The Bowflex Revolution® Assembly Manual 000-5821-061810E
Table of Contents Important Safety Instructions.................................. 1 Assembly................................................................. 10 Before Assembly / Tools You Will Need................... 2 Installing Accessories............................................. 22 Parts List ................................................................... 3 Storing Ropes......................................................... 24 Shipping Weights and Box Contents......................
Important Safety Instructions Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Before using this equipment, obey the following warnings: Read and understand all warnings on this machine. Carefully read and understand the Assembly Manual. • 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.
2 Before Assembly 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.
Parts List 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.
Parts List 4 Seat Rail Qty. 1 Shaft Qty. 1 Roller Bar Qty. 1 Foot Harness Qty. 2 Roller Pad Qty. 2 Assembled Unit Weight: End Cap Qty. 2 336.2 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.
Hardware Chart Qty 1 5 Allen Bolt 1/2” X 5” Qty 4 Washer 3/8” Qty 2 Allen Bolt 1/2” X 4 1/2” Qty 25 Washers 1/2” Qty 3 Allen Bolt 1/2” X 4 1/4” Qty 10 Nylock Nut 1/2” Qty 6 Washers 5/16” Qty 4 Allen Bolt 1/2” X 3 1/4” Qty 5 Allen Bolt 1/2” X 3/4” Qty 4 Allen Bolt 5/16” X 1” Qty 12 Allen Bolt #8-32” X 3/8” Qty 4 Allen Bolt 3/8” X 3/4” Qty 2 Allen Bolt 5/16” X 1/2”
6 Unboxing Your Bowflex Revolution® Home Gym he Bowflex Revolution® Home Gym is very heavy. Whenever possible use two T 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 Top layer of styrofoam Open top flaps 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.
Unboxing Your Bowflex Revolution Home Gym ® 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: T he two Foot Caps that are packaged in this box will be installed in Step 3-5 (Figure E).
8 Unboxing Your Bowflex Revolution® Home Gym Step 3 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. 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.
Unboxing Your Bowflex Revolution Home Gym ® Step 4 Parts: • Platform ( Box 3) Tools: • 5/16” Allen Wrench Platform Main Frame 1/2” Allen Bolt Push up on Platform to align holes. 4-1 Insert Platform into main frame with the rubber pads pointing downward. 1/2” Washer Rubber Pads point 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.
10 Unboxing Your Bowflex Revolution® Home Gym 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. Separate styrofoam packing Lift box 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.
11 Assembling Your Bowflex Revolution® Home Gym Step 1 Remove Top Cover Tools: • 1/8” Allen wrench Remove screws Top Cover 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. 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.
12 Assembling Your Bowflex Revolution® Home Gym Step 3 Install Tension Shaft Main unit 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. Rounded edge on top Shaft If the Shaft is obstructed inside the Main Unit, loosen the tension screws in the Tension Shaft Holder (see Step 4).
Assembling Your Bowflex Revolution® Home Gym 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. Tension screws Tighten screws in order 1&1 , 2&2, 3&3, then 4&4.
14 Assembling Your Bowflex Revolution® Home Gym Step 5 Install Pre-Tension SpiraFlex® Packs. Tools: • 3/32” Allen Wrench (Box 1) Pre-tension SpiraFlex®Pack Side view of pre-tension SpiraFlex ® pack Hooks toward main unit #8-32 X 3/8” Allen screw 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.
15 Assembling Your Bowflex Revolution® Home Gym Step 7 Replace Top Cover Make sure inside edges of Shroud fit in slots on Top Cover Parts: • Top Cover Tools: • 1/8” Allen Wrench Front Allen Screw Top Cover Slots Inside Edge Rear Tab Shroud 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.
16 Assembling Your Bowflex Revolution® Home Gym Step 9 Install Lower Rail Parts: • Lower Rail (Box 5) 1/2” Washer 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.
