Bowflex Max Total 16/40 Page 98 Service Manual Download

Page: 98 / 151

Rear Shroud

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 and place them out of the work area.

Note:

Be aware that the Right and Left Upper Handlebar must be sup-

ported when removing the hardware.

4. Using a #2 Phillips screwdriver, remove the indicated screw from the

Rear Shroud.

5. 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.

6. Remove the Caps from the machine.

7. Using a 6mm hex wrench, remove the hardware exposed from below

the Cap from both sides of the machine.

8. Slide the Leg Assemblies off of the machine.

Left Upper

Handlebar

Right Upper

Handlebar

Cap

Leg Assembly

Right Stabilizer

Shroud

Left Stabilizer

Shroud

Cap

Leg Assembly

Summary of Contents for Max Total 16/40

Page 1: ...d Pedals 17 1 Noises Main 18 1 Noises Metallic Grinding or Scraping 19 1 Noises Rubbing Belt 20 1 Noises Clicking Clunking or Knocking 21 1 Noises Squeaking Squealing or Chirping 22 1 Contact Heart Rate Issues 23 1 Bluetooth Heart Rate Issues 24 1 Upper Drive Pulley 25 1 Power Off and Restart the Machine 26 1 Replacement Procedure Skill Level 27 Mechanical Modification Procedures 2 Adjust the Brak...

Page 2: ...ng labels become loose unreadable or dislodged replace the labels If purchased in US Canada contact Customer Service for replacement labels If purchased outside US Canada contact your local distributor for them Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety and will void the warranty Do not put the machine back in service unt...

Page 3: ... does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to ...

Page 4: ...he fitness machine Maximum User Weight 136 kg 300 lbs Total Surface Area footprint of equipment 9648 8 cm2 1494 5 in2 Maximum Pedal Height 48 5 cm 19 1 inches Machine Weight approx 70 5 kg 155 4 lbs Power Requirements AC Adaptor Input Voltage 100 240V AC 50 60Hz 1 5A Output Voltage 12V DC 5A Heart Rate Armband 1 Lithium Polymer battery not replaceable DO NOT dispose of this product as refuse This ...

Page 5: ...e machine needs to be leveled if your workout area is uneven or if the Rail Assembly is slightly off the floor To adjust 1 Place the machine in your workout area 2 Loosen the locking nuts and adjust the levelers until they are evenly balanced in contact with the floor Do not adjust the levelers to such a height that they detach or unscrew from the machine Injury to you or damage to the machine can...

Page 6: ...ve cover if provided from the Heart Rate Sensor before use Bluetooth Heart Rate Armband A Bluetooth Heart Rate Armband is provided with your fitness machine To use the Bluetooth Heart Rate Armband follow the instructions that were included with the Armband If you have a pacemaker or other implanted electronic device consult your doctor before using a Bluetooth armband or other Bluetooth heart rate...

Page 7: ...n active workout If the On Off LED button is pushed after being connected the workout must be restarted Bluetooth Audio in or out Your machine is able to play audio across a Bluetooth connection from your smart device through the console speakers The machine can also stream audio from the console to your Bluetooth device such as Bluetooth headphones Note Bluetooth audio can only be streamed in one...

Page 8: ... in a secure location Daily Before each use examine the exercise machine for loose broken damaged or worn parts Do not use if found in this condition Repair or replace all parts at the first sign of wear or damage After each workout use a damp cloth to wipe your machine and Console free of sweat Note Avoid excessive moisture on the Console Weekly Check for smooth roller operation Wipe the machine ...

Page 9: ...ert Y Shroud Right Fan D Upper Wiring Harness Resistance Cable Heart Rate Cable O Leveler Z Rail Assembly E Static Handlebar P Stabilizer AA AC Adapter F Upper Shroud Q Transport Wheel BB Stabilizer Shroud Right G Shroud Left R Stabilizer Shroud Left CC Cap H Crank Cover S Shroud Left Fan DD Shroud Rear I Dynamic Handlebar Left T Fan Assembly Inserts EE Tray Insert J Leg U Frame Assembly FF Dynami...

Page 10: ...NN LL MM QQ HH GG Arm Drive Assembly HH Crank Arm Left II Drive Pulley Upper JJ Drive Belt KK Tensioner LL Fan Assembly MM Speed Sensor NN Disc Brake OO Fan Belt PP Drive Pulley Lower QQ Crank Arm Right RR Upper Body Sensor ...

Page 11: ...p While in Use C Resistance Does Not Respond D Machine Seized Up E Machine Slips During Use F Rollers and Pedals G Noises Main H Metallic Grinding or Scraping I Rubbing Belt J Clicking Clunking or Knocking K Squeaking Squealing or Chirping L Contact Heart Rate M Bluetooth Heart Rate N Upper Drive Pulley ...

