Bowflex Revolution FT User manual

The Bowflex Revolution®FT
Home Gym
Assembly Instructions
P/N: 001-7060 Rev B(6/07/2007)

2
Before You Start ........................................................... 2
Tools You Will Need / Hardware Contents........................ 3
Box Contents................................................................ 5
Assembling Your Bowflex Revolution® FT Home Gym ......... 9
Important Contact Numbers ......................................... 26
Table of Contents
Before You Assemble
Select where you are going to locate your Bowflex Revolution®FT carefully. The best place for your
Bowflex Revolution®FT is on a hard, level surface. For best results, assemble your the unit in the location
where you intend to use it. Allow a workout area of at least 10’ length x 6’ width (2.6m L x 2m W) of
free space for safe operation of the Bowflex Revolution®FT.
Every effort has been made to provide you with a clear and accurate assembly / owners manual. Should
you find any inconsistencies, have questions about your Bowflex Revolution® FT Home Gym or have
suggestions for improving our manuals, please call 800-628-8458 for assistance.
Basic Assembly Principles
Here are a few basic tips that will make your assembly of the Bowflex Revolution®FT quick and easy.
By using these principles, you can simplify each process and save yourself extra time and effort.
1. To make the assembly process go faster, gather the pieces you need for each step and thoroughly
read the assembly instructions for that step prior to starting assembly for the step.
2. When tightening a locknut on a bolt, use a combination wrench to grip the locknut and ensure that
it is fastened securely.
3. When attaching two pieces, gently lift and look through the bolt holes to help guide the bolt through
the holes.
4. As a general rule, and for all bolts and nuts on your Bowflex Revolution®FT, turn bolts or nuts
toward the right to tighten and left to loosen. Or you can remember the mnemonic: “Righty tighty,
lefty loosey.”
Before You Start

3
These Tools Are Not Provided in the Box
Phillips Head Screwdriver
3/4” and 9/16” Wrenches or Adjustable Wrenches
* Tool and Hardware specifications subject to change
without notice.
Hex Wrenches Are Provided in the Box
3/32” Allen Wrench for #8 Allen Screws
5/16” Allen Wrench for 1/2” Allen Screws
7/32” Allen Wrench for 3/8” Allen Screws
1/8” Allen Wrench for Top Cover Screws
3/16” Allen Wrench (used on XP model only)
Tools You Will Need
Hardware Card (Box 2)
3
12
6
5
4
3
1
10
7
8
2
11
9
13
ITEM NO. QTY. DESCRIPTION
1 2 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”X3/4”
2 2 NYLOCK NUT 1/2”
3 1 WRENCH, ALLEN HEX 3/32”
4 1 WRENCH, ALLEN HEX 1/8”
5 1 WRENCH, ALLEN 7/32”
6 1 WRENCH, ALLEN HEX 5/16”
7 2 WASHER 3/8”
8 4 WASHER 1/2”
9 5 SPRING CLIP
10 4 1/2” PLASTIC PLUG
11 4 3/8” PLASTIC PLUG
12 2 BUTTON HEAD CAP SCREW 1/2”x3 1/4”
13 1 WRENCH, HEX 3/16”
Hardware Contents
3
NOTE: When building the FT model you will have 1 extra spring clip, two extra 1/2” plugs and two extra 3/8” plugs.

4
42
6
5
3
2
1
8
6
9
11
10
12 7
2
3
Only two needed for XP model.
Use 4 for FT model.
Hardware
Hardware Card (Box 3)
ITEM NO. QTY. DESCRIPTION
1 6 BUTTON HEAD CAP SCREW 3/8”x 2 3/4”
2 16 NARROW WASHER 3/8”
3 7 NYLOCK NUT 3/8”
4 2 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”x 3/4”
5 5 BUTTON HEAD CAP SCREW WITH THREADLOCK 1/2”x 1”
6 9 NARROW WASHER 1/2”
7 1 BUTTON HEAD CAP SCREW 3/8”x 4”
8 2 NYLOCK NUT 1/2”
9 1 BUTTON HEAD CAP SCREW 1/2”x 4 1/2”
10 2 RUBBER PAD
11 4 CABLE HOOK
12 1 BUTTON HEAD CAP SCREW 1/2”x 4”
NOTE: When building the FT model you will have two left over 3/8” washers.

