Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S.

ORIGINAL MANUAL - ENGLISH VERSION ONLY

8027842.090122.C

VeloCore

™

Service Manual

Page Number

Section Code

Bikes

™

Section

Replace the Idler Pulley (Tensioner)

Replace the Pedals

Replace the Resistance Magnet Carriage

Replace the Resistance PCB

Replace the Resistance Adjuster

Replace the Shrouds / Front Fenders

Replace the Speed Sensor

Replace the Tilt Sensor PCB

Service Manual

8027841.090122.C

Page Number

105

125

132

140

145

148

Table of Contents

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Summary of Contents for Nautilus Bowflex VeloCore Series

Page 1: Table Of Contents
Replace the Crank Arm Replace the Drive Belt Replace the Drive Pulley Replace the Flywheel Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. ORIGINAL MANUAL - ENGLISH VERSION ONLY 8027842.090122.C...
Page 2 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed United States and other countries. | The Bluetooth ®...
Page 3: Fcc Compliance
SAFETY WARNING LABELS AND SERIAL NUMBER WARNING! machine. • Keep children and pets away. • For Consumer Use Only. • • stop. • Spinning pedals can cause injury. • FCC Compliance void the user’s authority to operate the equipment. This product complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
Page 4 SPECIFICATIONS 16” monitor 22” monitor Machine Weight without Dumbbells: 39.6 cm (15.6”) 54.6 cm (21.5”) 133.6 cm (52.6”) 9290.2 cm (1440 in Power Requirements Input Voltage: 151.8 cm 61.2 cm Output Voltage: (59.8”) (24.1”) center. 140.3 cm (55.3”) 151.8 cm 61.2 cm (59.8”) (24.1”)
Page 5: Maintenance
MAINTENANCE done. Worn or damaged components must be repaired or replaced immediately. Only manufacturer supplied components can be used to maintain and repair the equipment. Disconnect all power to the machine before you service it. Daily: NOTICE: Weekly: with loose Pedals. Note: Monthly or after 20 hours:...
Page 6 The machine may be moved by one or more persons depending on their physical abilities and capacities. Make sure that you and Then rotate rollers. Push the machine into position. NOTICE: the computer operation. For safe storage of the machine, remove the power adapter and place in a secure location.
Page 7: Emergency Stop
To stop the pedals immediately, push down hard on the Emergency Brake/Resistance Adjustment This bike cannot stop the Pedals independently of the Flywheel. Reduce the pace to slow the Flywheel and Pedals to a stop. Do not dismount the bike until the Pedals have come to a complete stop.
Page 8 If a USB Device is attached to the USB Port, the Port will attempt to charge the Device. Depending on the amperage of device, the power supplied from the USB Port may not be enough to operate the Device and charge it at the same time. ®...
Page 9 Care should be used when mounting or dismounting the machine. Before mounting or dismounting the machine, be sure it is stabilized in the upright position with the Lean Lock Knob completely cause injury or damage to the equipment. Note: tightened. Pull the handle out to disengage and turn so that it points down, then release. Step off the machine before you adjust the seat.
Page 10 Foot pedals that are equipped for cycling shoes with cleats provide secure footing on the mechanism for the pedals and cleats (shoes). release. shoes with “Standard 2-Hole MTB SPD Cleat Mounts” (MTB SPD = Mountain Bike Shimano Pedaling Dynamics). 1. Be sure that the arrow on top of the Pedal points forward. 2.
Page 11 Console Alignment Tightly secure the screws. 3. Remove the remove the Console Mast End Cap. 5. Tightly secure the screws. 6. Remove the level it. 8. Tightly secure the screws. To lock the Flywheel, turn the Then rotate the Emergency Brake/Resistance For safe storage of the machine, remove the power supply and place in a secure location.
Page 12: Demonstration Mode
The machine ships with Demonstration Mode inactive. To activate the Demonstration mode: Console Display. The Console will display the menu. Note: In order to display the , the ™ app. Note: This is where Demo mode is activated and de-activated. the Console Display.
Page 13 Things to Check Solution No display/partial display/unit Check electrical (wall) outlet will not turn on plugged into the power inlet connector. Replace adapter or connection at unit connections/orientation connector should line up and snap into place. damage stuck in Pause mode Speed Sensor No Speed/RPM reading orientation...
Page 14 Things to Check Solution Check pedal to crank pedal/ Pedals seem to skip or connection slip with a sudden increase in connection Clicking sound when pedaling Check pedal to crank connection pedals. Click, tick or knocking sound Tightly secure all hardware. Seat post movement Check adjustment handle Be sure the adjustment handle is securely tightened.
Page 15 Maintenance Parts FF GG...