Page 12: ... be gently unplugged before completely removing the cover NO Remove console from console mast Unplug I O cables and inspect for damage Reconnect cables Each Cable connector 3 pin 4 pin 5 pin and 12 pin has a corresponding end connector with that many openings Be sure to orient the cables properly as shown and to fully connect the cable connectors Is the end of the adapter cord broken YES NO YES Co...

Page 13: ...ved The speed sensor is located at the front of the frame pointing at the fan Look closely at the tip of the sensor and check for any damage Remove the hardware from the right lower round cover To remove the right lower round cover the power plug inlet wire must be gently released from the inside of the cover Once the power plug inlet wire is released remove the cover from the machine YES YES Plug...

Page 14: ... Visually inspect the motor Check to make sure that the metal cable is properly attached to the motor and the brake arm Has the metal tension cable come off track or need adjustment Replace the cable Replace the brake assembly Reattach adjust the tension cable NO NO YES YES YES Begin any workout using the console Turn the Resistance Knob up and see if the Servo Motor and Brake Arm move Did they mo...

Page 15: ...the belt physically damaged Has the belt become jammed in the frame Replace Machine Engine YES Remove the right side lower round cover Are the magnets stuck to the brake disc Go to Troubleshoot ing Metallic Grinding and Scraping YES Does the issue persist Issue resolved Follow the Replace the Crank Arms procedure to remove and reorient one Crank Arm so that they are 180 opposite each other as show...

Page 16: ...rsist Issue resolved NO NO Does it slip less Does the issue persist Refer to the Replace The Drive Belt procedure 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 Re tighten the Drive Belt Tensioner Screw YES NO YES ...

Page 17: ...r wheel set Did this resolve the issue Issue resolved Issue resolved Replace both crank arms YES NO Remove both pedal arms Remove both plastic crank covers Be careful not to use a Phillips head screw driver that is too small These screws are sometimes very tight and can strip easily Use a 14mm socket to tighten both crank nuts as much as possible Did this resolve the issue YES YES NO YES Install W...

Page 18: ... Squeaking Squealing or Chirping Go to Troubleshoot ing Noise Issues Squeaking Squeal ing or Chirping Clicking Clunking or Knocking Go to Troubleshoot ing Noise Issues Clicking Clunking or Knocking Rubbing Go to Troubleshoot ing Noise Issues Rubbing Metallic Grinding or Scraping Go to Troubleshoot ing Noise Issues Metallic Grinding or Scraping ...

Page 19: ...e the source of the noise Contact Customer Care for Advanced Troubleshooting Follow the Adjust the Brake Assembly procedure Note It is normal for the brake disc to appear to wobble as long as it does not contact the magnets while spinning Have the magnets broken off the red plastic arm YES NO Replace the Brake Assembly and Brake Disc Replace Machine Engine NO Is the brake disc visibly forced away ...

Page 20: ... Which side is the noise coming from the left or right side NO Loosen the belt tensioner and reset the belt Go to Troubleshoot ing Upper Drive Pulley Is the upper pulley loose wobbly or crooked Are the 4 bolts loose Are any of the 4 bolts missing Is the noise coming from the upper pulley Remove the right lower round cover 4 screws Then remove the metal brake disc 3 screws Go to Troubleshooting Sli...

Page 21: ...tighten the 4 large bolts on the base assembly BOTTOM NO Does the noise persist Is the noise coming from the rollers or pedal arms YES NO NO Go to Troubleshoot ing Roller and Pedal Remove both pedal arms and rotate the cranks with your hands WARNING There will be grease on the crank arms Issue resolved Issue resolved Remove both the crank covers and manually rotate the crank arms Listen carefully ...

Page 22: ...bricant with a towel or cloth Test for noise on each side NO Apply a small drop of silicone based lubricant on the rails and then wipe the rails with a dry towel If too much lubricant is applied then the roller wheel may not roll Pedal the machine slowly to ensure that the roller wheels are turning freely Re attach the end caps loosely If they are pushed on too tight they will make squeaking noise...

Page 23: ...h equal pressure and as little movement as possible without touching the metal frame Does the issue persiﬆ Issue resolved Replace the Static Handlebar Assembly Explain that the HR may spike initially at a high rate when ﬁrﬆ touching the contact plates This is normal and it will normalize out after waiting a couple of minutes Try not to move the hands while waiting If a quicker HR reading is requir...

Page 24: ...p only push the On Oﬀ LED button once after the workout has ﬆarted It may take up to 60 seconds to connect If the On Oﬀ LED button is pushed multiple times the workout muﬆ be re ﬆarted Make sure that the Strap is fully charged Be sure that Bluetooth is enabled on the Console If the Bluetooth icon is red it is disabled Tap the icon and activate it Make sure you are using a Bluetooth Heart Rate HR S...

Page 25: ... the back of the pulley By manipulating the foot pedals the pulley will rotate allowing the ability to check all four screws Note whether all four screws are in place Note whether all screws stick out about the same distance Check that the belt is in place and is not visibly damaged Attempt to wiggle the pulley towards and away from the mast Observe whether the pulley wobbles as it rotates After i...

