Bowflex Revolution FT Assembly Instructions Manual

P/N: 001-7060 Rev B (6/07/2007)

The Bowflex Revolution®FT

Home Gym

Assembly Instructions

2

Table of Contents

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

Before You Start

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.”

Tools You Will Need

12

6

5

4

3

1

10

7

8

2

11

9

13

3

3

3

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)

Hardware Contents

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.

NOTE: When building the FT model you will have 1 extra spring clip, two extra 1/2” plugs and two extra 3/8” plugs.

Hardware Card (Box 2)

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”

4

4

2

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

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.

Hardware Card (Box 3)

4

5

6

2

2

3

1

BOX 1

5

Box Contents

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

6

8

9

10

7

BOX 2

Box Contents

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

BOX 3

21

18

14

19

13

15

11

17

16

12

20

7

Box Contents

Box 3 Contents

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

8

23

22

BOX 4

Box Contents

Box 4 Contents

ITEM NO. QTY. DESCRIPTION

22 1 DOCUMENT KIT

23 1 BUMPER

Assembly

7 ! 2 . ) . '

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.

NOTE: Some of the hardware needed for unboxing is located on the Box 3 Hardware Card

9

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)

Step 2

Rear Stabilizer Hardware

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)

Open top flaps

Figure A

Rear Stabilizer

Top layer of

styrofoam

Split box corners

along perforations

Figure B

Top layer of

styrofoam

Lower portion of

Main Frame

The two Foot Caps that are
packaged in this box will be installed
in Step 6. (Figure E)

Foot Caps

Figure E

Figure C

Figure D

10

Step 3 Assemble Rear Stabilizer

Assembly

Transport Wheel

Plate

Transport Wheel

Parts:

• Rear Stabilizer (Box 2)

• Rubber Pads (

• Transport Wheels (

Box 3 hardware card)

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

Rear Stabilizer

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.

Transport Wheel

Plate

Holes

Rubber Pad

Hardware (1:1):

2 Button Head Cap Screw With Threadlock (3/8” X 3/4 ”)

2 Washer (3/8”)

Assembly

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.

11

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.

Threaded bolt holes

point downward

1/2” Washer

1/2” Nylock Nut

Main Frame

Bracket

Rear Stabilizer

Wheels point

away from frame

1/2”x 3 1/4” Allen Bolt

1/2” Washer

3/8” Washer

3/8”x 3/4” Allen Bolt

Hardware (1:1):

2 Button Head Cap Screw With Threadlock (3/8” X 3/4”)

2 Button Head Cap Screw (1/2” X 3 1/4”)

4 Washer (1/2”)

2 Nylock Nut (1/2”)

2 Washer (3/8”)

12

Assembly

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.

Left Stabilizer

1/2” x 4 1/2” Allen Bolt

Bumper

Make sure threaded

hole is pointing down.

1/2”x 1” Allen Bolt

1/2” Washer

1/2” Nylock Nut

Main Frame

Hardware (1:1):

Right Stabilizer

4 Button Head Cap Screw With Threadlock (1/2” X 1”)

1 Button Head Cap Screw (1/2” X 4 1/2 ”)

6 Washer (1/2”)

1 Nylock Nut (1/2”)

Assembly

13

Step 6

3/8 x 2 3/4 ” Button Head

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.

3/8” Nylock Nut

6-2 Install but DO NOT TIGHTEN the hardware.

3/8” Washer

6-3 Install Foot Caps onto the ends of the Stabilizers.

Hardware (1:1):

Cap Screw

3/8” Washer

6 Button Head Cap Screw (3/8” X 2 3/4”)

12 Washer (3/8”)

6 Nylock Nut (3/8”)

Step 7

With the help of a partner, slowly roll the box completely over so the unit rests on the

Rear Stabilizer and Platform.

14

Assembly

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

Separate styrofoam

packing

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.

1/2”x 1” Allen Bolt

1/2” Washer

Hardware (1:1):

1 Button Head Cap Screw With Threadlock (1/2” X 1 ”)

1 Washer (1/2”)

Assembly

15

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.

Remove screws

Top Cover

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.

Remove front piece first

Styrofoam Packing

16

Step 12 Install Tension Shaft

Assembly

Main unit

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).

Rounded edge on top

Shaft

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.

Assembly

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.

17

Tension screws

Tension Shaft Holder

Tighten screws in order

1&1 , 2&2, 3&3, then

4&4.

18

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.

#8-32 X 3/8” Allen screw

Pre-tension

SpiraFlex®Pack

Side view of pre-tension

SpiraFlex pack

Hooks toward

main unit

Cam

®

Hardware (1:1): Hardware for this step located in Box 1

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.

Allen Bolt

12 Allen Bolt ( # 8-32 X 3/8”)

Remove Cam Holders

Cam Holders

Assembly

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.

Make sure inside edges

of Shroud fit in slots

on Top Cover

Front

Allen Screw

Slots

Inside Edge

Top Cover

Rear

Tab

Shroud

16-3 Install and completely tighten the
hardware.

20

7 ! 2 . ) . '

! 4 4 % . 4 ) / .

$ ! . ' % 2

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.

Assembly

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.

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.

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.

The cable clip
should stop here.

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.

