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20

Maintenance Procedures

Replace Cam Assembly (continued)

11. Install New Cam Assembly.

Reverse the disassembly procedure to install the new Cam Assembly with the

following notes.

1.When replacing the Lower Spool, make sure to wind the strap counter clockwise. ( Figure A )

Figure A

Lower Spool

2.When sliding the Tension Shaft back into position, slowly slide the shaft through until it clicks
into place. If you do not feel or hear a distinct click, make sure the shaft is centered by measuring
the amount of exposed shaft on each side of the main unit.

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Summary of Contents for Revolution FT

Page 1: ...The Bowflex Revolution Revolution XP and Revolution FT Home Gym Service Manual P N 000 6911 Rev A 04 2007 ...

Page 2: ...Specifications Approvals 3 Revolution Models 4 Preventative Maintenance 5 Untangle Derailed Rope 6 Adjust RopeTension 15 Replace Cam Assembly 15 Replace Rope 22 Table of Contents ...

Page 3: ...LatTower Revolution Revolution FT Revolution XP XP with LatTower Revolution Revolution FT Revolution XP XP with LatTower 336 2 lbs 152 5 kg 234 3 lbs 106 1kg 291 2 lbs 131 4kg 319 9 lbs 144 4kg 414 46 lbs 188 1kg 253 9 lbs 115 1kg 316 6 lbs 143 5kg 350 8 lbs 159kg 112 L x 63 W x 73 H 284cm x 160cm x 185cm 64 5 L x 37 8 W x 73 H 163 8cm x 98cm x 185 4cm 64 5 L x 37 8 W x 73 H 163 8cm x 98cm x 185 4...

Page 4: ... Revolution Revolution FT Revolution XP Revolution Models ...

Page 5: ... and straps for fraying or excessive wear Yearly Remove theTop Cover and inspect the condition of the internal components look for fraying or excessive wear on straps ropes and moving parts and replace as necessary Preventative Maintenance Before adding or removing resistance packs spray a light coating of silicone lube on the shaft This will allow the packs to slide easily on and off the shaft No...

Page 6: ... packs except for the attached pre stretch pack Step 1 RemoveTop Cover 1 1 Use a 1 8 allen wrench to remove the four allen bolts that secure theTop Cover See Figure 1 Set bolts aside for Step 14 1 2 RemoveTop Cover and set aside Step 2 Remove Shroud Clip 2 1 If there is a Clip securing the shrouds under top inside remove the Clip The clip may already have been removed after shipping See Figure 2 S...

Page 7: ...to remove the screw securingTension Adjust Knob Cap Figure 3a and set aside for Step 13 3 2 Once the Screw is removed use the screwdiver to gently pry the cap out of the knob Figure 3b Figure 4 Tension Adust Knob Step 4 RemoveTension Adjust Knob 4 1 Use a phillips head screwdriver to remove the four screws securing theTension Adust Knob See Figure 4 Set screws aside for Step 12 4 2 Remove theTensi...

Page 8: ...rter screws Set screws safely aside for Step 10 5 2 Remove the Shroud and set aside See Figure 5 Figure 6a Figure 6b Figure 6c Lower Spool Step 6 Remove Lower Spool 6 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool See Figure 6a Set bolt aside for Step 9 6 2 Remove the Spool Figure 6a unwrap the Strap Figure 6b and hook the Spool behind the frame Figure 6c to keep it out of y...

Page 9: ...ervice Manual Maintenance Procedures Untangle Derailed Rope continued Large Pulley Tangled Rope Figure 7a Figure 7b Step 7 Remove Large Pulley 7 1 Slide the Large Pulley Figure 7a and tangled Rope Figure 7b off of the axle ...

Page 10: ... re wrap the rope in the outer most channel on the Large Pulley Figure 8a 8 2 Slide the Large Pulley back onto the axle and finish wrapping the Rope by turning the Large Pulley in a clockwise direction NOTE Do not let go of the Large Pulley See Figure 8b Keep tension on the Rope to make sure it stays in the channel while performing the next step ...

Page 11: ... Spool Strap Figure 9a Figure 9b Figure 9c Step 9 Replace Lower Spool 9 1 While still holding the Large Pulley in place coil the Strap around the Spool in a counter clockwise dirction See Figure 9a 9 2 Slide the Spool back onto the axle Figure 9b and secure the Lower Spool with allen bolt Figure 9c ...

Page 12: ...pe passes between the guides on the inside of the Shroud Figure 10c and beneath the fender on the left side of the Pulley see Figure 10a 10 3 Secure the Shroud with five phillips head screws one longer screw and four shorter screws from Step 5 Note the location for the long screw in Figure 10d Figure 10b Figure 10c Left rope and rope guides Figure 10d Location of long screw to secure shroud Figure...