Page 26: ...arted 1 To power off the machine log the user out from the Console 2 Unplug the power cord from the machine To prevent unsupervised operation of the machine always disconnect the power cord from the wall outlet and machine power input Place the power cord in a secure location To restart the machine 1 Plug in the machine to a functioning wall outlet The machine will start up and the red Status LED ...

Page 27: ...el III Advanced knowledgeable about mechanical procedures To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet before cleaning maintaining or repairing this machine Place the power cord in a secure location When disposing of old parts obey the applicable local and provincial requirements ...

Page 28: ...or 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk t...

Page 29: ...nd only loosen the lowest indicated screw arrow from the Right Fan Cover Note Loosen the lowest screw by at least 3 full rotations 5 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 Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by p...

Page 30: ...30 6 At the maximum resistance setting the outer edge of the Brake Magnet should line up with the outer edge of the Brake Disc Brake Disc Brake Disc Brake Assembly Brake Magnet Brake Magnet Brake Disc ...

Page 31: ...und the Brake Disc 10 If the Brake Assembly only needs to be slightly adjusted loosen the front screw indicated by double tailed arrow that secures the Brake Assembly using a 10mm wrench Rotate the Brake Assembly until the Magnets are aligned and of equal distance from the Brake Disc If the Brake Assembly must be fully shifted loosen the 2 screws indicated by arrows that secure the assembly and sh...

Page 32: ...ine function 11 Installation is the reverse procedure 12 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual ...

Page 33: ...y from foot traffic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus repl...

Page 34: ...emove the 1 indicated screw from the Rear Shroud 3 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 just releases Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off Rear Shroud Rail Assembly Roller riding slightly outward or off of the Rail Assembly ...

Page 35: ...y back and forth or wiggle until it seems to settle into the correct configuration The Rollers will have adjusted with the Rail As sembly and should be more on with the groove of the Roller centered onto the Rail Assembly 7 Installation is the reverse procedure 8 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the ma...

Page 36: ...vice this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine fr...

Page 37: ...the Console Assembly 4 Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 5 Carefully disconnect the Cables and place the Console outside the work area Note Do not crimp any of the Console Cables Note Your machine may not match the images provided exactly Console Assembly ...

Page 38: ...White Wire from the others and cut it twice with scissors or wire cutters The first cut should be as near the 5 pin Wire Connector as possible and the second cut should be where the Cable Sleeve covers all the Wires Note Be sure not to cut or crimp any of the other Wires Resistance Knob Cable 5 pin 5 pin Wire Connector Console Mast Resistance Knob Cable White Wire 5 pin Wire Connector Cable Sleeve...

Page 39: ...connector with that many openings Be sure to fully connect the cable connectors When attaching the Console Assembly do not fully tighten the hardware until all hardware has been hand tightened 10 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...

Page 40: ...ower and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement p...

Page 41: ...rew arrow from the Right Fan Cover Note Loosen the lowest screw by at least 3 full rotations 5 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 Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to th...

Page 42: ...the Brake Disc from the machine 8 Place a piece of tape as a marker on the Brake Cable immediate ly above the Brake Arm During re assembly the tape will be a guide for the placement of the new Brake Arm on the Brake Cable Brake Disc Brake Assembly Magnets Brake Assembly Brake Arm Brake Cable Piece of tape ...

Page 43: ...tance setting the outer edge of the Brake Magnet should line up with the outer edge of the Brake Disc Brake Assembly Brake Disc Brake Arm Brake Spring Brake Cable Hardware Brake Cable 9 While applying upward pressure to the Brake Arm remove the hardware that secures the Brake Cable to the Brake Arm with a 2 5mm hex wrench Once loose gradually lower the Brake Arm Note Be aware that the Spring will ...

Page 44: ... be sure it does not make contact with the mag nets If further adjustment is needed repeat step 20 Keep fingers out of any pinch opportunities when rotating the Brake Disc 16 If the Brake Assembly needs to be adjusted use a 8mm open ended wrench to loosen the Brake Cable Securing Nut Turn the Adjustment Bar rel by hand until the magnet is placed correctly 17 Carefully rotate the Brake Disc If the ...

Page 45: ...ine function 20 Installation is the reverse procedure 21 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual ...

Page 46: ...equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the ...

Page 47: ...ose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 5 Carefully disconnect the Cables Note Do not crimp any of the Console Cables Note Your machine may not match the images provided exactly Console Assembly 6 Installation is the reverse procedure Note Do not cut or crimp the Cables Each Cable connector 3 pin 4 pin 5 pin and 12 pin has a correspond...

Page 48: ...nspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual ...

Page 49: ...e equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void th...

