As a Last Resort: What to Do When Your Bowflex SelectTech 552 or 1090 Handle is Stuck in its Base!

Hey all, if you ever find yourself tugging at a SelectTech handle that's stuck in its base...this is the super simple way to get it out of the base and apart to inspect and re-assemble it.
[UPDATE: Commenter Paulie pointed out that I had not mentioned the "foot method" in my video. That is correct. You should try that method first, and if it doesn't work, then try mine. Here's a link to the Bowflex foot method:
• How To Tutorial: Fixin...
Cheers,
Average Joe
𝗙𝗢𝗥 𝗔𝗩𝗘𝗥𝗔𝗚𝗘 𝗝𝗢𝗘 𝗣𝗥𝗢𝗗𝗨𝗖𝗧 𝗜𝗡𝗙𝗢 𝗔𝗡𝗗 𝗣𝗥𝗜𝗖𝗜𝗡𝗚, 𝗩𝗜𝗦𝗜𝗧:
www.averagejoeinnovations.com
𝗙𝗢𝗟𝗟𝗢𝗪 𝗢𝗡 𝗜𝗡𝗦𝗧𝗔𝗚𝗥𝗔𝗠:
/ average_joe_innovation...
𝗙𝗢𝗟𝗟𝗢𝗪 𝗢𝗡 𝗙𝗔𝗖𝗘𝗕𝗢𝗢𝗞:
/ averagejoeinnovationsllc
[𝗗𝗜𝗦𝗖𝗟𝗔𝗜𝗠𝗘𝗥: Bowflex®, SelectTech® trademarks are property of Nautilus®. Nautilus/Bowflex have had zero involvement with the development of AJI product upgrades. They aren't affiliated with AJI in any way, and AJI product upgrades are in no way endorsed by these companies.]

[@AverageJoeInnovationsLLC]

I've received a couple comments about the method in this video over the past few years. The method in this video should be see as a last resort. The very first thing to try is the "foot method" that Bowflex demonstrates here: kzbin.info/www/bejne/hqubpWZumNSmmMksi=57BQeefYsSyux-Sf&t=32 If the reason that your dumbbell was stuck in the first place has to do with a failed/failing component, you can find step-by-step disassembly, inspection and reassembly instructions in a playlist on my KZbin channel: kzbin.info/aero/PL-pg9u1pis_EWPeCLvN-DHjDIlbsEf74f beginning with Step 2. Cheers, Joe

[@rianhackworth5093]

Screw those other vids they explained what I already knew but not tell me how to fix it. thank you so much this was so helpful. Thee best video I found. We bought these because we knew how they worked but no one explained how to fix it

[@AverageJoeInnovationsLLC]

I'm glad it helped, Rian. Technically, disassembly is sort of the last resort, but the Bowflex recommended fix video here on KZbin just doesn't work in many cases. If ever you encounter any more difficulties with your SelectTechs, hit me up with an email. Chances are I've made a video about the issue and I can point you in the right direction. Happy 2023!

[@jonnakamoto5378]

Your video illustrates the power of a subject matter expert and a communication channel like KZbin to change the world in small but meaningful ways. Watching this and another video about how to assemble it fixed a problem that otherwise would have forced me to seek out expensive outside help (or even more likely just leaving it sitting around stuck). Talk about empowering! Thanks so much!

[@AverageJoeInnovationsLLC]

Hi Jon, thank you for your kind words. I'm glad these videos helped. I should mention that I reshoot some of my videos over time as I learn better techniques, new tricks and other information about which I wasn't previously aware. That way I can provide the latest, and hopefully most accurate, info to everyone. I leave this older content (like the video above) up on KZbin to increase the chances that folks will find my channel and content, but you can always click on my account name and go to my channel to see the latest content based on the most recent information and instructions available. There were also times in the past when something I said/did was simply incorrect/inaccurate. Since I shoot all of my videos in one take with no do-overs and no editing, I sometimes return to those videos and add corrections in the video description and/or as pinned comments. I recommend always expanding the video description or scrolling to look for a pinned comment to see if there is any errata. Wishing you and your family all the best throughout the rest of 2022. Cheers!

[@fernandotutor67]

Hi Joe I am stunned you made immediately a video to solve my problem....and it has worked!!! Now my dumbell is ok. Millions of thanks. Now I’d like to know how much would cost to send to Spain your metal disks for the 552i. Thank you for your superb explanations.

[@AverageJoeInnovationsLLC]

Hi Fernando...glad it helped. I am not always able to respond so quickly (like right now, days later). Lucky timing before. Glad to read that it worked out for you! Please shoot an email over to [e-mail] for pricing and ordering information. Wishing you and your family the best from across the Atlantic.

