How to Replace Bowflex Max Trainer Servo Motor

This article details how to replace the servo motor on the Bowflex Max Trainer models M5, M6, M7, and M8. Before servo motor replacement, inspect the cable that connects the flywheel to the motor. Also, inspect both anchor points. They can create the same symptoms as a bad servo motor. These symptoms may include:

• Brake error on the console.
• Resistance will not change.
• Intermittent resistance changes.
• Clicking noise when the machine powers on or when the resistance level changes on the console.

Tools needed

• #2 Phillips Screwdriver
• 8 mm Wrench
• 10 mm Wrench

Replacement Procedure:

• With power supplied to the machine, adjust the resistance to the highest setting.
• Unplug the AC adapter power cord from the machine and the wall outlet.
• Remove the right stabilizer shroud from the machine.
• With a #2 Phillips screwdriver,  completely remove the top three screws and then loosen the lowest screw from the right fan cover.

• The right fan cover includes a tab that has to be pressed upward so it will have clearance from the loosened screw. Push up on the tab while removing the right fan cover.
• The upper screw on the right fan cover is a machine screw, not a self-tapping screw. It will need to be used in that same spot for re-assembly.

• Place some pieces of cardboard between the brake magnets and the disc to keep the magnets from sticking to the disc in the next step.
• Now use a #2 Phillips screwdriver to remove the 3 screws from the brake disc.
• As gently as possible, remove the brake disc and put it aside.
• Use an 8mm open-end wrench to loosen the brake cable securing nut by 3 full turns. This should loosen it enough that the cable can be removed from its anchor point on the motor arm in the next step.
• After removing the spring from the brake arm, disconnect the power cable and remove the brake cable from the servo motor.
• Remove the 4 screws that hold the servo motor to the frame with a #2 Phillips screwdriver.
• With the #2 Phillips Screwdriver and the screws from the previous step, mount the new servo motor to the frame.
• Connect the power cable and brake cable to the servo motor.
• Gently install the brake disc.
• When replacing the servo motor it is advisable to also inspect the brake magnets alignment.
  • With the machine set to the maximum resistance setting, the magnet should hover over the disc. The edge of the brake magnet should be with the outer edge of the brake disc, not beyond the brake disc.
    
• If any adjustment is needed, loosen the brake cable securing nut with an 8 mm wrench.
  • Adjust the cable's length by turning the barrel with your hand until the magnet is placed correctly.
  • Tighten the cable securing nut.

• Rotate the brake disc slowly to verify it does not rub against the brake magnet.
  • If it rubs, follow the next three steps to fix the issue.
  • If it does not rub, you can skip the next two steps.

• The placement of the magnets around the brake disc is directly related to the consistency of drag and overall useability. To prevent issues the brake magnets should be aligned with the brake disc and centered around the brake disc on each side. If they are not properly centered and aligned, then the magnets will cause issues.
  
• If the entire brake assembly needs to be adjusted to make the magnets parallel to the brake disc:
  • Loosen only the front screw using a 10 mm open-end wrench for minor adjustment.
  • Loosen both screws for more adjustment.
  • Move the brake assembly to properly align the magnets' distance from the brake disc and alignment making it parallel to the disc.
  • Tighten the hardware.
• Carefully install the right fan shroud and install the lower 3 screws.
• Check the alignment of the shroud and tighten all 4 screws.
• Install the right stabilizer shroud.
• Re-connect the AC adapter.

Final Inspection

Inspect your machine to ensure that all hardware is tight, and components are properly assembled before use.