Bowflex Max Total 16/40 User manual

1
8027711.071522.B
8027706.071522.B
Service Manual
Table of Contents
Nautilus, Inc., [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2020 Nautilus, Inc.
| Bowflex, the B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. | The Bluetooth® word mark and
logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc. is under license. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
Bowflex™Max Total™16/40
Service Manual
™
™
Section Code Section Page Number
1 Important Safety Instructions 2
1 Safety Warning Labels and Serial Number 3
 1  Specications      4
1 Moving / Leveling the Machine 5
1 Bluetooth®Heart Rate Armband 6
1 Maintenance 8
1 Maintenance Parts Exploded View 9
1 Troubleshooting - Sections 11
1 No Power / Display Will Not Turn On 12
1 Machine Goes to Sleep While in Use 13
 1   ResistanceDoesNotRespond    14
1 Machine Seized Up 15
1 Machine Slips During Use 16
1 Rollers and 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/ModicationProcedures
2 Adjust the Brake Assembly 28
3 Adjust the Leg Assembly Alignment 33
 4  ModifytheResistanceKnobCable    36
Part Replacement
 5  ReplacetheBrakeAssembly     40
 6  ReplacetheConsoleAssembly     46
 7  ReplacetheConsoleRearPanel     49
8 Replace the Crank Arm, Left 53
9 Replace the Crank Arm, Right 57
10 Replace the Drive Belt 62
11 Replace the Drive Pulley 67
 12  ReplacetheDrivePulleyHardware    74
13 Replace the Fan Assembly 79
 14  ReplacetheFanBelt      82
15 Replace the Fan Pulley 89
16 Replace the Frame Assembly 97
17 Replace the Handlebar Pivot Assembly 106
18 Replace the Mid Mast Cables 108
19 Replace the PCBA Board 113
20 Replace the Power Inlet 119
21 Replace the Roller Wheel Assembly 122
 22  ReplacetheServoMotor     124
23 Replace the Shrouds 129
 24  ReplacetheSpeedSensorAssembly    134
25 Replace the Static Handlebar Assembly 136
 26  ReplacetheUpperBodySensorAssembly    140
 27  ReplacetheWiringHarness,Main    148

2
8027709.071522.B
Service Procedures
Important Safety Instructions
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.
Before servicing or using this equipment, obey the following warnings:
Read and understand the Service Manual before working on the machine. Failure to obey the instructions and safety warnings
could cause injury to the service technician or bystanders.
!To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power
cord from the wall outlet and/or the machine before cleaning, maintaining or repairing the machine. Place
the power cord in a secure location.
• Keep bystanders and children away from the product being serviced at all times.
• Makesurethattherepairisdoneinanappropriateworkspaceawayfromfoottrafcandexposuretobystanders.
• 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.
• Use only replacement parts and hardware that are supplied or approved by Nautilus. Failure to use Nautilus-approved replacement parts can
adversely affect the safety and functionality of the equipment creating a risk to users and will void the warranty.
• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing maintenance or
replacing components. If at any time the Warning 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untilallshrouds,instructions,warninglabelsandcorrectfunctionalityhavebeenveriedandtestedfor
correct performance.
•SAVE THESE INSTRUCTIONS.
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., [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2019 Nautilus, Inc. | Bowflex, the
B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. App Store is a service mark of Apple Inc. The Bluetooth® word
mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc. is under license. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
™
™
NOTICE: Thisdocumentprovidesimportantsafetyinstructions,adjustments,andgeneraltroubleshootinginformationforthemaintenanceoftheBowex™Max
Total™16/40.
If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To nd your local
distributor, go to: www.nautilusinternational.com
Important Safety Instructions and General Troubleshooting
Information for the Bowflex™Max Total™16/40

3
SAFETY WARNING LABELS AND SERIAL NUMBER
FCC Compliance
Changes or modications to this unit not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.
The machine and power supply comply 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.
Note: This machine and power supply have been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of
the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may
cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment 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 which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
This product complies with the European Radio Equipment Directive 2014/53/EU
ProductSpecicationLabelandSerialNumberLabel
(under Right Stabilizer Shroud)
WARNING!
• Injury or death is possible if caution is not used while using this
machine.
• Keep children and pets away.
• Read and follow all warnings on this machine.
• Refer to the Owner’s Manual for additional warnings and safety
information.
• The heart rate displayed is an approximation and should be used
for reference only.
•Notintendedforusebyanyoneunder14yearsofage.
• The maximum user weight for this machine is 136 kg. (300 lbs)
• This machine is for home use only.
• Consult a physician prior to using any exercise equipment.
(Label on machine is available in English and French Canadian
only.)
Console Serial Number Label