[@darryldowning1701]

The funny thing about all of this is he's not instructing you how to reconstruct the dumbbell. It seems to me to be incomplete instructions

[@AverageJoeInnovationsLLC]

Hi Darryl, hopefully it appeared at the end of the video for you, but you should see a thumbnail link to a re-assembly video at the very end of this video. If not, let me know. Also, if you head on over to my channel home page you'll find about 90+ videos that address various aspects of disassembly and reassembly. Hope that helps, man.

[@mrc10001]

Legend says that he is still trying to put this dumbbell back lol

[@AverageJoeInnovationsLLC]

LOL 👍

[@mrc10001]

@@AverageJoeInnovationsLLC it was just a joke bro..i know you are very technical... I know you can put it back quickly!

[@AverageJoeInnovationsLLC]

@@mrc10001 oh I knew you were joking. No worries. Rock on man and happy holidays!

[@kn-qz7by]

To be honest IMHO since this issue appears to be fairly common among Bowflex Selecttech dumbbells the blame for the issue lies squarely with Bowflex itself. You'd THINK the company would have worked out all the kinks in this product before releasing it for sale to the public. At the very least they should check each and every set of these dumbbells before shipping to ensure that everything works properly.

[@AverageJoeInnovationsLLC]

Hi kn. Bowflex has only issued one product recall for the SelectTech over the past couple decades. It was more than a decade ago and they misidentified the root of the problem. It seems as far as they are concerned there is no problem with their dumbbells, even though you and I (and countless others) know this to be untrue. As someone who has worked on product design teams for other companies in past lives, I can tell you that sometimes even a group of engineers can overlook something that is obvious to outsiders. There's a sort of tunnel vision that occurs within their bubble. It could be something as ridiculously simple as failing to test for a specific use case. This is why I rely on customer feedback to the extent that I do these days. Because I know that I may miss something that's obvious to someone else. So I throw my designs out there, and the feedback of hundreds of customers combined with my own experience using the products, help me understand what I need to do for the next iteration of the design. Bowflex, in contrast, appears to remain in a bubble with a design that is virtually unchanged for the past couple decades despite the first-hand experience of many hundreds of thousands of customers.

[@kn-qz7by]

@@AverageJoeInnovationsLLC If Bowflex only spent as much money on product design and engineering as it does on advertising maybe its product wouldn't have these issues.

[@BenFreedmanRacing]

I just got mine fixed by wiggling until I could turn both of the knobs, then putting it on its side and rocking the whole thing until it came out

[@Prog47]

Hey Joe. My problem is that the small plate stays on the handle when it's not supposed to and I have to push it down to get it off. Any ideas how to fix this?

[@AverageJoeInnovationsLLC]

Hey P, Do you own the 552 Series 1 like in the video above? Is it just the one small plate? Does it happen no matter which handle you use in that base? And no matter which way you face the handle in the base? I am not saying this is guaranteed to be the issue, but over time as these dumbbells age the plastic coverings on the weight plates begin to separate from the steel underneath. That creates a slight bulge and it can make the plate seem more thick than when it was new. And that can cause the plate to get stuck in the handle and not release properly, or it can make the dial more difficult to turn. If the same plate causes a problem in both handles, this would be my first guess. And I'd inspect the plate further to see precisely what is going on with it. Feel free to send me some photos of the plate and I will take a look when I have some time. My email is: [e-mail]

[@katadean]

Still great video, those springs went flying! I’m still having a problem with the white plastic tab that gets depressed when when you set it in the cradle, and then allows the dial to turn for weight selection- that plastic tab is stiff, sticky- just not budging very well. So when I get it back in the cradle, it sometimes doesn’t even depress, so I’m unable to change the dial/weight. Even after taking it all apart. Can that be lubricated? Any suggestions on the type of lubricant.

[@AverageJoeInnovationsLLC]

Oftentimes, a white locking pin and/or button is an indication of a knockoff.There may have been some older OEM SelectTechs equipped with white buttons and pins too, but I've mostly seen them on knockoffs. Some of the ones I've seen (and the couple that I own) have issues with locking pins getting hung up inside the cavities where the pins are installed. You could start by trying a silicone or PTFE-based dry lubricant offered by many brands including Blaster, 3M, WD-40 (grey can not blue), etc. Just a couple spritzes inside the cavity or on the body of the pin itself (not on the pin shaft). If that doesn't help, you may need to tweak the pin, button or cavity surfaces to get them to slide more smoothly with less interference. That means some trial and error, sanding, scraping, contouring, testing and repeating. It could even be the locking pin's spring catching on the inner edges of the cavity. Some of these manufacturers use a spring that's just too large in diameter. If you email me a couple photos of your pin, spring and the inner cavity taken from different angles, I can tell you where I think it's getting caught up. My email is [e-mail]. I'll reply when time permits. Cheers, Joe

[@AkshayGovind]

Can you please show how to reassemble? That's a lot of little pieces...