Page 13: ... top inside See Figure 11 If there is no Clip go to Step 12 Figure 13 Clip Figure 11 Figure 12 Step 12 ReplaceTension Adjust Knob 12 1 Use a phillips head screwdriver and four screws to secure theTension Adjust Knob See Figure 12 Step 13 ReplaceTension Adjust Knob Cap 13 1 Use a phillips head screwdriver and one screw to secure theTension Adjust Knob Cap See Figure 13 ...

Page 14: ...four allen bolts rom step 1 to secure theTop Cover See Figure 14 Step 15 Adjust RopeTension 15 1 Pull outTension Adjust Knob and rotate Large Pulley in a clockwise direction until it stops then release theTension Adjust Knob to lock See Figure 15 Step 16 Final Check Please inspect your machine to ensure that all fasteners are tight and everything is properly assembled ...

Page 15: ...wise direction until it stops then release the Tension Adjust Knob to lock Large Pulley Tension Adjust Knob Replace Cam Assembly 1 RemoveTop Cover 1 1 Use a 1 8 allen wrench to remove the four allen bolts that secure theTop Cover 1 2 RemoveTop Cover and set aside 2 Remove Shroud Clip 2 1 Remove the Clip securing the shrounds under top inside ...

Page 16: ...e the screwdiver to gently pry the cap out of the knob Figure B Figure A Figure B Tension Adust Knob Cap Tension Adust Knob Maintenance Procedures Replace Cam Assembly continued 4 RemoveTension Adjust Knob 4 1 Use a phillips head screwdriver to remove the four screws securing theTension Adust Knob 4 2 Remove theTension Adjust Knob and set aside Tension Adust Knob ...

Page 17: ...ide Shroud Replace Cam Assembly continued Maintenance Procedures 6 RemoveTension Shaft From Cam Assembly 6 1 Use a 7 32 allen wrench to loosen the eight bolts on theTension Shaft Holder Figure A 6 2 Pull theTension Shaft through Figure B until it clears the Cam Assembly Figure C being replaced Figure A Figure B Figure C Tension Shaft Holder Tension Shaft Cam Assembly ...

Page 18: ...lts from the Pre Tension Pack Figure A 7 2 Remove the Pre Tension Pack Figure B Figure A Figure B Pre Tension Pack Cam Assembly 8 Remove Lock Collar From Cam 8 1 Use a flat head screwdriver to pry up the bottom tab on the Lock Collar Figure A Detail A 8 2 Remove the Lock Collar from Cam Figure B Figure A Figure B Detail A Cam Lock Collar ...

Page 19: ...ce Manual Replace Cam Assembly continued Maintenance Procedures 9 Remove Cam 9 1 Remove Cam from Cam Axle 10 Remove Lower Spool 10 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool 10 2 Remove the Lower Spool ...

Page 20: ... notes 1 When replacing the Lower Spool make sure to wind the strap counter clockwise Figure A Figure A Lower Spool 2 When sliding theTension Shaft back into position slowly slide the shaft through until it clicks into place If you do not feel or hear a distinct click make sure the shaft is centered by measuring the amount of exposed shaft on each side of the main unit ...

Page 21: ...aft Holder tighten the screws in numerical order shown on the tensioner Tighten the two screws marked 1 then the two marked 2 and so on Tension Screws Tension Shaft Holder Tighten screws in order 1 1 2 2 3 3 then 4 4 Replace Cam Assembly continued Maintenance Procedures ...

Page 22: ...ol 2 1 Use a 7 32 allen wrench to remove the bolt securing the Lower Spool 2 2 Remove the Spool Figure A unwrap the Strap Figure B and hook the Spool behind the frame Figure C to keep it out of your way Figure A Figure B Figure C Lower Spool 3 Remove Large Pulley 3 1 Slide the Large Pulley off of the axle Large Pulley ...

Page 23: ...n 5 2 Tie a piece of string about 6 feet long to the end of the old Rope Figure A 5 3 Gently pull the old Rope through the Arm and and over the Upper Pulley leaving the string theaded through the arm Figure B Note Do not pull the string through the arm Leave enough string exiting at the Lower Pulley to pull the new Rope back through Figure A Figure B Upper Pulley Lower Pulley Rope Arm Rope String ...

Page 24: ...Thread the new Rope through the Arm by gently pulling the string from the Lower Pulley Lower Pulley Rope String 7 Clamp Rope In Large Pulley 7 1 Feed the Rope through the hole in the Large Pulley and clamp in place Note To be sure Rope is securely clamped leave about 1 4 showing on the inside of the clamp 1 4 of Rope showing 8 Reverse Steps 3 2 and 1 to reassemble ...

Page 25: ...nual 2005 Nautilus Inc All rights reserved 16400 S E Nautilus Drive Vancouver Washington USA 98683 Bowflex Bowflex Revolution Spiraflex and the Bowflex and Nautilus logos are either registered trademarks or trademarks of Nautilus Inc ...

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