4
SPECIFICATIONS
For safe operation, the location must be on a hard, level surface. Allow a
workoutareaofaminimum139.2cm(54.8in)x186.2cm(73.3in).Keep the
workoutareaclear0.6m(24in)alongthesideusedtoaccessthemachineand
to the rear of the machine. Be sure that the workout space you are utilizing has
adequate height clearance, taking into consideration the height of the user and
themaximumpedalheightofthetness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 product is to be recycled. For
proper disposal of this product, please follow the prescribed methods at an
approved waste center.
166 cm
(65.7 in)
125 cm
(49.3 in) 78.2 cm
(30.8 in)
1.86 m (73.3 in)
1.39 m
(54.8
in)
0.6 m
(24 in)
0.6 m
(24 in)

5
Moving the Machine
The machine may be moved by one or more persons depending on
their physical abilities and capacities. Make sure that you and others
are all physically  t and able to move the machine safely.
1. Grasp the Main Bar of the Static Handlebar Assembly to carefully tilt the
machine toward you onto the transport rollers. Be sure not to grab the
Console Display.
Be aware of the Handlebars and the weight of the machine before
tilting the machine.
2. Push the machine into position.
3. Carefully lower the machine into position.
NOTICE: Be careful when you move the machine. All abrupt motions can affect the computer operation.
Leveling the Machine
The machine needs to be leveled if your workout area is uneven or if the Rail Assembly is
slightlyofftheoor.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oor.
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 occur.
3. Tighten the locking nuts.
Make sure the machine is level and stable before you exercise.
Media Rack (Optional Accessory)
AnoptionalaccessorycanbeaddedtoyourtnessmachinethatwillholdadditionalmediaabovetheConsole.The
optional Media Rack easily attaches to your machine, adding more space for media and devices.
To order the optional Media Rack, contact Customer Service (if in US/Canada) or your local distributor (if outside
US/Canada).

6
USB Charging
If a USB Device is attached to the USB Port, the Port will attempt to charge the Device. The power supplied from the USB Port may not be enough to
operate the Device and charge it at the same time.
Using the Bowex™ JRNY™ App on your Portable Device (Optional)
Though you can access your completed workout information from your console with your JRNY™ membership, you can also access this information
remotely on your own device. Simply download the JRNY™ app to your device for access to your JRNY™ membership.
1. Downloadtheapp,named“Bowex™JRNY™App “. The app is available on Google Play™ and the App Store.
Note: For a complete list of supported devices, review the app on the App Store or Google Play™.
2. FollowtheinstructionsontheapptosyncyourdevicetoyourBowex™JRNY™membership.
When your device has access to the account, you will be able to review past workouts, coaching, and upcoming workouts with your JRNY™
membership*.
Bluetooth® Heart Rate Monitor Enabled
YourtnessmachineisequippedtobeabletoreceiveasignalfromaBluetooth®Heart Rate (HR) Monitor. Follow the instructions provided with your
Bluetooth®HR monitor.
If you have a pacemaker or other implanted electronic device, consult your doctor before using a Bluetooth®strap or other
Bluetooth®heart rate monitor.
Note: Be sure to remove the protective cover (if provided) from the Heart Rate Sensor before use.
Bluetooth® Heart Rate Armband
A Bluetooth®HeartRateArmbandisprovidedwithyourtness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 monitor.
Note: Be sure to remove the protective cover (if provided) from the Heart Rate Sensor before use.
1. Put the Bluetooth®Heart Rate Armband onto the upper portion of your forearm.
2. ConrmthattheBluetooth®wireless connection is active on the machine. If the Bluetooth®icon is blue, then it is active.
If the icon is red, then the Bluetooth®wireless connection must be activated. To activate the Bluetooth® wireless connection:
a. Tap the Bluetooth®icon.
b. Tap “Manage Bluetooth®”.
c, Slide the option from “OFF” to “ON”.
d. Tap Back to exit.
3. When ready to exercise, start your workout.
4. PushtheOn/OffLEDbuttonontheHeartRateArmband.BesuretoonlypushtheOn/OffLEDbuttononce.
*AJRNY™membershipisrequiredfortheJRNY™experience–seewww.bowex.com/jrnyfordetails.ForUnitedStatesandCanadacustomers,
youcanobtainaJRNY™membershipbycalling800-269-4126orvisitingwww.bowex.com/jrny.Whereavailable(includingtheUnitedStates),
you can also obtain a JRNY™ membership by downloading the JRNY™ app onto your phone or tablet and signing up within the downloaded app.
JRNY™ memberships may not be available in all countries.