5
Box Contents
4
5
6
2
2
3
1
Box 1 Contents
ITEM QTY. DESCRIPTION
1 1 PRE STRETCH HARDWARE PACK
2 4 20LB PACK ASSEMBLY
3 2 40LB PACK ASSEMBLY
4 2 PRE-STRETCH PACK ASSEMBLY
5 2 5LB PACK ASSEMBLY
6 2 10LB PACK ASSEMBLY
BOX 1

6Box Contents
8
9
10
7
BOX 2
ITEM NO. QTY. DESCRIPTION
7 1 REVOLUTION MAIN UNIT
8 1 BOX HARDWARE CARD
9 2 FOOT CAP
10 1 REAR STABILIZER
Box 2 Contents

7
Box Contents
BOX 3
21
18
14
19
13
15
11
17
16
12
20
ITEM NO. QTY. DESCRIPTION
11 1 SHAFT
12 1 BOWFLEX HANDLE KIT
13 1 PLATFORM
14 1 LEFT STABILIZER
15 1 RIGHT STABILIZER
16 4 PULLEY
17 1 SQUAT HARNESS
18 1 MULTI POINT FOOT HARNESS
19 1 TRANSPORT WHEELS
20 1 LEG EXT ROPE
21 1 BOX 3 HARDWARE CARD
Box 3 Contents

8
ITEM NO. QTY. DESCRIPTION
22 1 DOCUMENT KIT
23 1 BUMPER
Box 4 Contents
Box Contents
BOX 4
23
22

9
Assembly
Warning: The Bowflex Revolution®FT Home Gym is very heavy. Whenever possible
use two people to unbox the main unit.
We have designed the packaging to make unboxing the main unit as safe and easy
as possible.
Step 1
1-1 Open the top flaps of Box 2
(Figure A) and split the
corners along the perforations
to expose the top layer of
styrofoam. (Figure B)
Open top flaps
Split box corners
along perforations
Top layer of
styrofoam
Figure A Figure B
Figure C Figure D
Rear Stabilizer Top layer of
styrofoam
Lower portion of
Main Frame
Rear Stabilizer Hardware
Figure E
Foot Caps
Step 2
2-1 Remove the Rear Stabilizer,
and Hardware Pack, (Figure C)
then remove the top layer of
styrofoam to expose the lower
portion of the Main Frame.
(Figure D)
The two Foot Caps that are
packaged in this box will be installed
in Step 6. (Figure E)
NOTE: Some of the hardware needed for unboxing is located on the Box 3 Hardware Card
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10
Step 3 Assemble Rear Stabilizer
Parts:
• Rear Stabilizer (Box 2)
• Rubber Pads (Box 3 hardware card)
• Transport Wheels (Box 3)
Tools:
• 7/32” Allen Wrench
3-1 Insert Transport Wheels into Rear Stabilizer
making sure that the holes in the Stabilizer
and the plates on the Transport Wheels are
pointing up.
3-2 Install and completely tighten the hardware.
3-3 Press the Rubber Pads into the holes on the opposite
side of the hardware.
Rear Stabilizer
Hardware (1:1):
2 Button Head Cap Screw With Threadlock (3/8” X 3/4 ”) 2 Washer (3/8”)
Assembly
Rubber Pad
Transport Wheel
Transport Wheel
Plate
Holes
Transport Wheel
Plate

