Question about Bowflex Revolution Home Gym

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Pulley system "off track" inside main frame of 2005 boflex revolution

The main cable is off the track if the large pulley. We don't know how to get inside to get it back on the track. Both right and left sides are off track. We have both the user and assembly manuals and they are of no help. Can we take off the tension knobs? My husband owns an auto mechanic shop so he has lots of tools and expertise. Can you please help? The machine is used, but nothing appears to be broken or missing.

Thanks so much.

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  • Jay434 Nov 02, 2008

    Reassembled used bowflex revolution same problem. The handle just falls to the floor and the pulley chord (not yellow ribbon) is off track.

  • ahauze Nov 29, 2008

    I have the same issue too. I think I caused it by pully out the tensioner and turning the large pully the wrong way. The cable is all off the pully now and it is not obvious how it goes back on.



  • Anonymous Feb 17, 2009

    ahauze, do you have to take off tension plates and remove tension bar before taking the sides off? Thanks for your help.

  • castcore Feb 21, 2009

    Hi, my yellow cable is also loose, anything I need to do different.

  • 8r14n May 10, 2009

    Just a quick add: I had the same problem on one side of a Bowflex Revolution XP. When I was able to solve it that side made a rubbing noise like the cable was rubbing on something. I discovered inside where the cable enters the main unit (plastic grey thing) there is a smooth curved guide right after the pulley. It guides the cable into and onto the main wheel.

    I took off the stationary 5# weight so there was no tension on the cable and slide the cable behind the smooth curved guide. Put everything back together and no more noise.


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I had same problem. I fixed it by taking plastic sides off using a long phillips head screwdriver. Jay, you don't have to take the sides off to fix your problem. The sides come off only to untangle and rewind cables on pulleys. Pull the cables all the way out. Have a helper pull out and keep holding out the tension knob This is shown at the bottom of page nine in the manual. With someone holding the tension knob out turn the large pully located beneith the tension knob CLOCKWISE! I screwed mine up by turning it counter-clockwise. This winds the handle to the top and if you start with all the cable pulled off the pully, the cable should then wind itself nicely back onto the pully. Once the handle is all the way up, with the round ball on the cable jammed up against the pully, then and only then let go of the tension knob and let it fall back into place. If the handle falls down a few inches repeat this proceedure but push lower pully a bit harder and try to turn tension knob, while it is pulled out, in the opposite direction and it will then click into place one notch tighter and should hold the black ball on the cable firmly against the pulley. Let me know if this was helpful.


Posted on Dec 01, 2008

  • Michael Dockery
    Michael Dockery Jul 02, 2014


  • Michael Dockery
    Michael Dockery Jul 02, 2014

    I've had the same problem before and it seems to come back to haunt me on the same side, the problem being in the tension on one side but if you try to adjust then all of sudden chaos follows. I've tried watching the official instructions video by Bowflex but that did not work(the instructions being very similar to yours to the point of practically being the same). Anyways I'm looking inside my wonderful machine and I notice that the rope is actually off of the wheel and flipped over on top of the wheel(please ask for more info if this is confusing) and well frankly I don't know how to put it back on track. Pulling the rope down only makes it worse because the rope is actually off of the wheel. It makes it pretty difficult to put back on because of all of the little plastic rope guards that surround the wheel on the inside. Any suggestions how I can manually put the rope on track, should disassemble the whole side casing, do you know of any internal diagrams that feature the wheel? The last one might be obvious since it should be in the book, but all info helps. thank you!


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I am not sure my problem is the same as the previous one, but here we go.
Product: 2009 Bowflex Revolution

Situation: I tried to create more tension on the rope as advised by the Bowflex manual. I pulled the knob out turned counter clockwise and all hell broke lose.
Problem: There was no tension in the cable and the rope would just dangle with now resistance for the right side of the Bowflex.
Solution: (You may need two people!)
1) Unscrew the top portion of the Bowflex. ( 4 Screws) 2) Make sure the handles are in the 9 position 3) Make sure the yellow ribbon is not tangled due to the extra slack 4) You need to make sure the grey rope ball is all the way against the pulley. You can achieve this by turning the TENSION KNOB clockwise (but do not pull it out) until the grey ball is tightly against the pulley. 5) Have your partner place one finger under the yellow cable and pull to create tension again the ribbon so to not tangle due to the extra slack 6) Pull the tension knob OUT and with your other hand turn the disc that is directly behind it with groves clockwise until your partner tells you there is no longer any slack on the yellow ribbon 7) Screw back on the top portion of the Bowflex

Posted on Jul 26, 2009

  • Demarche Jan 09, 2011

    You may need to repeat this more than once if you've pulled the cables all the way down. Also, watch for the cable being jammed through the bottom of the wheel well, where the pulley exits the bottom of the housing.

  • morpheus001 Apr 10, 2011

    I found this to be helpful. I have same problem. In doing the solution the knob won't go any further clockwise. The cable is wound all the way and the ball is at the upper pulley. I reach the point where i can rotate the lower pulley clockwise. I can rotate the pulley up to a certain point but no more. Not being able to wind up the webbing enough to create the tension is affecting the fix in my case. I may to order a replacement part.


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Just a quick add: I had the same problem on one side. When I was able to solve it that side made a rubbing noise like the cable was rubbing on something. I discovered inside where the cable enters the main unit (plastic grey thing) there is a smooth curved guide right after the pulley. It guides the cable into and onto the main wheel.

I took off the stationary 5# weight so there was no tension on the cable and slide the cable behind the smooth curved guide. Put everything back together and no more noise.

Posted on May 10, 2009

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