Page 50: ...dicated by ovals from the Console Assembly 4 Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 5 Carefully disconnect the Cables Note Do not crimp any of the Console Cables Note Your machine may not match the images provided exactly Console Assembly ...

Page 51: ...y require two people 9 Carefully disconnect the USB Cable from the Console Front Panel to the Console Rear Panel Note Do not crimp any of the Cables 10 Swap in the new Console Rear Panel Console Rear Panel USB Cable Console Front Panel 11 Carefully bring the new Console Rear Panel over to the Console Front Panel Route the four Cables from the Console Front Panel through the opening on the new Cons...

Page 52: ...connector 3 pin 4 pin 5 pin and 12 pin has a corresponding end connector with that many openings Be sure to fully connect the cable connectors 15 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual ...

Page 53: ...bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure t...

Page 54: ...on for re use 5 Using a 5mm hex wrench remove the indicated hardware from the Left Upper Handlebar and place it out of the work area Note Be aware that the Left Upper Handlebar must be supported when removing the hardware 6 Place a rag or protective material below the Connector Arm to protect the Shrouds from potential scratches from the Connector Arms 7 Using a 6mm hex wrench remove the hardware ...

Page 55: ...ay have been over tightened when installed Try not to strip the screws when removing them 9 Remove the Left Crank Cover from the machine 10 Using a 9 16 or 14mm socket and wrench remove the indicated nut from the Crank Assembly 11 Adjust the Crank Puller until the end of the Bolt is inside the Nut as shown Bolt Nut Crank Cover ...

Page 56: ...e Crank Arm 15 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 16 Final Inspection Inspect your machine to ensure that ...

Page 57: ... bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure ...

Page 58: ...for re use 5 Using a 5mm hex wrench remove the indicated hardware from the Right Upper Handlebar and place it out of the work area Note Be aware that the Upper Handlebar must be supported when removing the hardware 6 Place a rag or protective material below the Connector Arm to protect the Shrouds from potential scratches from the Connector Arms 7 Using a 6mm hex wrench remove the hardware that co...

Page 59: ...om the machine 11 Place a towel or rag inside of the machine below the indicated screws with arrows The towel or rag should be placed so that it will catch the screws if dropped 12 Using a 2 Phillips screwdriver remove the screws indicated by arrows that secure the Upper Body Sensor Allow the Upper Body Sensor to hang on the Cable away from the Right Crank Arm Note Shrouds are removed for clarity ...

Page 60: ...wn 15 Carefully thread the Crank Puller into the Crank Arm Be sure the Crank Puller has at least three rounds of threads inserted 16 Using an adjustable wrench turn the inner portion the Bolt of the Crank Puller clockwise The Crank Arm Assembly will slide off as it is tightened Note Be aware that the Crank Arm Assembly will be loose and will need to be supported Bolt Nut ...

Page 61: ... reverse procedure excluding steps with the Crank Puller The Crank Puller is not required for re assembly Note When replacing the Right Crank Arm be sure the Right and Left Crank Arms are oriented inline and opposite each other The Crank Nut should be tightened to a torque value of 29 32 5 ft lbs or 350 390 in lbs 22 Final Inspection Inspect your machine to ensure that all hardware is tight and co...

Page 62: ...low to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can ca...

Page 63: ...place them out of the work area Note Be aware that the Upper Handlebars must be supported when removing the hardware 2 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the Right and Left Stabilizer Shrouds from the machine if equipped Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud Left Upper Handlebar Right Upper H...

Page 64: ...Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from the left side of the machine 8 Using a 6mm hex wrench remove the hardware exposed from below the Cap 9 Lift the Foot Pedal and slide the Leg Assembly straight off the machine Be sure to pull straight out or the Leg Assembly may be...

Page 65: ...ssembly 16 Remove the Left Fan Cover Assembly from the machine Be sure to note how the fan screens are set into the Left Fan Cover to assist with the replacement procedure 17 Using a 2 Phillips screwdriver remove the 2 indicated by ovals screws from the Crank Cover Repeat on the other side of the machine 18 Remove the Crank Covers from the machine Note The Crank Cover screws may have been over tig...

Page 66: ...Drive Belt Keep fingers out of any pinch opportunities when removing the Fan Belt 24 Replace and tighten the A screw on the Drive Belt Tensioner Arm and then tighten the B screw 25 Installation is the reverse procedure 26 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 inspect...

Page 67: ...rom foot traffic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replace...

Page 68: ...t of the work area Note Be aware that the Upper Handlebar must be supported when removing the hardware 2 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the Right and Left Stabilizer Shrouds from the machine Right Upper Handlebar Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud ...

Page 69: ...ver from the assembly Note the Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from the machine 8 Using a 6mm hex wrench remove the hardware exposed from below the Ca...