7
5. During your workout, the Heart Rate Armband may take up to 60 seconds to connect. When connected, the Bluetooth®Heart
Rate Device icon will be displayed along with your heart rate.
Note: The Armband can only be connected once to an 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 direction (in or out) at a time.

8
MAINTENANCE
Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is required to do the necessary tasks.
Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure that regular maintenance is
done. Worn or damaged components must be repaired or replaced immediately. Only manufacturer supplied components can be
used to maintain and repair the equipment.
If at any time the Warning 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.
To reduce the risk of electrical shock or unattended/unsupervised usage, always unplug the power cord from the wall outlet and the
machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
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rst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 to remove dust, dirt, or grime. Clean the rails and
surface of the rollers with a damp cloth.
Apply silicone lubricant to a dry cloth and wipe the rails to eliminate roller noise.
Silicone lubricant is not intended for human consumption. Keep out of reach of children. Store
in a safe place.
Note: Do not use petroleum based products.
Monthly
or after 20
hours:
Make sure all bolts and screws are tight. Tighten as necessary.
NOTICE: If necessary, only use a mild dish soap with a soft cloth to clean the Console. Do not clean with a petroleum based solvent,
automotive cleaner, or any product that contains ammonia. Do not clean the Console in direct sunlight or at high temperatures
Be sure to keep the Console free of moisture.

9
Maintenance Parts
C
A
F
FF
CC
ST
G
I
H
J
K
W
Y
BB
Z
O
O
Q
Q
O
O
L
R
H
DD
L
M
K
J
U
N
M
N
P
AA
X
EE
V
E
B
D
GG
KK
JJ
II
PP
OO
NN
LL
MM
QQ
HH
AConsole Assembly L Pedal W Shroud, Right
B Static Handlebars Cap M Foot Pad X Power Inlet
C Console Rear Cover N Foot Pad Insert 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 Dynamic Handlebar, Right
K Roller V Lower Wiring Harness

10
C
A
F
FF
CC
ST
G
I
H
J
K
W
Y
BB
Z
O
O
Q
Q
O
O
L
R
H
DD
L
M
K
J
U
N
M
N
P
AA
X
EE
V
E
B
D
GG
KK
JJ
II
PP
OO
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

11
TROUBLESHOOTING
Troubleshooting - Sections
A. No Power / Display Will Not Turn On
B. Machine Goes to Sleep 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

12
-
Go to Troubleshoot
ing: Console Lights
Up Partially
Replace the power
adapter Does the console turn
on?
Issue resolved.
NO YES
Plug the power plug
inlet wire back in.
Was the
wire already
unplugged when you
looked inside the
machine?
YES
NO
Plug the adapter
into the wall and the
machine. Does the console
turn on at all?
Does the outlet work
properly?
No Power / Display Will Not Turn On
BEGIN HERE YES
Unplug the power adapter from both
ends.
Inspect the entire cord for any visible
wires, cuts, breaks or crimps.
Check that the Adapter end is not broken.
Replace the Power
Adapter and Power
Inlet Plug.
Remove the hardware from the right side lower
round cover (4 screws). Carefully remove the
cover. The power plug inlet wire is attached to
the inside. It needs to 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
Connect the power
plug wire back into the
main I/O cable and
connect the power
adapter.
NO
Was a cable already
unplugged?
Use a different wall
outlet.
Replace the Power
Adapter.
Are there any visible
wires showing on the
adapter cord?
NO
NO
Plug the cable in.
Replace the power
plug inlet wire. Is the power plug inlet
damaged?
Does the console turn
on now?
Issue resolved.
Contact Customer
Care for Advanced
Troubleshooting.
YES
Test the wall power outlet with
something, to ensure it is working.
For example, plug a lamp in to the
wall power outlet.
YES
YES
NO
NO
YES

13
Contact Customer
Care for Advanced
Troubleshooting
YES
Machine Goes to Sleep While in Use
BEGIN HERE
Replace the Speed
Sensor Assembly
Issue resolved.
YES
NO
Does the issue
persist?
Is the sensor wire
unplugged from the
main wire harness?
Rotate the fan so that one of the
magnets meets the tip of the
sensor. Adjust the sensor so
that there is an 1/8 inch (3mm)
gap between the sensor and the
magnet (about the thickness of
2 pennies held together).
Plug the power back in and test
the machine.
NO
YES Is the sensor
damaged?
NO
Issue resolved.
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 the cable in.
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.
NO
Was a cable already
unplugged?

