How To Fix Broken Bowflex Dumbbells

If your Bowflex dumbbells are acting up, you’re probably frustrated. This simple repair guide for how to fix broken Bowflex dumbbells will help you get them working again without a huge cost. Many common issues, from stuck plates to a broken dial, can be fixed at home with basic tools and a little patience.

Before you start any repair, it’s crucial to identify the exact problem. The symptoms your dumbbells show will point you toward the right solution. Most repairs fall into a few common categories, which we’ll cover step by step.

Common Bowflex Dumbbell Problems and Symptoms

Knowing what’s wrong is the first step. Here are the most frequent issues:

Plates Not Engaging/Disengaging: You turn the dial, but the plates don’t lock in or release properly. The weight feels loose or won’t select at all.
Stuck or Stiff Dial: The selector dial is hard to turn or won’t move past a certain number.
Broken or Cracked Casing: You see visible damage to the plastic shell of the dumbbell.
Loose or Rattling Parts: You hear internal pieces shaking around when you move the dumbbell.
Incorrect Weight Selection: The dial says 25 pounds, but it feels like 10 or 50 pounds instead.

Tools You’ll Need for Most Repairs

Gather these items before you begin. You likely have most already.

Phillips head screwdriver
Flat head screwdriver
Needle-nose pliers
Rubber mallet (a regular hammer with a soft cloth will work carefully)
Clean cloth and isopropyl alcohol
Silicone-based lubricant (like WD-40 Specialist Silicone)
A clean, well-lit workspace

Safety First: Important Precautions

Always put safety first. These dumbbells contain heavy metal plates and springs under tension.

Work on a flat, stable surface.
Keep small parts organized so they don’t get lost.
If you feel unsure about a step, pause and reassess. It’s okay to seek help.
Never force a part that seems jammed; you might break it further.

Repair 1: Fixing Stuck or Non-Engaging Plates

This is often caused by dirt, dust, or lack of lubrication. Here’s how to clean and fix it.

Set the dial to the lowest weight setting (usually 5 or 10 lbs).
Carefully remove the outer plastic shell. There are usually screws on the end cap and along the seam. Keep track of all screws.
Once open, you’ll see the metal plates and the selector mechanism. Take a picture first for reference.
Use your cloth and isopropyl alcohol to gently wipe down all the metal plates and the rails they slide on. Remove any visible grime or rust.
Apply a small amount of silicone lubricant to the plate rails and the moving parts of the selector. Avoid getting lubricant on the dial numbers or plastic.
Manually move the plates back and forth to distribute the lubricant. Turn the dial through all settings to check for smooth operation.
Reassemble the casing and test the dumbbell before fully tightening all screws.

Repair 2: Fixing a Stiff or Stuck Selector Dial

A dial that won’t turn usually has a simple fix. The mechanism underneath might be jammed.

Remove the plastic shell as described in the previous steps.
Locate the circular dial mechanism on the side. Inspect it for any broken plastic teeth or obstructions.
Often, the dial’s alignment is off. Loosen the central screw that holds the dial on slightly (don’t remove it completely).
Realign the dial so the arrow points directly to the selected number when the plates are engaged. You may need to turn the internal mechanism by hand to find the correct position.
Tighten the central screw back down. Test the dial’s rotation. It should click firmly into each position.
If it’s still stiff, a tiny drop of silicone lubricant on the dial’s central post can help.

Repair 3: Replacing a Broken Plastic Casing

Cracks in the shell are common from drops. You can order replacement parts directly from Bowflex.

Note your dumbbell model number (usually on a label near the dial).
Contact Bowflex customer service or visit their website to order a new shell kit. They’re often sold as left and right halves.
Once you have the new parts, completely disassemble the old shell. Lay out all internal components in the order you remove them.
Transfer the internal mechanism and plates into the new shell, following your earlier photo for reference.
Secure all screws. Don’t overtighten, as you can strip the plastic threads.

Repair 4: Addressing Loose Internal Parts and Rattles

A rattle means something is out of place inside. You’ll need to open it up to investigate.

Open the dumbbell shell.
Check that all the metal weight plates are properly on their rails and that the spring clips are attached.
Ensure the long central rod (if your model has one) is secured at both ends.
Tighten any loose screws or bolts you find on the internal frame. Sometimes a loose spring can cause noise.
Reassemble and test. The rattle should be gone if you’ve secured the loose component.

When to Contact Bowflex Support

Some problems are too big for a DIY fix. Reach out to the manufacturer if:

The main selector mechanism is cracked or has broken plastic gears inside.
You have a bent or broken metal rail that holds the plates.
Your model is very old and replacement parts are no longer available.
You’ve tried the repairs above and the problem persists.

Have your model number and a description of the issue ready. They can provide specific advice or tell you if a replacement part is available.

Preventative Maintenance Tips

Taking care of your dumbbells prevents most issues. A little maintenance goes a long way.

Store them on a flat, level surface, not leaning against a wall.
Keep them in a dry area to prevent rust.
Every few months, wipe them down with a dry cloth to remove dust and sweat.
Once a year, consider a light internal cleaning and lubrication as shown in Repair 1.
Avoid dropping them. The plastic casing and internal alignment can be easily damaged from a fall.

FAQ: Your Bowflex Dumbbell Repair Questions

Can I fix Bowflex dumbbells myself?

Yes, in most cases. The repairs are often mechanical and straightforward if you’re comfortable with basic tools and following steps.

Where can I get replacement parts for my Bowflex weights?

The best source is Bowflex/Nautilus directly. You can also find some common parts, like shells or dials, on online marketplaces like eBay, but ensure they match your exact model.

Why do my Bowflex dumbbells not adjust properly?

The most common reason is dirt or lack of lubrication inside. A good cleaning and light lubrication of the plate rails and selector often solves it.

Is it worth repairing old Bowflex adjustable dumbbells?

Usually, yes. Compared to the cost of a brand new set, a simple repair is very economical. Even buying a replacement shell is often worth it.

What lubricant should I use on Bowflex dumbbells?

Always use a dry, silicone-based lubricant. Avoid grease or oil-based products, as they attract more dust and grime, which makes the problem worse over time.

Fixing your Bowflex dumbbells is a satisfying project that saves you money and gets you back to your workouts faster. By following this guide, you can diagnose the issue, perform the repair, and take steps to keep them functioning smoothly for years to come. Remember to work carefully and prioritize safety throughout the process.