Page 70: ...osened screw While pushing up on the tab remove the Left Fan Cover Assembly 14 Remove the Left Fan Cover Assembly from the machine Be sure to note how the fan screens are set into the Left Fan Cover to assist with the replacement procedure 15 Using a 2 Phillips screwdriver remove the 2 indicated screws from the Left Crank Cover 16 Remove the Left Crank Cover from the machine 17 Place a rag or prot...

Page 71: ...o the Left Crank Arm Be sure the Crank Puller has at least three rounds of threads inserted 22 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 Note Be aware that the Left Crank Arm will be loose and will need to be supported 23 Remove the Crank Puller from the Left Crank Arm Bolt Nut Left Crank Assembly Left Cra...

Page 72: ... free enough to be removed from the Drive Pulley Remove the Drive Belt Keep fingers out of any pinch opportunities when removing the Fan Belt 28 Using a 5mm hex wrench remove the four screws that attach the Drive Pulley Be sure to support the weight of the Drive Pulley when removing hardware because it will fall 29 Using a 5mm hex wrench attach the new Drive Pulley to the Frame Assembly 30 Replace...

Page 73: ...ft 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 33 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 74: ...affic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts ...

Page 75: ...at the Upper Handlebar must be supported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the indicated Cap from the machine 5 Using a 6mm hex wrench remove the hardware exposed from below the Cap 6 Slide the Left Leg Assembly off of the machine Upper Shroud Left Upper Handlebar Leg Assembly Cap ...

Page 76: ... the Connector Arm 10 Using a 6mm hex wrench remove the indicated hardware with arrows that connects the Left Connector Arm and the Pivot Arm Note The Connector Arm will pivot downward if not lowered slowly onto the rag protecting the Shroud 11 Using a 9 16 or 14mm socket and wrench remove the nut from the Left Crank Assembly 12 Adjust the Crank Puller until the end of the Bolt is flush with the N...

Page 77: ...he Replace the Drive Pulley Procedure for replacement instructions If one or more screws are currently missing skip to Step 21 If all four screws are present use an appropriately sized hex wrench to remove one of the four screws that attach the Drive Pulley 17 Using a 5mm hex wrench attach one of the replacement screws and lock washers provided in the kit Fully tighten the screw Once fully tighten...

Page 78: ...ft 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 20 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 79: ... 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to ...

Page 80: ...n 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 Note the Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self ...

Page 81: ...rocedure Note Your machine may not match the images provided exactly 8 Remove the Cone from the Fan Assembly There are 4 clips that attach the Cone that can be accessed behind the Fan Assembly Using a small standard screwdriver gently release the clips 9 Using a 5mm hex wrench remove the 4 screws from the Fan Assembly Be sure to support the Fan Assembly when removing hardware 10 Installation is th...

Page 82: ...ow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cau...

Page 83: ...dlebar and place it out of the work area Note Be aware that the Right Upper Handlebar must be supported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the Right and Left Stabilizer Shrouds from the machine if equipped Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud Right Upper Handleba...

Page 84: ...om the assembly Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from the machine 8 Using a 6mm hex wrench remove the hardware exposed from below the Cap 9 Sl...

Page 85: ...eeds to be pushed upward to clear the loosened screw While pushing up on the tab remove the Left Fan Cover Assembly 15 Using a 2 Phillips screwdriver remove the 2 indicated screws from the Right Crank Cover 16 Remove the Right Crank Cover from the machine Note The Right Crank Cover screws may have been over tightened when installed Try not to strip the screws when removing them 17 Place a rag or p...

Page 86: ...crews on the Right Shroud Remove the upper screws labeled last 20 Using a 2 Phillips screwdriver remove the 3 screws indicated by arrows from the Brake Disc 21 Carefully remove the Brake Disc from the machine exposing the lower Fan Belt Right Side Brake Magnets Brake Disc Fan Belt ...

Page 87: ...es when removing the Fan Belt 23 Loop the new Fan Belt around the lower Pulley and start it on the face of the Fan Pulley 24 Be sure the Fan Belt is centered on both pulleys 25 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 Heavy Duty Zip Tie ...

Page 88: ...hen rotating the Fan Pulley 27 Cut the Zip Tie without damaging the new Fan Belt or Fan Pulley 28 Installation is the reverse procedure 29 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 89: ...fic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts an...

Page 90: ...t out of the work area Note Be aware that the Right Upper Handlebar must be supported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud 4 Remove the Right and Left Stabilizer Shrouds from the machine Right Upper Handlebar Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud ...

Page 91: ...er from the assembly Note the Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from the machine 8 Using a 6mm hex wrench remove the hardware exposed from below the Cap...

Page 92: ... 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 15 Using a 2 Phillips screwdriver remove the 2 indicated screws from the Right Crank Cover 16 Remove the Right Crank Cover from the machine 17 Place a rag or protective material below the Right Connector Arm to protect the Shr...

