remove it. 12. Attach the new Brake Assembly, but do not fully tighten the hardware. 13. Attach the Brake Disc. 14. Reattach the Brake Spring and the Brake Cable to the Brake Arm, Brake Assembly and adjust to the tape marker.
Page 48 18. The Brake Magnets should be aligned with the Brake Disc and cen- tered around the Brake Disc. 19. If the Brake Assembly only needs to be slightly adjusted, loosen the front screw that secures the Brake Assembly using a 10mm hex wrench. Rotate the Brake Assembly until the Magnets are aligned and of equal Brake Disc distance from the Brake Disc.
Page 49: Replace The Console Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 50 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 3. Carefully lift the Console Assembly and expose the Cable Connections. Note: do not crimp any of the Console Cables.
Page 51 6. After noting their location for re-assembly, disconnect the indicated cables from the Console Board. Do not remove the Cables from the Con- sole Handlebar Assembly. Speaker Wireless Heart Rate Module Input/Output Cable Cable Resistance Level Target Burn Rate (Increase) (Increase) [ Zero Insertion Force (ZIF) [ Zero Insertion Force (ZIF)
Page 52 7. Using a #2 Phillips screwdriver, remove the 2 indicated screws that secure the Console Assembly to the Console Handlebar Assembly. 8. Remove the old Console Assembly noting how the cables route, and replace with the new Console Assembly. 9. Installation is the reverse procedure. Do not crimp the Cables. 10.
Page 53: Replace The Console Handlebar Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 54 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 3. Carefully lift the Console Assembly and expose the Cable Connections. Note: do not crimp any of the Console Cables.
Page 55 6. After noting their location for re-assembly, disconnect the indicated cables from the Console Board. Speaker Wireless Heart Rate Module Input/Output Cable Cable Resistance Level Target Burn Rate (Increase) (Increase) [ Zero Insertion Force (ZIF) [ Zero Insertion Force (ZIF) Connector ] Connector ] Contact Heart...
Page 56 7. Using a #2 Phillips screwdriver, remove the 2 indicated screws that secure the Console Assembly to the Console Handlebar Assembly. 8. Remove the Console Assembly noting how the cables route. 9. Route the cables from the new Console Handlebar Assembly to the Console Assembly.
Page 57: Replace The Crank Arm
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2016 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 58 1. From the side with the Crank Arm that needs to be replaced, remove the indicated Cap. Note: The following photos show the removal of the Right Crank Arm. 2. Using a 6mm hex wrench, remove the hardware exposed from below the Cap.
Page 59 7. Using a #2 Phillips screwdriver, remove the 2 indicated screws from the Crank Cover. 8. Remove the Crank Cover from the machine. Crank Cover 9. Using a 9/16” or 14mm socket and wrench, remove the indicated nut from the Crank Assembly. 10.
Page 60 11. Carefully thread the Crank Puller into the Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 12. Using a 16mm 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 61: Replace The Drive Belt
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 62 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on one side) from the Upper Shroud and remove it. Upper Shroud 3. Using a 5mm hex wrench, remove the indicated hardware from the Up- per Handlebars and remove them.
Page 63 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.
Page 64 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 65 20. 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 21. Using a 4mm hex wrench, remove the screw indicated by “A” from the Drive Belt Tensioner Arm.
Page 66: Replace The Drive Pulley
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 67 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on one side) from the Upper Shroud and remove it. Upper Shroud 3. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar.
Page 68 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.
Page 69 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 70 20. Using a 9/16” or 14mm socket and wrench, remove the nut from the Left Crank Assembly. Left Crank Assembly 21. Adjust the Crank Puller until the end of the Bolt is inside the Bolt Nut (as shown). 22. Carefully thread the Crank Puller into the Left Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted.
Page 71 25. 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 26. Using a 4mm hex wrench, remove the screw indicated by “A” from the Drive Belt Tensioner Arm.
Page 72 33. 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 73: Replace The Hardware Of The Drive Pulley
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2017 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 74 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on Upper Shroud one side) from the Console Assembly. 3. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar.
Page 75 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (ar- row) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed up- ward to clear the loosened screw.
Page 76 10. Using a #2 Phillips screwdriver, remove the 2 indicated screws (by ovals) from the Left Crank Cover. Note: The image displays the Right Crank Cover being removed. Pivot Arm 11. Remove the Left Crank Cover from the machine. 12. Place a rag or protective material below the Left Connector Arm to protect the Shroud from potential scratches from the Connector Arm.
Page 77 17. 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. Left Crank Assembly Note: Be aware that the Left Crank Arm will be loose and will need to be supported.
Page 78 22. 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
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 80 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right and Left Stabilizer Shrouds from the machine. 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.
Page 82: Replace The Fan Pulley
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 83 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on Upper Shroud one side) from the Upper Shroud. 3. Remove the Right and Left Stabilizer Shrouds from the machine. 4.
