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)


  • 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.

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