Page 93: ...e Crank Puller into the Right Crank Arm Be sure the Crank Puller has at least three rounds of threads inserted 22 Using a 16mm wrench turn the inner portion the Bolt of the Crank Puller clockwise The Right Crank Arm will slide off as it is tightened Note Be aware that the Right Crank Arm will be loose and will need to be supported 23 Remove the Crank Puller from the Right Crank Arm Bolt Nut ...

Page 94: ...d 3 screws on the Right Shroud Remove the upper screws labeled last 25 Using a 2 Phillips screwdriver remove the 3 indicated screws from the Brake Disc 26 Carefully remove the Brake Disc from the machine exposing the lower Fan Belt Right Side Brake Magnets Brake Disc Fan Belt ...

Page 95: ...from the back side of the Drive Pulley 29 Using a 5mm hex wrench remove the four screws that attach the Fan Pul ley Be sure to support the weight of the Fan Pulley when removing hardware because it will fall 30 Using a 5mm hex wrench attach the new Fan Pulley to the Frame As sembly 31 Loop the new Fan Belt around the lower Pulley and start it on the face of the Fan Pulley 32 Be sure the Fan Belt i...

Page 96: ...ging the new Fan Belt or Fan Pulley 36 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 Arms be sure the Right and Left Crank Arms are oriented inline and opposite each other The Crank Nuts should be tightened to a torque value of 29 32 5 ft lbs or 350 390 in lbs 37 Final Inspection Inspect yo...

Page 97: ...cause injury to the service technician or bystanders Keep bystanders children and pets away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist th...

Page 98: ... the hardware 4 Using a 2 Phillips screwdriver remove the indicated screw from the Rear Shroud 5 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 6 Remove the Caps from the machine 7 Using a 6mm hex wrenc...

Page 99: ... and expose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 11 Carefully disconnect the Cables while not allowing them to fall into the Console Mast Note Do not crimp any of the Console Cables 12 Using an 8mm hex wrench remove the indicated hardware from the Rail Assembly Static Handlebar Assembly ...

Page 100: ... Using new Hardware Items C B and A attach the Rail Assembly to the new Frame Assembly Some components of the machine can be heavy or awkward Use a second person when doing the assembly steps involving these parts Do not do steps that involve heavy lifting or awkward movements on your own NOTICE Hand tighten hardware Rail Assembly C X4 B A ...

Page 101: ... assistance of a second person carefully lift the old Frame As sembly from the Stabilizer Assembly and place outside the assembly area To protect your flooring carefully place it onto its side on some cardboard or a blanket 17 Using a 13mm wrench remove the hardware that secures the new Frame Assembly to the shipping plate 18 Carefully Lift the new Frame Assembly and Attach It to the Stabilizer As...

Page 102: ...d then the hardware just installed to the Stabilizer Assembly 20 Using a 2 Phillips screwdriver attach the Upper Shroud to the Frame Assembly 21 Attach the Rear Shroud and Caps to the Frame Assembly NOTICE Place the inside hook of the Rear Shroud on the Frame Assem bly and then pivot it up into place 2 X1 F ...

Page 103: ...103 22 Attach Leg Assemblies to Frame Assembly Be aware that the Legs are connected and when either of these parts move the other does as well 6mm H G B A X2 I X2 ...

Page 104: ...tatic Handlebar Assembly to the Frame Assembly Note When attaching the Static Handlebar Assembly do not fully tighten the hardware until all hardware has been hand tight ened Do not crimp any of the Console Cables X4 O N M ...

Page 105: ...bly steps involving these parts Do not do steps that involve heavy lifting or awkward movements on your own NOTICE Be sure to attach the Upper Handlebars so they can be correctly grasped by a User when on the machine 25 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected...

Page 106: ... minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to us...

Page 107: ...t Assembly Note The Connector Arm will pivot downward if not lowered slowly onto the rag protecting the Shroud 5 Using a 6mm hex wrench remove the indicated hardware by arrow that connects the Handlebar Pivot Assembly to the Console Mast 6 Slide the Handlebar Pivot Assembly off of the Console Mast and replace with the new assembly 7 Installation is the reverse procedure 8 Repeat Steps 2 7 on the r...

Page 108: ...eavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure t...

Page 109: ...dicated by ovals from the Console Assembly 4 Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 5 Carefully disconnect the Cables Note Do not crimp any of the Console Cables Note Your machine may not match the images provided exactly Console Assembly ...

Page 110: ... from scratches gently place all parts on a towel or piece of cardboard before attempting to replace any Cable s 10 From the top of the Static Handlebar Assembly there are 4 Cables Upper Body Sensor Cable 3 pin flat connector To replace go to the next Step Input Output I O Cable 14 pin two row connector To replace go to the next Step Resistance Knob Cable 5 pin flat connector To replace go to Step...

Page 111: ... the piece of wire or string and discard the old Cable If not replacing the Resistance Cable go to Step 21 14 To replace the Resistance Cable that connects to the Resistance Knob remove the hardware indicated by an arrow from the Static Handlebar Assembly using a 2 Phillips screwdriver 15 Gently flip over the Static Handlebar Assembly onto a towel or piece of cardboard 16 Using a 2 Phillips screwd...