Page 16 Console Drive Pulley Idler Pulley Flywheel Speed Sensor Magnet (5) Console Mast Speed Sensor G Seat Stem MM Power Inlet Seat with U.S./Canada machines) Seat End Cap PCB, Tillt Sensor Main Frame End Cap, Console Mast Transport Handle AA Main Shroud, Right Static Bumper Shroud BB Pivot Shroud, Right CC Fender, Right...
Page 17: Adjust The Belt Tension
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 18 Note: Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. in and cause injury. pedals move normally with no skipping (slip), the tension is correct. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc...
Page 19 Main shroud Note: It is not necessary to remove the Crank Arms and Center Disc in order to remove the Shroud. Center disc shroud Check the tension: pulleys and measure the distance. The Drive Belt should have only should turn only 90 degrees (1/4 turn, to vertical).
Page 20 Using a 13 mm open end wrench, loosen the inner Nut on the Tensioner pivot bolt Tensioning Bolt. Using a 13 mm open end wrench or socket and wrench, adjust the mount plate outer Nut on the Tensioning Bolt: If the Drive Belt is too loose—turn the Nut on the Tensioning Bolt clockwise.
Page 21 Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 22 Note: Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. To adjust the bike’s lean tension, go to step 2. To adjust the bike’s vertical alignment, go to step 8.
Page 23 Unlocked position To increase resistance— To decrease resistance— – same amount and direction as the upper cup. Check the lean tension. – achieved.
Page 24: Moving/Storing The Machine 6
Unlocked position – – 11. Re-install the parts that were removed in reverse order. 12. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 25 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 26 NOTICE: Do not power cycle or restart console during procedure. Always close the Advanced User Actions menu Note: Locked position Be sure the bike is stabilized in the upright position with If the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment.
Page 27 NOTICE: support. ™...
Page 28 Note: ) is not Disregard the current value.
Page 29: Mounting/Dismounting 9
Brake starts to engage. scrape. Disregard the current value. until it stops turning. CANCE ™...
Page 30: Adjustments 9
21. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 31: Adjust The Seat Post Mounting Bracket
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 32 Note: Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a 14 mm open end wrench, loosen the nuts on the Seat post aside.
Page 33 Remove the outer clamp pieces. Seat rail Outer clamp piece Seat clamp Outer clamp Outer clamp piece piece Seat clamp Seat clamp Outer clamp Outer piece clamp piece Seat clamp Seat rail Seat rail Seat clamp Seat rail Seat rail...
Page 34 sure they are seated on the Seat rails. Outer Outer Outer clamp clamp clamp piece piece piece Seat rail nuts. Install Seat onto the Seat post. Be sure the Seat is straight and level.
Page 35 Comparison—when the Seat clamp is reversed, the Seat is position 10. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 36 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 37 NOTICE: Do not power cycle or restart console during procedure. Always close the Advanced User Actions menu Note: Plug the AC Adapter into the machine and wall outlet. ™ ™ right hand corner 10 times to launch the Advanced User Actions menu.
Page 38 NOTICE: support. ™...
Page 39 Note: ) is not Locked position Console will display a prompt to do this. The screen will display current Tilt...
Page 40 13. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 41: Install Flywheel Shroud Pads
Read and understand all warnings on this machine. If at any time the Warning stickers become loose, unreadable or • Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Refer to the Assembly Manual for complete safety instructions.
Page 42 Installation Note: Shroud 4. Fully tighten the screw to hold the Pad in position. 6. Final Inspection Inspect your machine to ensure that all hardware is tight and Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 43 Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 44 Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Remove the Console mast cover and Console Mast End Cap. NOTICE:...
Page 45 NOTICE: operation. aside. NOTICE: NOTICE: screw.
Page 46 to the opening at the top. Console Mast. NOTICE: the computer operation. Using a #2 Phillips screwdriver, re-install the Console. NOTICE: computer operation. Install the Console Mast End Cap and Console mast cover. Make sure the Console is aligned with the machine. 10.
Page 47 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 48 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc Note: It is not necessary to remove the Crank Arm and Center Disc in order to remove the Shroud.
Page 49 Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Left side Center disc Main Note: It is not necessary to remove the Crank Arm and Center shroud Disc in order to remove the Shroud. Left Main shroud removed Center disc shroud...