Assembly

Step 17 Install Cable Hooks

Parts:

• Rope Hooks (Box 3 Hardware Card)

Tools:

• 5/16” Allen Wrench

• 7/32” Allen Wrench

• 3/4” Wrench or Adjustable Wrench

• 9/16” Wrench or Adjustable Wrench

17-1

Main Frame with the tabs on the hooks
inserted into the slots in the Main Frame.

17-2 Install and completely tighten the hardware.

Align the Hooks with the holes in the

NOTE: The remaining holes in the
Main Frame between the
Hook Holes should be plugged
with two 1/2” plugs and two
3/8” plugs from the Box 2
hardware card.
The remaining plugs are not
needed on this unit and
can be discarded.

3/8” Nylock nut

1/2” Nylock nut

21

Hook

Plug these holes

3/8”x 4” Button Head

Cap Screw

Main Frame

Hardware (1:1):

1 Button Head Cap Screw (3/8” X 4 ”)

1 Button Head Cap Screw (1/2” X 4 ”)

Hook

2 (1/2 “Plug)

1 Nylock Nut (3/8”)

1/2”x 4” Button Head

Cap Screw

2 (3/8 “Plug)

1 Nylock Nut (1/2”)

22

Assembly

Step 18 Install Pulleys

Parts:

Pulley

Spring

• Pulley Components (Box 3)

Hook Bolt

Tools:

• Screwdriver

Spring Cap

Hex Nut (discard)

NOTE: Remove and discard the hex nut to
disassemble the Pulley components.

18-1

Place a Spring Cap over a threaded hole in a
Stabilizer and screw the Hook Bolt into the
hole ONLY about three turns. (Figure A)

18-2

Place the Spring down over the Hook Bolt.
Compress the Spring and hook the Eyelet
under the Pulley to the Hook Bolt. (Figure B)

Hook Bolt

Spring Cap

Figure A

18-3

Place a screwdriver through the Spring and
Hook Bolt on the Pulleys and tightly screw
them into the Stabilizers. (Figure C)

NOTE: Place the pulleys with the
pre-installed cable closest to the main frame.

Pulley

Hook Bolt

Eyelet

Spring

Screwdriver

Figure B

Figure C

Assembly

Step 19 Un-install/Install Cables if necessary

Parts:

• Cables (Box 3)

19-1

pressing the insert out of the ball (Figure A)
and slide the ball off of the rope.

19-2 Cable the Cable under the Pulley closest
to the Main Unit and reinstall the Ball End
(Figure B).

Remove the Ball End from the Cable by

23

Cable

Pulley

NOTE: When not in use, store the Cable by wrapping it around
the cable Hooks as shown.

Figure A

Hooks

Figure B

24

Step 20 Apply Revolution FT Decal

Parts:

• Revolution® FT Decal (Box 4 Documentation Kit)

20-1

Apply the Decal to the Platform in the indented area as shown. .

Decal

Platform

Step 21 Final Inspection

7 ! 2 . ) . '

Please inspect your machine to ensure that all fasteners are tight and components are
properly assembled. Review all warnings affixed to machine.

Congratulations! You have successfully completed assembly of your Bowflex
Revolution® FT home gym!

Failure to visually check and test assembly

before use can cause damage to the Bowflex

Revolution® FT home gym and serious injury to

users and bystanders and can also compromise

the effectiveness of your exercise program.

25

26

Serial Number

Date of Purchase

Please record the following information for future reference.

Important Contact Numbers

If you need assistance, please have both the serial number of your machine and the date of
purchase available when you contact the appropriate Nautilus office listed below.

OFFICES IN THE UNITED STATES:

E-mail: [e-mail]

• TECHNICAL/CUSTOMER SERVICE
Nautilus, Inc.
World Headquarters
16400 SE Nautilus Drive
Vancouver, Washington, USA 98683
Phone: 800-NAUTILUS (800-628-8458)
Email: [e-mail]
Fax: [phone]

• CORPORATE HEADQUARTERS
Nautilus, Inc.
World Headquarters
16400 SE Nautilus Drive
Vancouver, Washington, USA 98683

Phone: 800-NAUTILUS (800-628-8458)

INTERNATIONAL:

For technical assistance and a list of distributors in
your area, please call or fax one of the following
numbers.

• INTERNATIONAL CUSTOMER SERVICE
Nautilus International S.A.
Rue Jean Prouvé 6
1762 Givisiez / Switzerland
Tel: + 41-26-460-77-77
Fax: + 41-26-460-77-70
Email: [e-mail]

BUSINESS OFFICES:

• SWITZERLAND OFFICE
Nautilus Switzerland S.A.
Tel: + 41-26-460-77-66
Fax: + 41-26-460-77-60

• GERMANY and AUSTRIA OFFICE
Nautilus GmbH
Tel: [phone]
Fax: [phone]

• ITALY OFFICE
Nautilus Italy s.r.l.
Tel: [phone]
Fax: [phone]

• UNITED KINGDOM OFFICE
Nautilus UK Ltd.
Tel: [phone]
Fax: [phone]

• CHINA OFFICE
Nautilus Representative Office
Tel: [phone]
Fax: [phone]

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.

©2007 Nautilus Inc. All rights reserved. 16400 S.E. Nautilus Drive, Vancouver, Washington, USA 98683.
Bowflex, Bowflex Revolution, and the Bowflex and Nautilus logos are either registered trademarks or trademarks of Nautilus, Inc.
All other trademarks are owned by their respective companies.

Printed in China