11
Step 4 Install Rear Stabilizer
Parts:
• Rear Stabilizer (From Step 3)
Tools:
• 5/16” Allen Wrench
• 7/32” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
4-1 Place the Rear Stabilizer in the bracket on the Main Frame with
the wheels pointing away from the frame. Make sure the two bolt
holes in the Rear Stabilizer are pointing downward.
4-2 Install but do not tighten two 3/8”x3/4” Allen Bolts and 3/8”
washers (Box 3 Hardware Card) in the underside of the Rear Stabilizer.
4-3 Install two 1/2”x3 1/4” Allen Bolts with 1/2” washers and Nylock Nuts
in the sides of the Rear Stabilizer.
4-4 Completely tighten all of the hardware.
Main Frame
Rear Stabilizer
Bracket
Wheels point
away from frame
Threaded bolt holes
point downward
Hardware (1:1):
2 Button Head Cap Screw (1/2” X 3 1/4”) 4 Washer (1/2”) 2 Washer (3/8”)
2 Nylock Nut (1/2”)
2 Button Head Cap Screw With Threadlock (3/8” X 3/4”)
1/2”x 3 1/4” Allen Bolt
1/2” Washer
1/2” Washer
1/2” Nylock Nut
3/8” Washer
3/8”x 3/4” Allen Bolt
Assembly

12
Step 5 Install Stabilizers and Bumper
Parts:
• Right and Left Stabilizer (Box 3)
• Bumper (Box 4)
Tools:
• 5/16” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
5-1 Insert Bumper into the Main Frame with the
threaded hole on the flat side pointing down as shown.
5-2 Align the Right and Left Stabilizers with the holes in the Main frame.
5-3 Install but DO NOT TIGHTEN the hardware.
NOTE: You will install an additional screw in the Bumper when the unit is upright.
Main Frame
Right Stabilizer
Hardware (1:1):
1 Button Head Cap Screw (1/2” X 4 1/2 ”) 6 Washer (1/2”)
1/2”x 1” Allen Bolt
1/2” Washer
Assembly
1/2” x 4 1/2” Allen Bolt
1/2” Nylock Nut
1 Nylock Nut (1/2”)
Left Stabilizer
Bumper
4 Button Head Cap Screw With Threadlock (1/2” X 1”)
Make sure threaded
hole is pointing down.

13
Step 6
Parts:
• Platform (Box 3)
• Foot Caps (Box 2)
Tools:
• 7/32” Allen Wrench
• 9/16” Wrench or Adjustable Wrench
6-1 Align Platform with Stabilizers making
sure the rubber pads are pointing
downward.
6-2 Install but DO NOT TIGHTEN the hardware.
6-3 Install Foot Caps onto the ends of the Stabilizers.
Assembly
Step 7
With the help of a partner, slowly roll the box completely over so the unit rests on the
Rear Stabilizer and Platform.
Hardware (1:1):
6 Button Head Cap Screw (3/8” X 2 3/4”) 12 Washer (3/8”)
3/8” Washer
3/8 x 2 3/4 ” Button Head
Cap Screw
6 Nylock Nut (3/8”)
3/8” Washer
3/8” Nylock Nut

14
Step 8
8-1 Lift the box up and off of the styrofoam packing.
8-2 Separate the styrofoam packing. Remove plastic
wrapping from the engine.
Lift box
Styrofoam packing
Separate styrofoam
packing
Step 9
Tools:
• 5/16” Allen Wrench
9-1 Install one 1/2”x” Allen Bolt.
9-2 Make sure Platform is flat and level and
completely tighten hardware from steps 5
through 9.
Hardware (1:1):
1 Button Head Cap Screw With Threadlock (1/2” X 1 ”) 1 Washer (1/2”)
1/2”x 1” Allen Bolt
1/2” Washer
Assembly

15
Top Cover
Remove screws
Step 10 Remove Top Cover
Tools:
• 1/8” Allen wrench
10-1 Use a 1/8” Allen Wrench to remove the four
screws in the Top Cover, then remove
the Top Cover and set it aside. Set screws
aside for Step 16.
Assembly
Styrofoam Packing
Remove front piece first
Step 11 Remove Styrofoam Inner Packing
11-1 Remove and discard the three pieces of
Styrofoam Inner Packing.
Note: You must open the plastic bag
and remove each piece of styrofoam
individually.