Page 50 Left side knob knob shaft knob shaft knob shaft knob shaft Using a small (2-3mm) steel pin and hammer, gently push the Roll NOTICE: pin so that it does not get lost. knob collar knob collar knob shaft knob shaft...
Page 51 knob Top cap Tube Installation is the reverse procedure. NOTICE: 11. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 52: Replace The Bumper
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 53 NOTICE: Note: Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips screwdriver, loosen and remove the screws that Using a #2 Phillips Screwdriver, remove the 3 screws (a) that Note: Repeat on the other side.
Page 54 Upper bumper Upper bumper Upper Upper bumper bumper bumper bumper Unlocked position Installation is the reverse procedure. Note: the Tilt Sensor” procedure. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 55: Replace The Bumper Cup
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 56 NOTICE: Note: Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips screwdriver, loosen and remove the screws that Using a #2 Phillips Screwdriver, remove the 3 screws (a) that Note: Repeat on the other side.
Page 57 From the left side of the bike— Upper bumper Upper bumper Upper Upper bumper bumper bumper bumper Unlocked position From the right side of the bike— Lock nut Lock nut threaded rod threaded rod...
Page 58 clockwise direction. threaded rod threaded rod 10. Installation is the reverse procedure. Note: the Tilt Sensor” procedure. 11. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 59: Replace The Center Discs
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 60 Note: Be sure Locked position locked position. Be sure the bike is stabilized in the upright position with If the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment. Crank Arm.
Page 61 Puller is in the correct position, only 1-2 threads on the outer portion (CP2) Note: Left side Using a #2 Phillips Screwdriver, remove the 3 screws (a) that Center disc NOTICE: Crank Shaft ® ® NOTICE: ® ® Crank Nut...
Page 62 12. Re-install the threaded Cap on the Crank Arm. Crank Arm 13. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 63: Replace The Console
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 64 Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Remove the Console mast cover and Console Mast End Cap. NOTICE:...
Page 65 NOTICE: at the top. NOTICE: operation.
Page 66 Using a #2 Phillips screwdriver, install the new Console. Make sure the Console is level and aligned with the machine. NOTICE: computer operation. Mast. Set up the new Console on your machine: Note: machine. Note: your on Connect. Fitness Assessment workout to unlock all workout content Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and...
Page 67: Replace The Console Mast
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 68 Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Remove the Console mast cover and Console Mast End Cap. NOTICE:...
Page 69 NOTICE: operation. down iinto the machine. NOTICE: two people. Mast mount—older version...
Page 70 remove all slack. NOTICE: onto the mast mount. Hand tighten the screws Mast mount—older version NOTICE: screw.
Page 71 to the opening at the top. Console Mast. NOTICE: the computer operation. 13. Using a #2 Phillips screwdriver, re-install the Console. NOTICE: computer operation. Install the Console Mast End Cap and Console mast cover. Make sure the Console and Console Mast are aligned with the Console Mast.
Page 72: Replace The Crank Arm
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 73 Note: Locked position Be sure locked position. Be sure the bike is stabilized in the upright position with If the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment. Note: The Left Pedal is reverse-threaded.
Page 74 Using a 16 mm socket and wrench, remove the Crank Nut under the threaded Cap. Crank Nut Crank Shaft Puller is in the correct position, only 1-2 threads on the outer portion (CP2) Note: old parts. Crank Shaft ® ® Crank Nut NOTICE: ®...
Page 75 ® 12. To reinstall a Pedal, s and the Pedal does not turn smoothly into the Crank Arm, make sure that the threads are aligned correctly. Be sure that the Pedal is going on remove the Pedal and start again. Note: The Left Pedal is reverse-threaded.
Page 76: Replace The Drive Belt
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 77 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc Note: It is not necessary to remove the Crank Arms and Center Disc in order to remove the Shroud.
Page 78 Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Left side Center disc Main Note: It is not necessary to remove the Crank Arms and Center shroud Disc in order to remove the Shroud. Left Main shroud removed Center disc shroud...
Page 79 mount plate Left side mount plate mount plate Spindle clip Spindle clip Tensioner Tensioner eyebolt eyebolt To loosen the Flywheel hardware, use a 19mm open end wrench to...