[@AverageJoeInnovationsLLC]

Hi Akshay, if you click on my name to view my channel, you can browse my videos where you will find several that cover reassembly.

[@Krimreaper1]

The guard on one if my 552 db fell off while I was working out, and all the plates fell out. I got replacement screws but I couldn’t get to the nuts, so it won’t catch. Do you think taking it apart is the best action? I am afraid I won’t be able to get it back together properly. And that it will fall apart again even if I do get it back. Would you repair or replace it? Thanks

[@AverageJoeInnovationsLLC]

Heya, Krim. The crossbar worked itself loose? That's wild. This is the first time I've heard of that happening. If you're inserting the screws and they aren't catching on anything, it's likely one of two reasons: 1. if yours are equipped with threaded bosses (not nuts) then the bosses have stripped and you'd need to tap them. 2. if yours are equipped with nuts, then they've fallen out. Hopefully they are not lost. They sometimes get caught in the plastic ribs of that assembly so you may find them when you disassemble the dumbbell. If they are lost, you can likely find more at any hardware store. Taking it apart is your only way to fix the problem. As you experienced, without the crossbar to keep the plates from spinning on the handle, the plates will fall out. It's a super simple repair. I have detailed step-by-step videos for disassembly and reassembly: www.averagejoeinnovations.com/#installation Just click the + sign on the right hand side of my website to expand the section. Then click the link for each step and it'll begin playing the in adjacent video player. Definitely pick up some thread lock. If you're in the States, Harbor Freight sells it for just a couple bucks per bottle and it's plenty good enough. Use it on those screws as well as the bolt/nut on the end of your dumbbell shaft and you should not have a problem with it coming loose again. Cheers, Joe

[@XDr3aM]

Do you have a video of how to reassemble the handle ?

[@AverageJoeInnovationsLLC]

Sure do...if you click my KZbin account name and look at my installation Playlist there are step-by-step reassembly videos.

[@vgs44]

I have the 1090 which one side doesn’t let go of the weights and spins freely without locking. Any advice

[@AverageJoeInnovationsLLC]

My very first guess, based solely on my understanding of what you described, would be that the dial lugs have sheared off. If the dial turns but none of the discs turn with it, then one or more dial lugs are gone. Check out the beginning of this video to see what I mean: kzbin.info/www/bejne/rIaYYpSBn82psLcsi=56vt0yLjrrjp0ByM If that's not the case, feel free to email a video of the issue to me and I'll take a look and let you know what I think it might be. Please note that it may take a day or two to reply depending on my workload.

[@mikegraziano5142]

To all, This is a great tutorial. I have the Series 1 and I am stuck at the get go. I cannot remove the bolt. I have the two 3/4" - 19MM ratchets and no matter how much torque I apply, it will not unscrew. I've used 3-in-one machine oil and let that soak in to no avail. Does anyone have any thoughts? By the way, this dumbbell has never been serviced so it was tightened at the time of assembly by a gorilla. 😆 Does anyone have any thoughts?

[@AverageJoeInnovationsLLC]

Hiya Mike, I answered you via email, so this is for anyone else who might want to know how I'd approach this problem. My gut feeling is that these things are assembled using impact wrenches (which is also why it's not a wise idea to use impacts on wheel lugs). With nearly every SelectTech I own, the nut on one end of the shaft is jammed on with such force that it deformed the lock washer beneath it. And the other nut, while tight, is usually the one that breaks free. You'll usually see a red or blue residue after removing the bolt/nut indicating the use of thread lock too. I have had only one bolt that was so incredibly difficult to remove that I ended up using a breaker bar (1/2" drive 24" if I recall) with a pipe slipped over the end to create enough torque to break it free. The most challenging part is finding a way to hold the dumbbell steady while applying so much force. Ideally, you'd want an equally long breaker bar or large ratchet on the bolt/nut that is on the opposite end of the shaft to counteract the force. And, if possible, someone in the middle holding the dumbbell steady without grabbing the dials or crossbars or anything that might accidentally snap. You *could* possibly pull it off as a one-man job, but it may be easier with 2 or 3 people. If you lay the dumbbell flat on a floor horizontally and attach the breakers to each end bolt/nut vertically, and pull those breakers in opposite directions, you should be able to get that bolt/nut to budge. It just needs to break free...then it will turn fine. If you're concerned about damaging the dumbbell, try wrapping it in a towel so that the person holding it steady isn't holding a dial or crossbar or anything that might snap accidentally. Wishing everyone a very Happy New Year!

