Bowflex Revolution User manual

The Bowflex Revolution™
Home Gym
Assembly Instructions
P/N: 000-5821 Rev A (9/2005)

Before You Start ......................................................................1
Tools You Will Need / Hardware Chart............................2
Parts List ...................................................................................3
Shipping Weights and Box Contents ..............................5
Unboxing Your Bowflex Revolution ................................7
Assembling Your Bowflex Revolution..........................11
Installing Accessories.........................................................22
Attaching Ropes ..................................................................24
Table of Contents
Before You Assemble
Select where you are going to locate your Bowflex Revolution™ carefully. The best place for your Bowflex Revolution™
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’ idth (2.6m L x 2m W) of free space for safe operation of the Bowflex Revolution™.
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 You Start

These Tools Are Not Provided in the Box
Phillips Head Screwdriver
Wrench (3/4”) or Adjustable Wrench
* Tool and Hardware specifications subject to change
without notice.
Hex Wrenches Are Provided in the Box
3/32” Allen Wrench for #8 Allen Bolts:
5/16” Allen Wrench for 1/2” Allen Bolts:
7/32” Allen Wrench for 3/8” Allen Bolts:
1/8” Allen Wrench for Top Cover Screws:
1TY !LLEN"OLTv8v
1TY !LLEN"OLTv8v
1TY7ASHERv
1TY
.YLOCK.UTv
1TY7ASHERSv
1TY !LLEN"OLTv8v
1TY !LLEN"OLTv8v
1TY !LLEN"OLTv8v
1TY !LLEN"OLTv8v
1TY!LLEN"OLTv8v
1TY !LLEN"OLTv8v
1TY7ASHERSv
1TY !LLEN"OLTv8v
Tools You Will Need
Hardware Chart
1

2
LB0ACK
1TY
LB0ACK
1TY
LB0ACK
1TY
LB0ACK
1TY
0RESTRETCHLB0ACK
1TY
&RONT3TABILIZER
1TY
&OUR"AR!SSEMBLY
1TY
3NAP(OOK
1TY
,OWER2AIL
1TY
2EAR3TABILIZER
1TY
3EAT!SSEMBLY
1TY
0REACHER#URL&RAME
1TY
,EG0RESS0LATE
1TY
0REACHER#URL0AD
1TY
(ANDLE'RIP
1TY
,OW2OW&OOT0LATE
1TY
0REACHER#URL3TRAP
1TY
0LATFORM
1TY
,EG0RESS3EAT"ACK
1TY
,ARGE3EAT"ACK
1TY
Bowflex Revolution™Home Gym Parts List
2

3
Bowflex Revolution™Home Gym Parts List
3EAT2AIL
1TY
3HAFT
1TY
2OLLER0AD
1TY
%ND#AP
1TY
2OLLER"AR
1TY
&OOT(ARNESS
1TY
3

4Bowflex Revolution™Home Gym Shipping Weights
If you have any questions regarding parts or assembly of your Bowflex Revolution™,
please call 1-800-NAUTILUS (1-800-628-8458) for assistance.
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
Rear Stabilizer
Hardware Pack A
Hardware Pack B
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
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
Box 5: Shipping Weight: 94.77 lbs. [43kg.]
Shaft/Bumper Assembly
Lower Rail w/ Slider
Seat rail w/Seat Roller Assembly
Bench Assembly
4

55

6Unboxing Your Bowflex Revolution™Home Gym
Warning: 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 split the
corners along the perforations
to expose the top layer of
styrofoam. (see Figure B)
Open top flaps
Split box corners
along perforations
Top layer of
styrofoam
Step 2
2-1 Remove the Rear Stabilizer,
and Hardware Packs (see Figure C),
then remove the top layer of
styrofoam to expose the lower
portion of the Main Frame.
(see Figure D)
Figure A Figure B
Figure C Figure D
Rear Stabilizer
Hardware Packs
Top layer of
styrofoam
Lower portion of
Main Frame
WARNING
ARNING
6

7
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.
3-2 Install but do not tighten two 3/8”x3/4” 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.
Main Frame
Rear Stabilizer
Bracket
Feet point away
from frame
Threaded bolt holes
point 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”)
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
Unboxing Your Bowflex Revolution™Home Gym 7

8
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

9
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

10
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 Remove Top Cover
Tools:
• 1/8”Allen wrench
1-1 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 7.
Assembling Your Bowflex Revolution™Home Gym
Styrofoam Packing
Remove front piece first

11
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 the Tension
Shaft Holder (see Step 4).
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
Assembling Your Bowflex Revolution™Home Gym

12
Step 4 Tighten Tension Shaft Holder
Tools:
• 7/32”Allen Wrench
4-1 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
Assembling Your Bowflex Revolution™Home Gym

13
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
the Tension 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.

14
Step 7 Replace Top Cover
Parts:
• Top Cover
Tools:
• 1/8” Allen Wrench
7-1 If the screws are still in the Top Cover
from Step 1, remove them to avoid
dropping them into the Main Unit.
7-2 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.
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

15
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

16
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

17
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

18
Step 13 Install Four Bar Assembly
Parts:
• Four Bar Assembly (from Step 12)
Tools:
• 5/16” Allen Wrench
• 3/4”Wrench or Adjustable Wrench
13-1 Remove the twist ties. With the Four
Bar tilted as shown in Figure B, align the
hole in the Lower Rail with the lower holes
in the Four Bar assembly.
13-2 Install but do not tighten the hardware.
13-3 Pull the Pop Pin on the Four Bar assembly and
rotate the Four Bar Assembly until the Pop Pin
locks into place in the lower hole on the Lower
Rail.
Hardware (1:1):
1 Allen Bolt (1/2” X 5”) 2 Washer (1/2”) 1 Nylock Nut (1/2”)
Four Bar Assembly
1/2”x 5” Allen Bolt
1/2”Washer
1/2” Nylock Nut
Figure A
Figure B
Lower Hole
Pop Pin
Four Bar Assembly
Lower Rail
Lower Rail
Assembling Your Bowflex Revolution™Home Gym