16
Step 12 Install Tension Shaft
Parts:
• Main Unit
• Shaft (Box 3)
12-1 Align the rounded side of the
Tension Shaft with the rounded
side of the hole in the Main Unit
and slowly slide the Shaft through
until it clicks into place.
If the Shaft is obstructed
inside the Main Unit,
loosen the tension
screws in the Tension
Shaft Holder (see Step 13).
Note: If you didn’t 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. There should be an equal measure on each
side.
Rounded edge on top
Shaft
Main unit
Assembly

17
Step 13 Tighten Tension Shaft Holder
Tools:
• 7/32” Allen Wrench
13-1 Use a 7/32” Allen Wrench to tighten the Tension Shaft Holder by
tightening the screws in numerical order shown on the tensioner.
Tighten the two screws marked 1, then the two marked 2, etc.
Note: Do not replace Top Cover at this time.
Tighten screws in order
1&1 , 2&2, 3&3, then
4&4.
Tension Shaft Holder
Tension screws
Assembly

18
Side view of pre-tension
SpiraFlex pack
Hooks toward
main unit
Pre-tension
SpiraFlex®Pack
Step 15 Remove Cam Holders.
Tools:
• Phillips Head Screwdriver
15-1 Use a Phillips Head Screwdriver
to remove the Cam Holders.
Note: The Cam Holders are only
needed when the Spiraflex®
packs are not installed and
may be discarded or recycled.
Cam Holders
Allen Bolt
Remove Cam Holders
Cam
#8-32 X 3/8” Allen screw
®
Hardware (1:1): Hardware for this step located in Box 1 12 Allen Bolt ( # 8-32 X 3/8”)
Assembly
Step 14 Install Pre-Tension SpiraFlex® Packs.
Tools:
• 3/32” Allen Wrench (Box 1)
Parts:
• Pre-tension SpiraFlex®Packs (Box 1)
14-1 Align the rounded edge of the Pre-tension
SpiraFlex®Pack with the rounded edge of
the Tension Shaft and slide it all the way
onto the shaft.
14-2 When the Pack makes contact with
the Cam, continue to apply pressure
and twist the Pack to the left until
you feel the Pack seat into place.
14-3 Install and completely tighten
hardware, installing screws in a star
pattern around pre-tension pack.

19
Step 16 Replace Top Cover
Parts:
• Top Cover
Tools:
• 1/8” Allen Wrench
16-1 If the screws are still in the Top Cover
from Step 1, remove them to avoid
dropping them into the Main Unit.
16-2 Replace the Top Cover front end first.
Make sure inside edge of the Shroud
fits into the slots in the Top Cover.
Now seat the rear making sure the
tabs on the Top Cover fit inside the
Shroud.
16-3 Install and completely tighten the
hardware.
Make sure inside edges
of Shroud fit in slots
on Top Cover
Inside Edge
Slots
Front
Rear
Top Cover
Tab
Shroud
Allen Screw
Assembly

20
Before Installing the Cable Hooks (Step 17), make sure the Cables are properly tensioned
according to the following procedure . If there is slack in the Cables, the Support Plate Bolts
could cause interference.
Adjusting Cable Tension
Pay close attention to maintenance of the cable tension. Over time and with heavy use, the
cables are designed to give slightly. Located on the main engine housing is a tension control
knob which allows you to increase the tension in the cables.
Checking for incorrect cable tension is simple.
1. Position the adjustable swing arms in the upper most position.
2. Check to see if clips at end of cable hang down or if they are tight against the pulley.
3. If cables don’t have enough tension, use the tension control knob on the side of the machine to
tighten the cables. (See image).
4. To increase tension, pull tension knob outward and turn the large pulley clockwise. The clip on
the cable should be touching the pulley.
In this image, the cable clip extends a few
inches below the pulley, so there is not enough
tension in the cable. The cable clip should be
tight against the pulley with appropriate tension.
There are tension knobs on each side of the machine. To increase
cable tension, pull knob and turn the large pulley clockwise. You’ll
know when you have enough tension when the cable retracts and
the cable clip touches the pulley.
The cable clip
should stop here.
Large pulley. This is what you
need to turn to increase the
tension on the cable. Pull the
tension knob and use your
other hand to turn the large
pulley clockwise.
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Assembly