[@mikegraziano5142]

@@AverageJoeInnovationsLLC Hey Joe, Thanks for the email and the post here. I was just about to write to you as I saw your video on the web site at kzbin.info/www/bejne/h2azg6Gsra2Dmbcrel=0 I have put acetone on the nuts to see if it will help release the Loctite. I will also get some help. Stand by for an update and Happy New Year.

[@mikegraziano5142]

Hey Joe, Well, I finally got those nuts off. As you suspected, it took two people and two breaker bars. Thanks again for your advice and those great videos. Rgds mjg

[@mayssm]

As soon as a single ball bearing or spring fell out, I'd be cursing up a storm.

[@AverageJoeInnovationsLLC]

I've been there years ago when I began messing with these dumbbells. Placing a towel under the dumbbell to catch bearings and springs is the way to go. Trying to find ones that fall on the floor is an exercise in frustration. Cheers.

[@jemimabucknell8803]

I don't have any socket thingys 😢

[@AverageJoeInnovationsLLC]

Hiya, J. Yes, having to find a couple sockets and ratchets is a bit of a pain for some folks. I know consumers have a love-hate relationship with Harbor Freight here in the States, but when it comes to affordable sockets and ratchets just to do a job like this, HF is often one of the least expensive options in town. I hope you were able to find the tools and address whatever issue you had with your dumbbells. Cheers, Joe

[@GregDZ33]

How did you remove the covers?

[@AverageJoeInnovationsLLC]

Hi, Greg. Sorry about the delayed reply. I was away on a trip for 5 weeks overseas with limited internet access. I'm back in the States now and playing catch up with filling orders and answering questions. You may have already solved your issue by now. But if you haven't, here's a video about removing the covers: kzbin.info/www/bejne/ZpK8cmxooMiCfMk Cheers.

[@XDr3aM]

I don’t have that bolt on mine

[@AverageJoeInnovationsLLC]

Hi Joe, If you have a 552 Series 2 or a 1090 dumbbell it'll have nuts on each end rather than bolts. They'll still be 19mm (3/4"). Other than that, everything else will be the same as far as this process. Hope that helps.

[@XDr3aM]

@@AverageJoeInnovationsLLC thanks I didn’t realize that you have to remove the plastic caps I should be good now

[@AverageJoeInnovationsLLC]

@UCcxzkgr8RYsn7A22HT0OV_g That's correct, Joe. Those are plastic end caps. Here's a brief video about removing them: kzbin.info/www/bejne/ZpK8cmxooMiCfMk Sorry about that. I mistakenly assumed that your end caps had been removed already.

[@gescandon7529]

Dang glad I didn't do this. Just tun it over and remove 4 screws 😂

[@AverageJoeInnovationsLLC]

It all depends on the nature of the jam. The method in this video should be see as a last resort. The very first thing to try is the "foot method" that Bowflex demonstrates here: kzbin.info/www/bejne/hqubpWZumNSmmMksi=57BQeefYsSyux-Sf&t=32 If the reason that your dumbbell was stuck in the first place has to do with a failed/failing component, you can find step-by-step disassembly and reassembly instructions in a playlist on my KZbin channel: kzbin.info/aero/PL-pg9u1pis_EWPeCLvN-DHjDIlbsEf74f beginning with Step 2. Cheers, Joe

[@lapinmaki]

You don't have to do that.

[@AverageJoeInnovationsLLC]

HI Jouto, after trying simple solutions first--for example, the dial position that I point out at the beginning of the video--this is and should be your last resort. In some instances, you have no choice but to do it.

[@lapinmaki]

@@AverageJoeInnovationsLLC Okay, I jjust feel hard to believe it. I bought pair of those about week ago.. And one of them was stuck. I looked solution from internet and found few videos about what to do. And now it works quite well and I think that become better when I use them more.

[@AverageJoeInnovationsLLC]

@@lapinmaki I'm glad you found a solution that worked. Especially for a pair stuck after just one week. If ever you have other issues with the dumbbells, search my channel. I have more than 90 videos about these dumbbells and I own several pairs, some over 12 years old. Stay safe. Cheers, Joe

[@BxAllMightYy]

Find the bowflex video, don't do this

[@AverageJoeInnovationsLLC]

Bowflex's method demonstrated in its video only works in some cases, not all. Whether it works depends on why it is stuck in the first place. People who try the method above are typically here because the Bowflex method didn't work for them. Cheers, Joe

[@andyquirk9985]

This isn’t helpful at all, how the hell do you put it back together?!

[@AverageJoeInnovationsLLC]

Hi Andy. I recommend you watch one of the 50+ other videos on my channel that show how to assemble these handles.

[@dakota9275]

My ends don’t have “open” nuts...they’re covered

[@AverageJoeInnovationsLLC]

Hey Dakota, here's your first step: kzbin.info/www/bejne/j5-rq6FofqeFb9k