Page 112: ... wire or string and discard the old Resistance Cable 21 Re assemble the machine in the reverse order of when the parts were removed Note Do not cut or crimp the Cables Each Cable connector 3 pin 4 pin 5 pin and 14 pin has a corresponding end connector with that many openings Be sure to fully connect the cable connectors When attaching the Console Assembly do not fully tighten the hardware until al...

Page 113: ...t for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a ris...

Page 114: ... and place them out of the work area Note Be aware that the Right and Left Upper Handlebar must be sup ported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the Right and Left Stabilizer Shrouds from the machine Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud Left Upper Handlebar Right...

Page 115: ...ight Fan Cover from the assembly Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from both sides of the machine 8 Using a 6mm hex wrench remove the hardware ...

Page 116: ...Cover Assembly 14 Remove the Left Fan Cover Assembly from the machine Be sure to note how the fan screens are set into the Left Fan Cover to assist with the replacement procedure 15 Using a 2 Phillips screwdriver remove the 2 indicated screws from the each of the Crank Covers Note The Crank Cover screws may have been over tightened when installed Try not to strip the screws when removing them 16 R...

Page 117: ...cated above the Servo Motor After noting how the cables connect to the PCBA Board Assem bly disconnect the cables from it Note Be sure not to crimp or cut any of the cables Right Side Left Side PCBA Board Assembly Servo Motor Servo Motor ...

Page 118: ... a short 2 Phillips screwdriver attach the new PCBA Board Assembly to the Frame and connect the cables 22 Re install all remaining parts that were removed in reverse order 23 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 assem bled and inspected for correct performance in accordance with ...

Page 119: ...ving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stickers and instructional placards applied to the product stay present a...

Page 120: ...y at least 3 full rotations 4 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 Note the Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the uppe...

Page 121: ... Inlet from the inside of the Right Fan Cover 8 Installation is the reverse procedure 9 Final Inspection Inspect your machine to ensure that all hardware is tight and compo nents 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 Power Inlet Securing Ring Power Connector Brake Disc Power Cable ...

Page 122: ...e you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the m...

Page 123: ...before re assembly 4 Attach the new Roller Wheel Assembly with the provided hardware The new Roller Wheel Assembly includes two Small Metal Washers and two Large Felt Washers Make sure the Small Metal Washers are installed on the outside of the Wheel Brackets while the Large Felt Washers are on the inside of the Wheel Bracket to the outside of the Roller Wheels Note The Wheel Bracket is sized so t...

Page 124: ...tes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users k...

Page 125: ...ted screw arrow from the Right Fan Cover Note Loosen the lowest screw by at least 3 full rotations 5 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 Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close...

Page 126: ...e Servo Motor Arm 9 Remove the Brake Spring from the Brake Arm 10 Disconnect the Cables from the Servo Motor 11 Using a 2 Phillips screwdriver remove the 4 screws that attach the Servo Motor to the Frame 12 Attach the new Servo Motor to the Frame and reconnect the Cables 13 Carefully replace the Brake Disc Brake Magnets Brake Disc Fan Belt Servo Motor Brake Cable Securing Nut Servo Motor Arm Servo...

Page 127: ...djustment Barrel by hand until the magnet is placed correctly 16 Carefully rotate the Brake Disc If the Brake Disc does not rub against the Brake Magnet skip to step 19 Keep fingers out of any pinch opportunities when rotating the Brake Disc Note The Brake Disc may appear to have a slight wobble This is normal and will not affect machine function Brake Magnet Brake Disc Brake Disc Brake Assembly B...

Page 128: ...are aligned and of equal distance from the Brake Disc If the Brake Assembly must be fully shifted loosen the 2 screws indicated by arrows that secure the assembly and shift it until centered and aligned with the Brake Disc Fully tighten the hardware 19 Installation is the reverse procedure 20 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly ass...

Page 129: ...ow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cau...

Page 130: ... and place them out of the work area Note Be aware that the Right and Left Upper Handlebar must be sup ported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud and remove it 4 Remove the Right and Left Stabilizer Shrouds from the machine Right Stabilizer Shroud Left Stabilizer Shroud Upper Shroud Left Upper Handlebar Right...

Page 131: ...ight Fan Cover from the assembly Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from both sides of the machine 8 Using a 6mm hex wrench remove the hardware ...

Page 132: ...Cover Assembly 14 Remove the Left Fan Cover Assembly from the machine Be sure to note how the fan screens are set into the Left Fan Cover to assist with the replacement procedure 15 Using a 2 Phillips screwdriver remove the 2 indicated screws from the each of the Crank Covers Note The Crank Cover screws may have been over tightened when installed Try not to strip the screws when removing them 16 R...

