How To Take Apart Bowflex Dumbbells

If you need to move, repair, or simply understand your equipment better, knowing how to take apart Bowflex dumbbells is a useful skill. This guide provides a clear, step-by-step disassembly guide to help you safely break down your adjustable dumbbells.

Before you start, please note: Disassembling your Bowflex dumbbells will almost certainly void the manufacturer’s warranty. This process requires mechanical aptitude and caution. If your dumbbells are under warranty, contact Bowflex customer service first. Always prioritize safety to avoid injury or damaging the internal components.

This section covers the general principles for disassembling Bowflex SelectTech dumbbells, common to many models like the 552 and 1090. The exact internal mechanism can vary slightly, but the core concepts remain the same.

Tools and Preparation You’ll Need

Gathering the right tools before you start is crucial. Trying to improvise can strip screws or damage the plastic casing.

A clean, well-lit workspace with a soft surface (like a towel or mat)
Phillips head screwdrivers (multiple sizes, including a long-shank driver)
Hex key/Allen wrench set (metric and standard)
Needle-nose pliers and possibly a small pry tool
A small container or bag for organizing screws and small parts
Your dumbbell’s user manual for reference diagrams (if available)

Initial External Disassembly Steps

First, you need to remove the outer shell to access the weight selection mechanism inside. This is usually the most straightforward part.

Remove the End Cap: Look for screws on the outer face of the dumbbell’s end cap. There are usually 4-6 Phillips head screws. Remove them carefully and set them aside.
Separate the Halves: The main body of the dumbbell consists of two plastic clamshell halves held together by numerous screws along the seam. Methodically remove all these screws. Place them in your container as you go.
Gently Pry Open: Once all screws are removed, you may need to gently pry the two halves apart with a pry tool or flathead screwdriver. Be patient, as there maybe plastic clips holding it together. Don’t force it.

Important Safety Note Here

As you open the casing, be aware of springs and small parts that could be under tension. Open the shell slowly and keep your face clear. It’s a good idea to wear safety glasses for this step.

Working with the Internal Mechanism

Now you’ll see the heart of the Bowflex dumbbell: the dial assembly, selector plates, and steel weight plates. This is where attention to detail is key.

Document Everything: Take photos with your phone at each stage before removing parts. This will be your map for reassembly.
Remove the Dial: The selector dial is typically held by a central screw or bolt. Remove this to lift the dial face off. Underneath, you’ll see the selector plate(s) that engage with the weight plates.
Lift Out the Weight Plates: The steel weight plates are stacked on a central rod or guide. They may have spacers between them. Carefully lift the stack out, noting their order and orientation. The first plate often has a different shape or key.
Disengage the Locking Pins: This is the trickiest part. Small metal pins or latches lock the selected plates in place. They are often spring-loaded. Use needle-nose pliers to carefully release tension and remove these pins and their springs. Keep track of exactly where each spring came from.

You might encounter grease or lubricant on the internal parts. Have some paper towels ready to clean your hands and the parts if needed, but avoid harsh chemicals that could degrade plastic.

Common Issues You Might Find Inside

Disassembly often reveals the source of common problems. Here’s what to look for:

Broken or Worn Springs: This is the most common failure, causing plates not to lock properly.
Bent or Stuck Locking Pins: These can prevent smooth weight selection.
Debris or Corrosion: Dust, dried grease, or moisture can hinder movement.
Cracked Selector Plates: Plastic gears or plates can crack over time, especially if the dumbbell was dropped.

Reassembly and Final Tips

Putting everything back together is essentially the reverse process, but with added care.

Clean Components: Wipe down all metal plates and the inside of the housing with a dry cloth.
Reinstall Springs and Pins First: Carefully place the springs and locking pins back into their original positions. This is where your photos are vital.
Re-stack Weight Plates: Place the plates back on the central guide in the exact reverse order you removed them. A mistake here will prevent the dial from functioning.
Replace Selector Plate and Dial: Align the selector plate(s) correctly and secure the dial face back on with its central screw.
Close the Housing: Carefully align the two plastic halves, ensuring no wires or springs are pinched. Reinsert and tighten all screws firmly but don’t overtighten and strip the plastic threads.
Test Before Final Use: Before lifting, sit the dumbbell on a flat surface and turn the dial through all weight settings. Listen for smooth clicks and ensure plates engage and disengage properly.

A final word of caution: If the problem seems to complex or you lack confidence, seeking a professional repair service is the safest option. A misassembled dumbbell can fail during use and cause serious injury.

FAQ: Bowflex Dumbbell Disassembly

Can I fix a rattling sound inside my Bowflex dumbbell?
Yes, a rattle often indicates a broken spring or a dislodged pin. Disassembly will let you identify and replace the broken part.

Where can I find replacement parts?
Contact Bowflex customer service directly. They may sell official parts. Third-party springs and pins can also be found online, but ensure compatibility with your specific model.

Is it hard to take apart Bowflex 552 dumbbells?
The process requires patience and the right tools. It’s not overly complex for someone comfortable with basic mechanical tasks, but it is detailed. The steps for the 552 model are very similar to the general guide above.

My dial turns but the weight doesn’t change. What’s wrong?
This typically points to an issue with the connection between the dial and the internal selector plate, or broken engagement pins. The internal mechanism likely needs inspection.

How do I put my Bowflex dumbbells back together?
Reassembly is the reverse of disassembly. Rely heavily on the photos you took during teardown to ensure every spring, pin, and plate goes back in its original position. Take your time and test the dial function before using.