Bowflex Revolution and Revolution XP Home Gyms, Rope Replacement Instructions

The following are the steps to replace the rope on a Bowflex Revolution home gym. This procedure is for all Revolution and Revolution XP home gym models by Bowflex.

Tools Needed:

• Allen Wrench Set (1/8", 7/32")
• Philips Screwdriver
• Flathead Screwdriver
• String (approx. 6 Ft length)

Procedure:

• Start with the 1/8" Allen wrench and remove the top cover. There are 4 bolts you will remove. Set the cover aside.
• Now, remove the shroud clip that holds the side shrouds together under the top inside.
• Remove the screw holding the 'tension adjust' knob cap using the Phillips screwdriver.
• After removing the screw, gently pry the cap out of the knob using the screwdriver.
• Remove the 4 screws holding the tension adjust knob. Remove the knob and set it aside.
• Still using the Phillips screwdriver, remove the 5 screws holding the shroud from the side being serviced.
• Remove the shroud and set it aside.
• Remove the bolt that holds the lower spool using the 7/32" Allen wrench.
• Remove the spool and unwrap the strap from the spool (as shown).
• Hook the spool between the rear stabilizer and frame (as shown). 
• Next, remove the large pulley by sliding it off the axle.
• Remove the cam (engine drive assembly) from the cam axle.
• Lift the arm to its full upright position.
• Tie or tape the string to the end of the old rope (as shown).
• Pull the old rope through the arm and over the upper pulley; this will thread the string through the arm. Be sure to leave enough string at the lower pulley to grab and pull or thread the new rope back through.
• Untie or untape the old rope from the string at the upper pulley and tie or tape the new rope in its place.
• Pull or thread the new rope through the arm by grabbing the string left exposed at the lower pulley and gently pulling.
• You will feed the rope through the hole in the large pulley and then clamp it in place. Confirm the rope is secure in place by leaving 1/4" of rope exposed through the clamp.
• With the cam on its axle, re-install the large pulley.
• Unhook the spool from between the rear stabilizer and frame, re-wrap the strap, and re-install the spool. Note: The strap wraps counterclockwise around the lower spool.
• Install and tighten the mounting bolt with the 7/32" Allen wrench.
• Reinstall the shrouds in reverse as removed.
• Check the machine for operation.

This completes how to replace a rope on the Bowflex Revolution and Revolution XP home gyms.