Page 133: ...n face wrench remove the Securing Ring from the outside of the Right Fan Cover B Remove the Power Inlet from the inside of the Right Fan Cover 21 Installation is the reverse procedure 22 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 as sembled and inspected for correct performance in acco...

Page 134: ...you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the mac...

Page 135: ...east 3 full rotations 4 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 Note the Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper scre...

Page 136: ... Phillips screwdriver attach the new Speed Sensor Be sure to place it 3mm 1 8 from the Speed Sensor Magnet on the Fan Disc 8 Route the new Speed Sensor Cable under the bracket and con nect the cable 9 Installation is the reverse procedure 10 Final Inspection Inspect your machine to ensure that all hardware is tight and compo nents are properly assembled Do not use until the machine has been fully ...

Page 137: ...e equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void th...

Page 138: ...dicated by ovals from the Console Assembly 4 Carefully tilt the Console Assembly off of the Static Handlebar and expose the Cable Connections Note Do not crimp any of the Console Cables This step may require two people 5 Carefully disconnect the Cables Note Do not crimp any of the Console Cables Note Your machine may not match the images provided exactly Console Assembly ...

Page 139: ...e Console Cables 9 Replace the old Static Handlebar Assembly for the new one 10 Installation is the reverse procedure Note Do not cut or crimp the Cables Each Cable connector 3 pin 4 pin 5 pin and 12 pin has a corresponding end connector with that many openings Be sure to fully connect the cable connectors 11 Final Inspection Inspect your machine to ensure that all hardware is tight and components...

Page 140: ... all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replace...

Page 141: ...re from the Right and Left Upper Handlebar Note Be aware that the Right and Left Upper Handlebar must be sup ported when removing the hardware 3 Using a 2 Phillips screwdriver remove the 4 screws 2 indicated on one side from the Upper Shroud 4 Remove the Right Stabilizer Shroud from the machine Right Stabilizer Shroud Upper Shroud Left Upper Handlebar Right Upper Handlebar ...

Page 142: ...remove the Right Fan Cover from the assembly Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine To assist with assembly note that the upper screw is a machine screw and not a self tapping screw 7 Remove the indicated Cap from the machine 8 Using a 6mm hex wrench remove the hardware ex...

Page 143: ...rdware 13 Place a rag or protective material below the Right Connector Arm to protect the Shrouds from potential scratches from the Right Connector Arm 14 Using a 6mm hex wrench remove the hardware that connects the Right Connector Arm to the Right Pivot Arm indicated by arrow Note The Connector Arm will pivot downward if not lowered slowly onto the rag protecting the Shroud 15 Using a 2 Phillips ...

Page 144: ...he Right Shroud from the machine Right Side Note Shrouds are removed for clarity Upper Body Sensor Right Crank Arm Upper Body Sensor Cable Note View into Shrouds from above Upper Body Sensor 19 Using a 2 Phillips screwdriver remove the screws indicated by ar rows that secure the Upper Body Sensor Allow the Upper Body Sensor to hang on the Cable away from the Right Crank Arm ...

Page 145: ...y thread the Crank Puller into the Crank Arm Be sure the Crank Puller has at least three rounds of threads inserted 23 Using an adjustable wrench turn the inner portion the Bolt of the Crank Puller clockwise The Crank Arm Assembly will slide off as it is tightened Note Be aware that the Crank Arm Assembly will be loose and will need to be supported 24 Remove the Crank Puller from the Crank Arm ...

Page 146: ...mbly so it is in the same orientation 27 Using the 2mm hex wrench tighten the two screws that secure the Inner Codewheel Assembly 28 Slide the Right Crank Arm Assembly onto the machine Note Be sure not to damage or break the Outer Codewheel on the Right Crank Arm or the one still remaining on the machine 29 Re attach the Upper Body Sensor so that it is centered on the Outer and Inner Codewheels 30...

Page 147: ... 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 32 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 148: ...ice of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stickers and in...

Page 149: ...crew and not a self tapping screw 4 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 Note The Power Cable is attached to the inside of the Right Fan Cover Be sure not to crimp the cable by placing the Right Fan Cover close to the front of the machine 1 Unplug the AC Adapter from the wal...

Page 150: ...wer Zip Ties without damaging the Cables 7 Disconnect all the Cables that connect to the lower part of the old I O Cable 8 Connect all the Cables to the new I O Cable 9 Attach the unattached end of the new I O Cable to the old I O Cable using a piece of wire or string I O Cable Route Zip Tie Zip Tie I O Cable ...

Page 151: ...l the old I O Cable out of the frame routing the new I O Cable into place 15 Remove the piece of wire or string and discard the old I O Cable 16 Secure the lower Cables with a replacement Upper Zip Tie 17 Re assemble the machine in the reverse order of when the parts were removed Note When attaching the Console and Static Handlebar Assembly do not fully tighten the hard ware until all hardware has...

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