Bowflex Revolution User manual

The Bowflex Revolution®
Assembly Manual
000-5821-061810E

Important Safety Instructions................................. 1
Before Assembly / Tools You Will Need.................. 2
Parts List .................................................................. 3
Shipping Weights and Box Contents ..................... 4
Hardware Chart........................................................ 5
Unboxing.................................................................. 6
Assembly................................................................ 10
Installing Accessories............................................ 22
Storing Ropes ........................................................ 24
Attaching Ropes..................................................... 26
Adusting Rope Tension.......................................... 28
Table of Contents
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], customerservice@bowflex.com |
outside U.S. +01-360-859-5180, [email protected] | Printed in China | ©2005. Nautilus, Inc. All rights reserved. Nautilus, Inc. (www.NautilusInc.
com) trademarks include NAUTILUS®, BOWFLEX®, SCHWINN® and UNIVERSAL® and respective logos. Other trademarks are the property of their
respective owners.

11
Important Safety Instructions
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Read and understand all warnings on this machine.
Carefully read and understand the Assembly Manual.
Before using this equipment, obey the following warnings:
• Keep bystanders and children away from the product you are assembling at all times.
• Do not assemble this machine outdoors or in a wet or moist location.
• Make sure assembly is done in an appropriate work space away from foot traffic and exposure to bystanders.
• 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.
• Set up this machine on a solid, level, horizontal surface.
• Do not try to change the design or functionality of this machine. This could compromise the safety of this
machine and will void the warranty.
• 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 void
the warranty.
• Do not use until the machine has been fully assembled and inspected for correct performance in accordance
with the Owner’s Manual.
• Read and understand the complete Owner’s Manual supplied with this machine before first use. Keep the
Owner’s and Assembly Manuals for future reference.
• Do all assembly steps in the sequence given. Incorrect assembly can lead to injury.

2
Select where you are going to locate your Bowflex Revolution®home gym carefully.The best place for
your Bowflex Revolution®home gym is on a hard, level surface. For best results, assemble the unit in the
location where you intend to use it. Allow a workout area of at least 120” length x 84” width (304.8 cm L x
213.4 cm W) of free space for safe operation of the machine.
Basic Assembly Principles
Here are a few basic tips that will make your assembly of the Bowflex Revolution® 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®, turn bolts or nuts toward the
right to tighten and left to loosen. Or you can remember the mnemonic: “Righty tighty, lefty loosey.”
Before Assembly
These Tools Are Not Provided in the Box
Phillips Head Screwdriver
Wrench (3/4”) or Adjustable Wrench
Utility knife or scissors
* Tool and Hardware specifications subject to change
without notice.
Hex Wrenches Are Provided in the Box
3/32” Allen Wrench 7/32” Allen Wrench
5/16” Allen Wrench 3/16” Allen Wrench
5/32” Allen Wrench
1/8” Allen Wrench for Top Cover Screws:
Tools You Will Need

3
40 lb. Pack
Qty. 2
20 lb. Pack
Qty. 4
10 lb. Pack
Qty. 4
5 lb. Pack
Qty. 2
Pre-stretch 5 lb. Pack
Qty. 2
Front Stabilizer
Qty. 1
Four Bar Assembly
Qty. 1
Snap Hook
Qty. 5
Lower Rail
Qty. 1
Rear Stabilizer
Qty. 1
Seat Assembly
Qty. 1
Preacher Curl Frame
Qty. 1
Leg Press Plate
Qty. 1
Preacher Curl Pad
Qty. 1
Handle Grip
Qty. 2
Low Row Foot Plate
Qty. 1
Preacher Curl Strap
Qty. 1
Platform
Qty. 1
Leg Press Seat Back
Qty. 1
Large Seat Back
Qty. 1
Parts List