Page 80 Tensioner pivot bolt mount plate location Tensioner pivot bolt Tensioner pivot bolt 10. Using a 13 mm open end wrench, loosen the inner Nut on the Tensioning Bolt. Tensioner Tensioner pivot bolt pivot bolt Inner nut Inner nut 11. Using a 13 mm open end wrench or socket and wrench, loosen the outer Nut on the Tensioning Bolt (turn counterclockwise): Tensioner Note:...
Page 81 NOTICE: Tensioner eyebolt Speed sensor Spindle clip Pulley to the outside. turn the Drive Pulley. NOTICE: Make sure to avoid damage to the Speed Sensor (on the pulley Mount Plates. Be sure the Flywheel pulley is on the right side. Put the replacement Drive Belt in position around the Flywheel Idler pulley NOTICE:...
Page 82 16. Put the Drive Belt onto the Drive Pulley. Make sure the Drive Belt is aligned on the Flywheel pulley, Idler Pulley and Drive Pulley turn the Drive Pulley and Flywheel. to the locations that were marked in step 6. Using a 10mm wrench, install Tensioner eyebolt Spindle clip...
Page 83 21. Using a 13 mm socket and wrench or open end wrench, tighten the inner Nut on the Tensioning Bolt. Tensioner pivot bolt mount plate location tighten the Flywheel hardware, use a 19mm open end wrench to hold the on the opposite side with a 19mm socket and wrench. one.
Page 84: Replace The Drive Pulley
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 85 NOTICE: procedure. Note: Be sure Locked position locked position. Be sure the bike is stabilized in the upright position with the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment.
Page 86 Puller is in the correct position, only 1-2 threads on the outer portion (CP2) Note: Main shroud shroud...
Page 87 Left side Main shroud Left Main shroud removed shroud...
Page 88 Tensioner pivot bolt mount plate location Tensioner pivot bolt Tensioner pivot bolt 10. Using a 13 mm open end wrench, loosen the inner Nut on the Tensioning Bolt. Tensioner Tensioner pivot bolt pivot bolt Inner nut Inner nut 11. Using a 13 mm open end wrench or socket and wrench, loosen the outer Nut on the Tensioning Bolt (turn counterclockwise): Note: Tensioner...
Page 89 Pulley to the outside. the Drive Pulley. pulley Left side 13. Using eye protection and snap ring removal tool, remove the Snap Pulley shaft Crank spacer the old Drive Pulley, and place them onto the new Drive Pulley in the same location.
Page 90 NOTICE: Belt onto the Drive Pulley. Make sure the Drive Belt is aligned on the Flywheel Pulley, Idler Pulley and Drive Pulley. the Drive Pulley. 17. Check the Drive Belt tension: pulleys and measure the distance. The Drive Belt should have only should turn only 90 degrees (1/4 turn, to vertical).
Page 91 21. Using a 13 mm socket and wrench or open end wrench, tighten the inner Nut on the Tensioning Bolt. Tensioner pivot bolt mount plate location NOTICE: Crank Shaft ® ® NOTICE: ® ® Crank Nut 27. Re-install the threaded Cap on the Crank Arm. 28.
Page 92: Replace The Flywheel
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 93 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc Note: It is not necessary to remove the Crank Arms and Center Disc in order to remove the Shroud.
Page 94 Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Left side Center disc Main Note: It is not necessary to remove the Crank Arms and Center shroud Disc in order to remove the Shroud. Left Main shroud removed Center disc shroud...
Page 95 mount plate Left side mount plate mount plate Spindle clip Spindle clip Tensioner Tensioner eyebolt eyebolt To loosen the Flywheel hardware, use a 19mm open end wrench to...
Page 96 Tensioner pivot bolt mount plate location Tensioner pivot bolt Tensioner pivot bolt 10. Using a 13 mm open end wrench, loosen the inner Nut on the Tensioning Bolt. Tensioner Tensioner pivot bolt pivot bolt Inner nut Inner nut 11. Using a 13 mm open end wrench or socket and wrench, loosen the outer Nut on the Tensioning Bolt (turn counterclockwise): Tensioner Note:...
Page 97 NOTICE: Tensioner eyebolt Speed sensor Spindle clip Pulley to the outside. turn the Drive Pulley. NOTICE: Make sure to avoid damage to the Speed Sensor (on the pulley Flywheel Mount Plates. Be sure the Flywheel pulley is on the right side. Put the Drive Belt in position around the Flywheel Idler pulley NOTICE: pulley...
Page 98 16. Put the Drive Belt onto the Drive Pulley. Make sure the Drive Belt is aligned on the Flywheel pulley, Idler Pulley and Drive Pulley turn the Drive Pulley and Flywheel. to the locations that were marked in step 6. Using a 10mm wrench, install Tensioner eyebolt Spindle clip...
Page 99 21. Using a 13 mm socket and wrench or open end wrench, tighten the inner Nut on the Tensioning Bolt. Tensioner pivot bolt mount plate location tighten the Flywheel hardware, use a 19mm open end wrench to hold the on the opposite side with a 19mm socket and wrench. one.
Page 100 Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 101 Note: Be sure Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. If only replacing the Seat Stem Bushing, go to Step 11. If replacing the Handlebar Post Bushing, continue to Step 3.
