Bowflex Max Trainer, Roller Wheels and Pedal Arm, Troubleshooting Issues

Do you have a Bowflex Max Trainer and are you having issues with the roller wheels or pedal arms? We discuss the common complaints and offer some steps to troubleshoot these issues.

Common Complaints:

• Roller wheel clicking or rubbing
• Damaged roller wheels
• Roller wheels falling off of rails (misaligned leg assembly)
• Pedal arm noise

Tools Required:

• #2 Standard or Flathead Screwdriver
• 14mm Socket and Wrench
• #2 Phillips Screwdriver
• 6mm Hex Wrench
• 8mm Hex Wrench
• Torque Wrench

Troubleshooting Steps:

Roller Wheel Noise:

1. Identify the Noise:
   • Listen carefully for a clicking or rubbing noise coming from the roller pedal arm wheel area.
     Note: Contact between the roller wheel and roller arm bracket is a normal operational sound and does not indicate a malfunction.
2. Inspect the Roller Wheels:
   • Visually inspect the roller pedal arm wheels for any signs of damage.
   • If damage is found, order replacement roller pedal arm wheels.
3. Check the Roller Wheel Alignment:
   • Verify that the roller pedal arm wheels are properly aligned and remain on the rails during use.
   • If the roller wheels appear misaligned or disengage from the rails, click here learn about how to adjust the leg assembly alignment.

Pedal Arm Noise:

1. 1. Initial Pedal Arm Check:
      • If the noise originates from the pedal arm area, proceed with the steps that follow.
   2. Pedal Arm Removal:
      • Remove both pedal arms. You will need the 6mm hex wrench. Click here to learn how to remove the pedal arms.
   3. Crank Cover Removal:
      • Remove both plastic crank covers. You will need a #2 Phillips screwdriver. Click here to read more about crank arm cover removal.

        Caution

      The screws for the crank arm cover may be tight and prone to stripping. Use a properly sized screwdriver.

       

   4. Crank Nut Tightening:
      • Tighten both crank nuts securely. You will need the 14mm socket and wrench.
      • Proper torque range for the crank nut is 29 ft lbs to 32.5 ft lbs (or 350 - 390 in lbs).
      • Reinstall the pedal arms and test the machine.
      • Does the noise remain?
   5. Pedal Arm Swap:
      • If the noise continues, remove the pedal arms.
      • Swap the pedal arms to the opposite sides and reinstall them.
      • Try the machine again.
      • Does the noise remain?
   6. Component Replacement:
      • If the noise follows a pedal arm after swapping the pedal arm assembly, you need to replace a pedal arm assembly.
      • If the noise remains in the original place, you will need to replace the crank assembly for the affected side. The side that is noisy.
      • Important: A 22mm crank puller is required to replace the crank arm assembly. If you do not have one, you will need to order a 22mm crank puller.