4
Seat Rail
Qty. 1
Shaft
Qty. 1
Roller Pad
Qty. 2
End Cap
Qty. 2
Roller Bar
Qty. 1
Foot Harness
Qty. 2
Assembled Unit Weight: 336.2 lbs. [152.5 kg.]
Shipping Box Weight and Contents:
Box 1:
Shipping Weight: 33.85 lbs. [15.4kg.]
Pre-stretch pack
5 lb. Pack
10 lb. Pack
20 lb. Pack
40 lb. Pack
Pre-stretch Hardware Pack
Documentation Kit
Box 2:
Shipping Weight: 133.34 lbs. [60.5kg.]
Main Frame Assembly
Bowflex Revolution®/Revolution®XP/FT Common Hardware Card
Box 3:
Shipping Weight: 70.96 lbs. [32.2kg.]
3 D-Ring Strap
Platform
Preacher Curl Frame
Preacher Curl Pad
Small Seat Back Assembly
Handle Kit
Foot Harness Kit
Bowflex Revolution® Main Assembly Hardware Card
Box 4:
Shipping Weight: 81.54 lbs. [37kg.]
Low Row Foot Plate
Front Stabilizer
Leg Press Plate
Four Bar Assembly
Roller Pads
End Caps
Preacher Curl Bar
Leg Extension Assembly
Box5:
Shipping Weight: 94.77 lbs. [43kg.]
Shaft/Bumper Assembly
Lower Rail w/ Slider
Seat rail w/Seat Roller Assembly
Bench Assembly
Parts List

5
Qty 4 Allen Bolt 1/2” X 3 1/4”
Qty 4 Allen Bolt 3/8” X 3/4”
Qty 4 Washer 3/8”
Qty 10
Nylock Nut 1/2”
Qty 25 Washers 1/2”
Qty 5 Allen Bolt 1/2” X 3/4”
Qty 3 Allen Bolt 1/2” X 4 1/4”
Qty 2 Allen Bolt 1/2” X 4 1/2”
Qty 1 Allen Bolt 1/2” X 5”
Qty 12 Allen Bolt #8-32” X 3/8”
Qty 4 Allen Bolt 5/16” X 1”
Qty 6 Washers 5/16”
Qty 2 Allen Bolt 5/16” X 1/2”
Hardware Chart

6Unboxing Your Bowflex Revolution®Home Gym
The Bowflex Revolution®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
(see Figure A) and cut the
corners along the dotted lines
to expose the top layer of
styrofoam. (see Figure B)
Open top flaps
Cut box corners
along dotted lines
and fold flaps down
Top layer of
styrofoam
Figure A Figure B

7
Unboxing Your Bowflex Revolution®Home Gym
Figure E
Foot Caps
Figure D
Figure C
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).
NOTE: The two Foot Caps that are packaged in this
box will be installed in Step 3-5 (Figure E).
Rear Stabilizer
Rear Stabilizer Hardware
Lower portion of
Main Frame
Top layer of
styrofoam

8Unboxing Your Bowflex Revolution®Home Gym
Step 3
Parts:
• Rear Stabilizer (Box 2)
Tools:
• 5/16” Allen Wrench
• 7/32” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
3-1 Place the Rear Stabilizer in the bracket on the
Main Frame with the feet pointing away from the
frame Make sure the two bolt holes in the Rear
Stabilizer are pointing downward.
Hardware (1:1):
2 Allen Bolt (1/2” X 3 1/4”) 4 Washer (1/2”)
2 Washer (3/8”)
2 Nylock Nut (1/2”) 2 Allen Bolt (3/8” X 3/4”)
3-2 Install but do not tighten two 3/8”x 3/4” Allen Bolts
and 3/8” washers in the underside of the Rear
Stabilizer.
3-3 Install two 1/2”x3 1/4” Allen Bolts with 1/2” washers
and Nylock Nuts in the sides of the Rear Stabilizer.
3-4 Completely tighten all of the hardware.
3-5 Slide the Foot Caps onto the feet of the Rear
Stabilizer.
Main Frame
Rear Stabilizer
Bracket
Feet point away
from frame
Threaded bolt holes
point downward
1/2”x 3 1/4” Allen Bolt
1/2”Washer
1/2”Washer
1/2” Nylock Nut
3/8”Washer
3/8”x 1/4” Allen Bolt
Foot Cap