Page 102 Handlebar Handlebar 10. Re-install all remaining parts that were removed in reverse order. If not replacing the Seat Stem Bushing, go to Step 19.
Page 103 Seat stem handle mount NOTICE: Note: It is not necessary to remove the Threaded Plug and Friction Insert Friction insert Seat stem Threaded mount Note: Be sure to notice how the Friction Insert is oriented within the...
Page 104 Seat stem upward until the Seat Stem Bushing is released. Continue pushing upward to remove the old Bushing. Seat stem 18. Re-install all remaining parts that were removed in reverse order. 19. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 105: Replace The Idler Pulley (Tensioner)
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 106 Note: Be sure Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc Note: It is not necessary to remove the Crank Arms and Center Disc in order to remove the Shroud.
Page 107 remove it at this time. Tensioner pivot bolt Tensioner pivot bolt Tensioner pivot bolt mount plate location Using a 13 mm open end wrench or socket and wrench, remove the outer Nut (lock nut) on the Tensioning Bolt (turn counterclockwise): Set it Note: necessary.
Page 108 Note: Tensioner pivot bolt Tensioner pivot bolt Idler pulley Idler pulley assembly assembly belt belt pinch hazards. NOTICE: 10. Install the new Tensioning Bolt and inner and outer Nuts. Make sure the Drive Belt is aligned on the Flywheel pulley, Idler Pulley and Drive Pulley.
Page 109 11. Check the Drive Belt tension: pulleys and measure the distance. The Drive Belt should have only should turn only 90 degrees (1/4 turn, to vertical). 12. Using a 13 mm open end wrench or socket and wrench, adjust the outer Nut on the Tensioning Bolt: Tensioner If the Drive Belt is too loose—turn the Nut on the Tensioning Bolt...
Page 110 one. 17. Re-install all remaining parts that were removed in reverse order. NOTICE: 18. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 111 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 112 NOTICE: Note: Be sure the locked position. Using a #2 Phillips Screwdriver, remove the 3 screws (a) that Note: Repeat steps 2 and 3 on the other side. Left side Unlocked position NOTICE:...
Page 113 Lean Lock Knob assembly Cam lockout Left side Wire end Wire end lockout Brackets. Note: Frame. If replacing the Lean Lock Knob assembly, continue to Step 8. If not replacing the Lean Lock Knob assembly, go to Step 12.
Page 114 Lockout handle Lockout Lockout...
Page 115 correctly. Align the ridge on the handle with the Bushing cutout. Left side Lockout cutout (left side) Mount tube notch Note: Lean Lock Knob assembly NOTICE: Cam lockout 14. Re-install the Front Fenders. Wire end Wire end 15. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the...
Page 116 Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 117 NOTICE: Note: Locked position Be sure locked position. Be sure the bike is stabilized in the upright position with If the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment. NOTICE: computer operation.
Page 118 I/O cable I/O cable Tilt sensor PCB Tilt sensor PCB mast mount. Lower wiring Lower wiring Using a 17 mm wrench or nutdriver, remove the thin Nut that harness harness Using a #2 Phillips screwdriver, remove the screws that attach Power inlet Power inlet Ziptie...
Page 119 15. Re-install all remaining parts that were removed in reverse order. NOTICE: 16. Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 120 Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 121 Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Remove the Console mast cover and Console Mast End Cap. NOTICE: computer operation.
Page 122 NOTICE: operation. down iinto the machine. NOTICE: two people. Mast mount—older version...
Page 123 remove all slack. NOTICE: onto the mast mount. Hand tighten the screws Mast mount—older version NOTICE: screw.
Page 124 to the opening at the top. Console Mast. NOTICE: the computer operation. 13. Using a #2 Phillips screwdriver, re-install the Console. NOTICE: computer operation. Install the Console Mast End Cap and Console mast cover. Make sure the Console and Console Mast are aligned with the Console Mast.
Page 125: Replace The Pedals
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 126 Note: Locked position Be sure locked position. Be sure the bike is stabilized in the upright position with If the Lean Lock mechanism is not engaged, the bike may become unbalanced and fall, which can cause injury or damage to the equipment. Note: The Left Pedal is reverse-threaded.
Page 127 does not turn smoothly into the Crank Arm, make sure that the threads are aligned correctly. Be sure that the Pedal is going on straight into Pedal and start again. Note: The Left Pedal is reverse-threaded. 15mm Repeat with the other Pedal. Note: tightened.
Page 128: Replace The Resistance Magnet Carriage