17 Assembling Your Bowflex Revolution® Home Gym 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. Seat Rail Pop Pin Reverse view of Seat Assembly Seat Assembly Step 10 Install Seat Rail Parts: • Seat Rail (Box 5) Tools: • 5/16” Allen Wrench • 3/4” Wrench or Adjustable Wrench 1/2” Washer 1/2” Nylock Nut Seat Rail 10-1 Remove the twist ties through the bushings.
18 Assembling Your Bowflex Revolution® Home Gym Step 11 Install Seat Assembly Parts: • Seat Assembly (Box 5) Pop Pin 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.
19 Assembling Your Bowflex Revolution® Home Gym Step 13 Install Four Bar Assembly Parts: • Four Bar Assembly (from Step 12) 1/2”x 5” Allen Bolt Tools: • 5/16” Allen Wrench • 3/4” Wrench or Adjustable Wrench Four Bar Assembly 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. Lower Rail 13-2 Install but do not tighten the hardware.
20 Assembling Your Bowflex Revolution® Home Gym Step 14 Install Four Bar Assembly (continued) 1/2”x 4 1/4” Allen Bolt Tools: • 5/16” Allen Wrench • 3/4” Wrench or Adjustable Wrench 1/2” Washer 1/2” Nylock Nut 14-1 The upper holes in the Four Bar Assembly should now be aligned with the hole in the Seat Rail. Install hardware and completely tighten hardware from steps 11 and 12.
21 Assembling Your Bowflex Revolution® Home Gym Step 16 Install Roller Shaft and Roller Pads Parts: • Roller Shaft (Box 4) • Roller Pads (Box 4) • End Caps (Box 4) • Preacher Curl Strap (Box 3) 16-1 Insert the Roller Shaft through one of the holes in the Leg Extension Assembly, then slide the Preacher Curl Strap onto the Roller Shaft and insert the Roller Shaft through the other side of the Leg Extension Assembly.
22 Assembling Your Bowflex Revolution® Home Gym Step 18 Remove Zip Ties Tools: • Scissors or utility knife 18-1 C ut and remove the zip-tie on each Swing Arm cable. NOTICE: R efer to the Bowflex Revolution® Owner’s Manual for instructions about adjusting the cable tension. Zip-tie Step 19 Final Inspection Please inspect your machine to ensure that all fasteners are tight and components are properly assembled. Review all warnings affixed to machine.
Install Bowflex Revolution® Accessories Install Preacher Curl 1 Pull out the pop-pin and slide the Preacher Curl Assembly into place. Preacher Curl Assembly 2 When the Preacher Curl is at the desired height, release the pop-pin to lock in place. Pop-pin Install Leg Press Plate Place the cross bar on the Leg Press Plate in the hooks on the Main Unit.
Install Bowflex Revolution® Accessories 24 Install Leg Press Seat Back Slide the Leg Press Seat back arms into the the Seat Roller Assembly and tilt back to lock into place. Leg Press Seat back Seat Roller assembly Hooks Install Bench Cross Bar 1 Place the hooks on the Bench frame over the posts on the Seat Roller Assembly 2 Lay the bench flat on the Seat Rail or place the cross bar in the hooks on the Main Unit for an incline.
25 Storing Bowflex Revolution® Ropes Store Leg Press Ropes Side View Step 1 Step 1 Step 2 Step 2 Step 3 Step 3 Step 4 Step 4
26 Storing Bowflex Revolution® Ropes Store Leg Extension Ropes Tuck Leg Extension Ropes into the hole under the Lower Rail when not in use.
Attaching Bowflex Revolution® Ropes Attach Leg Press Ropes 27
28 Attaching Bowflex Revolution® Ropes Attach Leg Extension Ropes
Adjusting Rope Tension 29 Pay close attention to maintenance of the rope tension. Over time and with heavy use, the ropes 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 ropes. 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 rope hang down or if they are tight against the pulley. 3.
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® Home Gym or have suggestions for improving our manuals, please call 800-628-8458 for assistance.
