Repairing the Bowflex Max Trainer (M7 in my case)

Since I’m doing this again… I found some updated/better directions, here is a great FB post with user-to-user support. It’s where the pictures I’m using below are from. Pay particular attention to the Indexing part. I never read or had input and this could be the issue as to why my servo didn’t last but a few days.
https://www.facebook.com/groups/bowflexmaxtrainer/posts/8545118512188185/

The original M7 (and other models) tend to develop a clicking noise when selecting a resistance level. There are several reasons this could be occurring, however in my and others cases, one of the nylon gears strips. I found my original to be devoid of grease in the gear faces. Hmm. The correct part number has been out of stock for the last year. Here is a workaround;

The Servo Motor kit below requires you to disassemble the assembly and swap the original motor for the one in the new assembly listed below. You will notice that the Potentiometer is NOT wired in.

• SVC KIT, SERVO, MAX SE
  Part Number: 1000513753
  Retail Price: US$15.99

If you feel uncomfortable opening and swapping the motor/potentiometer assembly, then you can order the following Servo assembly. Not, you will have to swap over the Brake Cable bracket and the 1/4 pie cable horn.

• SERVO MOTOR ASSY, RESISTANCE, LX
  Part Number: 1000512725 Find it here
  Retail Price: US $18.99

The Replacement Process

The Bowflex process is poorly documented. They have a youtube video that skips steps such as plugging the Servo in. My biggest PITA point was attempting to follow by removing the side panel and getting my hands inside. I could barely get my hands in, let alone spin the stubby screwdriver. Taking note from their video, they worked from the back, and I noted there were no plastic panels on the other side, the entire unit was opened up. I saw one video on youtube where the guy removed most of the plastic housing. This was no quick task, it was lots of screws. I taped the screws with painter’s tape to keep track of what went where. Once I removed the panels, I used my long P2 screwdriver to remove the servo.

The best advice I have found now that I’m doing this yet again…

How to Properly Position (“Index”) the new Servo Motor’s “Arm:

This procedure applies when you are using the servo motor from a Bowflex HVT or Bowflex LX3/LX5 machine on a Max Trainer. When using those servo motors, you will remove/discard the existing “arm” (the part of the servo motor that rotates) and replace it with the arm from your faulty Max Trainer servo motor.

IMPORTANT – DO NOT install the Max Trainer’s servo motor’s arm until you have FIRST completed the following “indexing” steps! Simplistically, what you are doing is setting the new servo motor to the max resistance level, AND THEN installing the arm in its correct position.

The servo motor’s arm has 8 “teeth” that engage to corresponding grooves on the servo motor arm’s socket. Thus, the arm can be installed in 8 different positions…but which position is the correct one to use? Here’s how to position it correctly.

STEPS TO PROPERLY “INDEX” THE SERVO MOTOR’S ARM:

1. Unplug the power cord from the Max Trainer.
2. If you haven’t already done so, unplug the existing, faulty servo motor from the main wiring harness.
3. Plug in the new servo motor to the main wiring harness. You can do this with or without mounting the new servo motor to the Max Trainer’s frame and with or without removing the existing arm on the new servo motor…your choice.
4. Plug in the power cord to the Max Trainer.
5. Select and start the “Manual” workout program (note that on the M5, the “Manual” program is selected simply by pressing the “START” button).
6. Repeatably press the “RESISTANCE LEVEL UP” button to set the resistance level to its maximum setting. You should see/hear the new servo motor’s arm socket rotating clockwise.
   1. NOTE: You do NOT have to pedal to change the resistance level. The screen will go to PAUSED mode after 5 seconds (because of no pedaling), but the RESISTANCE LEVEL UP button will still function and you can simply press the START button again at any time to un-pause the display to then show its current resistance level setting.
7. Confirm that the display shows that the resistance level is set to max, and then unplug the power cord from the Max Trainer. This will “freeze” the servo motor at the max resistance level position.
8. The servo motor is now “indexed” at its max resistance level position, and NOW you can install the arm onto the new servo motor in its correct position per the following details.