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 129 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Left side Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc and then the top screws.
Page 130 NOTICE: senso sensor r Carriage.
Page 131 Left side Carriage to the Resistance Adjuster. NOTICE: Inner pivot pivot Pivot mount Note: Inner pivot install the new pivot screws and washers. NOTICE: touch the Flywheel. 10. Re-install all remaining parts that were removed in reverse order. Left side NOTICE: is the same as noted in step 5.
Page 132: Replace The Resistance Pcb
Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed States and other countries. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 133 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Left side Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc and then the top screws.
Page 134 long #2 Phillips screwdriver, remove the indicated hardware (arrows) and remove the old Resistance PCB. Resistance PCB NOTICE: Resistance Cable Using a long #2 Phillips screwdriver, attach the new Resistance NOTICE: Re-install all remaining parts that were removed in reverse order. NOTICE: Final Inspection Inspect your machine to ensure that all hardware is tight and components...
Page 135 This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 136 NOTICE: procedure. Note: Locked position Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc Note: It is not necessary to remove the Crank Arm and Center Disc in order to remove the Shroud.
Page 137 Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Left side Center disc Main Note: It is not necessary to remove the Crank Arm and Center shroud Disc in order to remove the Shroud. Left Main shroud removed Center disc shroud...
Page 138 Left side Left side NOTICE: Pivot Pivot Pivot Pivot bracket bracket NOTICE: knob rod knob rod...
Page 139 the Frame center post. NOTICE: Left side Pivot bracket Pivot step 8. Slot in frame 14. Using a 10 mm open end wrench and 3 mm Magnet Carriage. NOTICE: 15. Re-install all remaining parts that were removed in reverse order. NOTICE: 17.
Page 140: Replace The Shrouds / Front Fenders
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 141 NOTICE: Note: Be sure Locked position the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. If you are replacing the Main Shrouds, continue to step 2. If you are replacing the Front Fenders, go to Section 2 of this procedure.
Page 142 Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Left side Center disc Main Note: It is not necessary to remove the Crank Arm and Center shroud Disc in order to remove the Shroud. Installation steps are the reverse procedure. NOTICE: Final Inspection Inspect your machine to ensure that all hardware is tight and components...
Page 143 Section 2 Using a #2 Phillips Screwdriver, remove the 3 screws (d) that attach Note: Installation is the reverse procedure. Final Inspection Inspect your machine to ensure that all hardware is tight and components Left side Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 144 Section 3 Using a #2 Phillips Screwdriver, remove the 3 screws (e) that attach Note: Using a #2 Phillips Screwdriver, remove the 2 screws (e) that attach Left side Note: Installation is the reverse procedure. NOTICE: Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.
Page 145: Replace The Speed Sensor
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 146 NOTICE: procedure. Locked position Note: Be sure the locked position. Be sure the bike is stabilized in the upright position bike may become unbalanced and fall, which can cause injury or damage to the equipment. Left side Using a #2 Phillips Screwdriver, remove 3 screws (a) that attach Center disc and then the top screws.
Page 147 Cable support loop NOTICE: Speed sensor wire Resistance cable harness Speed sensor Using a #2 Phillips screwdriver, remove the indicated hardware Speed sensor Using a #2 Phillips screwdriver, install the new Speed Sensor. loop. NOTICE: Re-install all remaining parts that were removed in reverse order. NOTICE: Final Inspection Inspect your machine to ensure that all hardware is tight and components...
Page 148: Replace The Tilt Sensor Pcb
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand all Warnings on this machine. Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed ORIGINAL DOCUMENT - ENGLISH VERSION ONLY This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 149 NOTICE: Note: Be sure Locked position the locked position. Using a #2 Phillips Screwdriver, remove the 3 screws (a) that Note: Repeat steps 2 and 3 on the other side. Left side...
Page 150 NOTICE: Tilt sensor Tilt sensor Console Console cable cable sensor cable sensor cable Installation is the reverse procedure. NOTICE: Final Inspection Inspect your machine to ensure that all hardware is tight and components Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.

Nautilus Bowflex VeloCore Series Service Manual

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