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.
Page 85 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 86 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.
Page 87 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.
Page 88 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 89 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.
Page 90: Replace The Frame Assembly
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 | © 2017 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 91 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. 3. Using a 5mm hex wrench, remove the indicated hardware from the Right and Left Upper Handlebar.
Page 92 9. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 10. Carefully lift the Console Assembly and expose the Cable Connec- tions. Note: do not crimp any of the Console Cables. This step may require two people.
Page 93 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.
Page 94 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 95 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 96 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 97 23. Connect the Console Assembly to the Frame Assembly NOTICE: Do not crimp the Console Cable.
Page 98 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 99: Replace The Handlebar Pivot Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2017 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 100 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. Note: Be aware that the Upper Handlebar must be supported when removing the hardware. 3.
Page 101: Replace The Input/Output (I/O) Cable
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 | © 2017 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 102 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. 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 103 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 104 10. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 11. Carefully lift the Console Assembly and expose the Cable Connec- tions. Note: do not crimp any of the Console Cables. This step may require two people.
Page 105: Replace The Power Inlet
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 106 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. 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 107 Power Cable 5. Using a 15mm open end wrench, remove the Securing Ring from the outside of the Right Fan Cover. 6. Remove the Power Inlet from the inside of the Right Fan Cover. Power Inlet Securing Ring 7. Disconnect the Power Inlet from the Power Connector behind the Brake Disc.
Page 108: Replace The Roller Wheel Assembly
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 109 1. Unplug the AC Power Adapter from the machine and wait 5 minutes. 2. Using two 6mm hex wrenches, remove the Roller Wheel Assembly from the 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 110: Replace Self-Tensioning Fan Belt
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 111 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on one side) from the Upper Shroud. Upper Shroud 3. Remove the Right and Left Stabilizer Shrouds from the machine. 4.
Page 112 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.
Page 113 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 114 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.
Page 115 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.
Page 116 27. 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. 28. Loop the new Fan Belt around the lower Pulley and start it on the face of the Fan Pulley.
Page 117 31. 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. 32. Put on eye protection and cut the Zip-Tie without damaging the new Fan Belt or Fan Pulley.
Page 118: Replace The Servo Motor
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 119 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. 4. 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 120 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 a 8mm open ended wrench, loosen the Brake Cable Secur- ing Nut until the Brake Cable can be released from the Servo Motor Arm.
Page 121 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 Brake Cable Securing Nut Brake Disc 15. If the Brake Assembly needs to be adjusted, use a 8mm open ended wrench to loosen the Brake Cable Securing Nut.
Page 122 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. 18. If the Brake Assembly only needs to be slightly adjusted, loosen the front screw that secures the Brake Assembly using Brake Disc a 10mm hex wrench.
Page 123: Replace The Shrouds
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 124 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on one side) from the Upper Shroud. Upper Shroud 3. Remove the Right and Left Stabilizer Shrouds from the machine. 4.
Page 125 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 126 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 127 Right Side Left Side 20. 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. 21.
Page 128: Replace The Speed Sensor
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 129 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine. 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 130 Note: Left Fan Cover is hidden for image clarity. 5. Using a #2 Phillips screwdriver, remove the screw that attaches the Speed Sensor. Brake Note: The distance of the new Speed Sensor Magnet must be the Disc same distance from the Fan Disc for proper operation. Be sure to note the distance before removing the Speed Sensor Magnet.
Page 131: Replace The Tensioner
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 | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 132 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a #2 Phillips screwdriver, remove the 4 screws (2 indicated on one side) from the Upper Shroud and remove it. Upper Shroud 3. Using a 5mm hex wrench, remove the indicated hardware from the Left Upper Handlebar and remove it.
Page 133 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws 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 134 13. Using a #2 Phillips screwdriver, remove the indicated (by oval) screw and only loosen the lowest indicated screw (arrow) from the Left Fan Cover. 14. 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 135 20. 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 21. Observe the location of the “A” screw in the opening of the Tensioner. This will help with re-assembly.
Page 136: Replace The Wireless Heart Rate Module
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2015 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and Bowflex Max Trainer are trademarks owned by or licensed to Nautilus, Inc.
Page 137 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location. 1.
Page 138 4. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 5. Carefully lift the Console Assembly and expose the Cable Connec- tions. Note: do not crimp any of the Console Cables. This step may require two people.
Page 139 8. Attach a piece of wire or string to the upper Heart Rate Cable of the Wireless Heart Rate Sensor (where it attached to the Console). 9. Gently remove the Wireless Heart Rate Sensor and Cable, routing the newly attached wire or string down to the Rear Shroud opening. Note: If the Wireless Heart Rate Sensor was attached by an adhesive, be sure to remove any residue to be able to attach the new Sensor correctly.

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