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®
The Bowflex Revolution XP
Home Gym
Assembly Instructions
P/N: 001-7057 Rev C (05/10/07)
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Table of Contents Before You Start ....................................... 2 Tools You Will Need / Hardware Contents .... 3 Box Contents ............................................ 6 Assembling Your Bowflex Revolution ..........10 Important Contact Numbers ......................29 Before You Start Before You Assemble Select where you are going to locate your Bowflex Revolution®XP carefully. The best place for your Bowflex Revolution®XP is on a hard, level surface. For best results, asse
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Tools You Will Need Hex Wrenches Are Provided in the Box These Tools Are Not Provided in the Box Phillips Head Screwdriver 3/32” Allen Wrench for #8 Allen Screws 3/4” and 9/16” Wrenches or Adjustable Wrenches 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 * Tool and Hardware specifications subject to change 3/16” Allen Wrench for Upholstery Screws without notice. Hardware 9 12 2 8 7 10 11 1 3 4 13 6 5 Hardware Card
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Hardware 12 7 10 9 2 5 2 6 6 Only two needed for XP model. Use 4 for FT model. 3 8 3 1 Used on the FT model only 2 11 4 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 P
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Hardware 9 6 8 5 2 3 7 4 1 Hardware Card (Box 4) ITEM NO. QTY. DESCRIPTION 1 6 BUTTON HEAD CAP SCREW 3/8”x 4” 2 8 NARROW WASHER 5/16” 3 18 NARROW WASHER 3/8” 4 6 NYLOCK NUT 3/8” 5 8 BUTTON HEAD CAP SCREW WITH THREADLOCK 5/16”x 1” 6 1 SEAT BOTTOM LOCK PIN 7 6 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”x 3/4” 8 1 LEG EXTENSION PIN 9 4 END CAP
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Box Contents BOX 1 1 3 2 2 6 5 4 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
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Box Contents BOX 2 8 10 9 7 Box 2 Contents ITEM NO. QTY. DESCRIPTION 7 1 REVOLUTION MAIN UNIT 8 1 BOX HARDWARE CARD 9 2 FOOT CAP 10 1 REAR STABILIZER
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Box Contents BOX 3 12 16 21 17 11 15 18 13 19 14 20 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 2 LEG EXT CABLES 21 1 BOX 3 HARDWARE CARD
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Box Contents BOX 4 33 32 29 24 30 35 34 26 28 31 25 22 23 27 Box 4 Contents ITEM NO. QTY. DESCRIPTION 22 1 SEAT TUBE 23 1 LOWER SEAT CONNECTOR 24 1 HARDWARE CARD BOX 4 25 1 LEG EXT ASSEMBLY 26 4 FOAM ROLLER PAD 27 2 ROLLER TUBE 28 1 SEAT TUBE CAP 29 1 DOCUMENTS KIT 30 1 BACK PAD 31 1 BACK PAD BRACKET 32 1 SEAT PAD BRACKET 33 1 SEAT PAD 34 1 RIGHT SEAT SUPPORT PLATE 35 1 LEFT SEAT SUPPORT PLATE
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10 10 Assembly (Unboxing) WARNING ® Warning: The Bowflex Revolution XP 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 Top layer of Open top flaps styrofoam Step 1 1-1 Open the top flaps of Box 2 (Figure A) and split the corners along the perforations to exp
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11 Assembly (Unboxing) Transport Wheel Plate Transport Wheel Step 3 Assemble Rear Stabilizer Transport Wheel Parts: Plate • Rear Stabilizer (Box 2) • Rubber Pads (Box 3 hardware card) • Transport Wheels (Box 3) Holes 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
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1 Assembly (Unboxing) 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” was
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1 Assembly (Unboxing) Step 5 Install Stabilizers and Lower Lat Connector Parts: • Right and Left Stabilizer (Box 3) • Lower Seat Connector (Box 4) Tools: • 5/16” Allen Wrench • 3/4” Wrench or Adjustable Wrench 5-1 Insert Lower Seat Connector 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
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1 Assembly (Unboxing) Step 6 3/8 x 2 3/4 ” Button Head Cap Screw Parts: • Platform (Box 3) • Foot Caps (Box 2) Tools: • 7/32” Allen Wrench • 9/16” Wrench or Adjustable Wrench 3/8” Washer 6-1 Align Platform with Stabilizers making sure the rubber pads are pointing downward. 3/8” Nylock Nut 3/8” Washer 6-2 Install DO NOT TIGHTEN the hardware. 6-3 Install Foot Caps onto the ends of the Stabilizers. Hardware (1:1): 6 Button Hea
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1 Assembly (Unboxing) 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. Separate styrofoam packing Lift box Styrofoam packing Step 9 Tools: • 5/16” Allen Wrench 9-1 Install one 1/2”x3/4” Allen Bolt. 1/2”x 1” Allen Bolt 9-2 Make sure Platform is flat and level and completely tighten hardware from steps 5 through 9. 1/2” Washer Hardware (1:1): 1 Button Head Ca
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1 Assembly Step 10 Remove Top Cover Top Cover Remove screws 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 front piece first Styrofoam Packing 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
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1 Assembly Main unit Step 12 Install Tension Shaft Parts: Rounded edge on top • 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 Shaft 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 hea
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1 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. Tension screws Tighten screws in order 1&1 , 2&2, 3&3, then 4&4. Tension Shaft Holder
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1 Assembly Side view of pre-tension Step 14 Install Pre-Tension SpiraFlex® Packs. ® SpiraFlex pack Pre-tension Hooks toward ® SpiraFlex Pack Tools: main unit • 3/32” Allen Wrench (Box 1) #8-32 X 3/8” Allen screw 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. Cam 14-2 When the Pack mak
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0 Assembly Allen Screw Step 16 Replace Top Cover Make sure inside edges Top Cover of Shroud fit in slots on Top Cover Rear Parts: Slots • Top Cover Front Tab Inside Edge Tools: • 1/8” Allen Wrench Shroud 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 i