9
2 Allen Bolt (3/8” X 3/4”)
Step 5
5-1 If possible, use two people to slowly roll the box completely over so the
unit rests on the Rear Stabilizer and Platform.
Step 4
Parts:
• Platform ( Box 3)
Tools:
• 5/16” Allen Wrench
4-1 Insert Platform into main frame with
the rubber pads pointing downward.
4-2 Install but do not tighten four 1/2”x 3/4”
Allen Bolts in the sides of the frame.
You may have to push up on the wheel
end of the platform to allow screws to
align with the threaded hole in the platform.
You will install an additional screw in the
Platform when the unit is upright.
Rubber Pads point
downward
Main Frame
Platform
Hardware (1:1):
4 Allen Bolt (1/2” X 3/4 ”) 4 Washer (1/2”)
1/2” Allen Bolt
1/2”Washer
Push up on Platform
to align holes.
Unboxing Your Bowflex Revolution®Home Gym

10
Step 6
6-1 Lift the box up and off of the styrofoam packing.
6-2 Separate the styrofoam packing. Remove plastic
wrapping from the engine.
Lift box
Styrofoam packing
Separate styrofoam
packing
Step 7
Tools:
• 5/16” Allen Wrench
7-1 Install one 1/2”x3/4” Allen Bolt.
7-2 Completely tighten hardware from
steps 4 and 7.
Hardware (1:1):
1 Allen Bolt (1/2” X 3/4 ”) 1 Washer (1/2”)
1/2”x 3/4” Allen Bolt
1/2”Washer
Unboxing Your Bowflex Revolution®Home Gym

11
Step 2 Remove Styrofoam Inner Packing
2-1 Remove and discard the three pieces of
Styrofoam Inner Packing.
Note: You must open the plastic bag
and remove each piece of styrofoam
individually.
Top Cover
Remove screws
Step 1 RemoveTop Cover
Tools:
• 1/8” Allen wrench
1-1 Use a 1/8” Allen Wrench to remove the four
screws in theTop Cover, then remove
theTop Cover and set it aside. Set screws
aside for Step 7.
Assembling Your Bowflex Revolution®Home Gym
Styrofoam Packing
Remove front piece first

12
Step 3 Install Tension Shaft
Parts:
• Main Unit
• Shaft ( Box 5 )
3-1 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 theTension
Shaft Holder (see Step 4).
Note: If you did not feel or hear a distinct click, make sure the shaft
is centered by measuring the amount of exposed shaft on each
side of the Main Unit.There should be an equal measure on each
side.
Rounded edge on top
Shaft
Main unit
Assembling Your Bowflex Revolution®Home Gym

13
Step 4 Tighten Tension Shaft Holder
Tools:
• 7/32” Allen Wrench
4-1 Use a 7/32” Allen Wrench to tighten theTension 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 replaceTop Cover at this time.
Tighten screws in order
1&1 , 2&2, 3&3, then
4&4.
Tension Shaft Holder
Tension screws
Assembling Your Bowflex Revolution®Home Gym

14
Side view of pre-tension
SpiraFlex pack
Hooks toward
main unit
Pre-tension
SpiraFlex®Pack
Step 6 Remove Cam Holders.
Tools:
• Phillips Head Screwdriver
6-1 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”)
Assembling Your Bowflex Revolution®Home Gym
Step 5 Install Pre-Tension SpiraFlex® Packs.
Tools:
• 3/32” Allen Wrench (Box 1)
Parts:
• Pre-tension SpiraFlex® Packs (Box 1)
5-1 Align the rounded edge of the Pre-tension
SpiraFlex® Pack with the rounded edge of
theTension Shaft and slide it all the way
onto the shaft.
5-2 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.
5-3 Install and completely tighten
hardware, installing screws in a star
pattern around pre-tension pack.