14
NO
Does the resistance
respond now?
Is the metal tension
cable broken?
Is the red, magnetic
brake arm broken?
Does the fan turn
freely?
Resistance Does Not Respond
BEGIN HERE
YES
Plug the power cord back in, and power up the display. If the inlet wire
was unplugged, plug it back in.
Go to Troubleshoot-
ing: Machine Seized
Up
NO
Is the red light
around the
Resistance Knob
lit?
NO
YES
Replace the Servo
Motor.
If stll not working,
replace the Static
Handlebar Assembly
NO
Remove the right side
lower round cover.
Issue resolved.
Replace the Mast
Harness Cable
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 move?
Plug the cable in.
NO
Was
a cable already
unplugged?
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.
YES
YES

15
YES Does the Upper Belt
need to be replaced?
Replace Upper Belt Contact Customer
Care for Advanced
Troubleshooting
YES Does the Lower Belt
need to be replaced?
Replace Lower Belt
Remove the left pedal arm, and left side
crank cover. This will expose the left
crank and upper belt pulley.
Is the belt physically damaged? Has the
belt become jammed in the frame?
NO YES
Machine Seized Up
BEGIN HERE
Attempt to spin the fan by hand,
back and forth. Inspect the 4
round magnets on the fan.
Are the
magnets, or the fan
making contact with
either the motor, or
the frame?
Inspect the lower belt. Is
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 shown.
Are the Crank Arms
opposite each other
180*?
YES
NO
NO
NO
NO
NO
Attempt to rotate the Crank Arms by hand.
The Pedals may also be “bottomed out”.
Safely grasp the Static Handlebars and apply your weight
to the heel of the higher foot. While still grasping the Static
Handlebar, lean back slightly applying more weight onto the
heel. Once the Pedals begin to move, resume your
intended workout.

16
Tighten the belt
tension a little more.
YES
Machine Slips During Use
BEGIN HERE
Replace the Upper
Belt Tensioner and
Upper Belt
Does the issue
persist?
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

17
Rollers and Pedals
BEGIN HERE
Is a clicking
or rubbing noise being
caused by contact
between the roller
wheel and the roller
arm bracket?
NO
Follow the “Adjust the
Leg Assembly
Alignment” procedure.
YES
The noise is a normal function,
and is not harmful to the
machine.
Did this resolve the
issue?
Has the problem now
switched sides?
NO
Issue resolved.
Replace one of the
pedal arms.
Replace the roller
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 Wave Washer
between Pedals and
Crank Arms.
NO
YES
Are
Wave Washers
installed between
Pedals and Crank
Arms.
Remove
both pedal
arms and
swap them
around.
YES
NO
Are the roller wheels
visibly damaged?
NO

18
Noise Issues - Main
BEGIN HERE
Rattling Around Inside
From Bottom of
Machine
What type of noise is
it?
Go to Troubleshoot-
ing: Upper (Drive)
Pulley
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

19
NO
Adjust magnets so
they stop making
contact. Issue
resolved.
Can the
magnets be adjusted
so they don’t touch the
brake disc?
YES
YES
Replace the Brake
Assembly
Noise Issues - Metallic Grinding or Scraping
BEGIN HERE
Are the magnets
making contact with
the metallic brake
disc?
YES
NO
Carefully operate machine and
attempt to locate 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 from the frame
in such a way that it is
causing the contact with the
magnets?
Remove the user right
side lower round cover
(4 screws).

20
Is the upper belt
traveling off the pulley?
Is the lower belt
traveling off the pulley?
If unsure, remove the tall plastic rear
cover. Use the machine while
listening carefully.
If the machine is not making any
noise, check both belts starting with
the user left side.
YES
The belt needs to be
replaced.
Loosen the belt
tensioner and replace
the belt.
Noise Issues - Rubbing / Belt
BEGIN HERE
YES
Remove the left pedal arm and
left side crank cover. This will
expose the left crank and upper
belt pulley.
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:
Slips During Use
Is the belt damaged?
Is any
part of the belt
tensioner bent or
damaged?
Replace the belt
tensioner.
YES
Is the belt
damaged?
NO
YES
The belt needs to be
replaced.
Loosen the belt
tensioner and replace
the belt.
Loosen the belt
tensioner and reset
the belt.
NO
NO
YES NO
LEFT RIGHT
YES NO