15
Step 7 Replace Top Cover
Parts:
• Top Cover
Tools:
• 1/8” Allen Wrench
7-1 If the screws are still in theTop Cover
from Step 1, remove them to avoid
dropping them into the Main Unit.
7-2 Replace theTop Cover front end first.
Make sure inside edge of the Shroud
fits into the slots in theTop Cover.
Now seat the rear making sure the
tabs on theTop Cover fit inside the
Shroud.
7-2 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
Ta b
Shroud
Step 8 Install Low Row Foot Plate
Parts:
• Low Row Foot Plate (Box 4)
Tools:
• 5/16” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
8-1 Align holes in the Foot Plate with the
holes in the Main Unit.
8-2 Install and completely tighten
the hardware.
Hardware (1:1):
2 Allen Bolt (1/2” X 4 1/4”) 4 Washer (1/2”) 2 Nylock Nut (1/2”)
Low Row Foot Plate Main Unit
1/2”Washer
1/2” Nylock Nut
1/2”x 4 1/4 Allen Bolt
Allen Screw
Assembling Your Bowflex Revolution®Home Gym

16
Step 9 Install Lower Rail
Parts:
• Lower Rail (Box 5)
Tools:
• 5/16” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
9-1 Remove the twist ties through the
bushings.
Align the Lower Rail with the
lower holes in the Low Row
Foot Plate. Make sure the
pulley assembly on the Lower
Rail is pointing downward.
9-2 Install and completely
tighten the hardware.
1/2”x 4 1/2” Allen Bolt
1/2”Washer
1/2” Nylock Nut
Lower Rail
Pulley Assembly
Lower Holes in
Low Row Footplate
Hardware (1:1):
1 Allen Bolt (1/2” X 4 1/2”) 2 Washer (1/2”) 1 Nylock Nut (1/2”)
Assembling Your Bowflex Revolution®Home Gym

17
Step 10 Install Seat Rail
Parts:
• Seat Rail (Box 5)
Tools:
• 5/16” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
10-1 Remove the twist ties through the
bushings. Align the Seat Rail with the
upper holes in the Low Row Foot Plate.
Seat rail will be slightly inclined
when installed.
10-2 Install and completely
tighten the hardware.
2 Washer (1/2”) 1 Nylock Nut (1/2”)
Hardware (1:1):
1/2”Washer
1/2” Nylock Nut
Seat Rail
Upper Holes in
Low Row Footplate
1/2”x 4 1/2” Allen Bolt
1 Allen Bolt (1/2” X 4 1/2”)
NOTE:To ease assembly, before proceeding to Step 10, remove
the Seat Assembly from the Seat Rail by pulling the Pop
Pin and sliding the Seat Assembly off of the Seat Rail.
Reverse view of Seat
Assembly
Pop Pin
Seat Rail
Seat Assembly
Assembling Your Bowflex Revolution®Home Gym

18
Step 11 Install Seat Assembly
Parts:
• Seat Assembly (Box 5)
11-1 Slide the Seat Assembly onto the
Seat Rail. Make sure the Pop Pin
is on the left when facing the unit as
shown.
Reverse view of Seat
Assembly
Pop Pin
Seat Rail
Seat Assembly
Step 12 Install Front Stabilizer to Four Bar Assembly
Parts:
• Four Bar (Box 4)
• Front Stabilizer (Box 4)
Tools:
• 5/16” Allen Wrench
• 3/4” Wrench or Adjustable Wrench
12-1 Place the Four Bar Assembly on the
Front Stabilizer with the Front Stabilizer feet
pointing in the same direction as the point on
the Four Bar as shown.
12-2 Install but do not tighten two
3/8”x 3/4” Allen Bolts and
two 3/8” Washers in the top holes.
12-3 Install two 1/2”x 3 1/4” Allen Bolts
and two 1/2” Washers in the side holes.
12-4 Completely tighten all of the hardware.
Hardware (1:1):
2 Allen Bolt (1/2” X 3 1/4”) 4 Washer (1/2”)
4 Washer (3/8”)
2 Nylock Nut (1/2”) 2 Allen Bolt (3/8” X 3/4”)
Four Bar Assembly
Front Stabilizer
Feet Point in this
direction
Point on Four Bar
this direction
1/2”x 3 1/4 Allen Bolt
1/2”Washer
1/2” Nylock Nut
3/8”Washer
3/8” Allen Bolt
Assembling Your Bowflex Revolution®Home Gym