HOW TO Repair And Fix BOWFLEX DUMBBELLS 552 1090

In this video I will show you how to fix your Bowflex dumbbell. Works with version 552 and 1090.
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[@KevinPon.]

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[@mrolo72]

What is the blue tool that you used to remove the dumbbell stickers (endcaps)? I can't seem to get the right leverage with a flathead screwdriver, even with the thin bits. I bought a automobile trim removal tool, thinking it would hook under the disk, and no dice.

[@KevinPon.]

Oh 😂 that's a prying tool for taking off cellphone screens. You can also use a thin fine blade to pop off the sticker but be careful 🍻

[@AverageJoeInnovationsLLC]

Hey Kevin, a few tips to make your life easier in the future. I've done this process literally (not figuratively) hundreds of times. 1. Lay down a towel to catch parts just in case something doesn't go as planned. 2. Always disassemble and reassemble the dumbbell with the shaft oriented vertically, never horizontally. You started out ok when loosening the nut, but flipping the dumbbell onto its side is a no-no. Horizontal makes it easier to lose bearings and springs. As an extra precaution you can also secure the steel discs to the plastic crossbar assembly with a couple pieces of tape such as blue painter's tape. That will apply pressure to the bearings and springs and keep them from falling out. I don't bother but I've been repairing these dumbbells for ages. 3. There's no need to remove the last dial from the shaft unless you need to replace it. Just leave it on and stand the shaft upright. The dial will act as a stable base. At this point you should inspect the dials, discs and locking pins for wear or damage. They'll need to be replaced too. As you discovered during disassembly you had a broken dial and a loose crossbar reinforcement. 4. slide your 4 discs down the shaft and onto the dial. Rotate them and they will "fall" into place when the lugs line up correctly. It was interesting that you used this easier method when you installed the second 4 discs later in your video. But you chose the extra steps earlier on with the first 4 discs. 5. No need to make sure that the long slot on the steel plate points downward as you said at 4:27 and again at 5:20 and again at 6:27. That slot's initial position is irrelevant and can point in any direction. Doesn't matter. It'll line up correctly when you rotate the assembly on the shaft as described above in #4. Just rotate and it will drop into place...usually making a clicking sound once it does....as you actually demonstrate at 5:52 6. If your bearings do fall out, don't try to put them back in while the steel plate is still wedged in there the way you're doing it at 4:50. You're over complicating it. Just take that plate out completely. You can use a dab of grease or petroleum jelly to stick the springs and bearings into place so they don't fall out as easily. Steel plate slips right back into place. 7. By now you may have figured out that the steel reinforcing bar that you were holding in place at 6:40 should not be loose like that. It's supposed to be screwed in to the plastic crossbar above it. That's what reinforces the crossbar. And that crossbar is responsible for keeping the weight plates from rotating on the handle during a workout. If they rotate they fall. One of several ways the plates can fall out of these handles. 8. 7:43 is a no-no as well. Leave the dumbbell vertical the way you had it. Fully hand tighten the nut until you can't with your fingers. Make sure you are pushing up on the shaft from below with your other hand to maximize the number of threads accessible by the nut up top. Then arrange your ratchets the way you did when you first loosened the nut. One down below and the other up top. Now snug up the assembly. Then and only then can you lay the dumbbell sideways if you like for the final tightening. I never bother. I just tighten it up vertically. 9. At 8:10 you're not done yet. You should always check to make sure you didn't over tighten the nut. You can do that by engaging the locking pin buttons on the bottom side of the handles and rotating the dials. If they turn smoothly, great. If they're difficult to turn, back the nut off a half turn and try again. Repeat until the dials are neither loose nor difficult to turn. 10. Finally, at 8:40 you really should do more than just lift a full dumbbell from the base. Set it at several different weights. Each time, remove the dumbbell from the base and give it a good shake. Use your hands to physically wiggle each plate and see if any wiggle loose. BONUS: Technically speaking, if you broke a disc you should disassemble everything to assess the damage before ordering any replacement parts....as you made need to order more than just one or two parts. Otherwise you'll have your new part in-hand and discover (as you did during disassembly) that something else was also broken. Never ever use SelectTechs for body weight exercises or drop them to the floor from any height. You will risk damaging the discs, pins, dials and tabs on the weight plates. They aren't made for the forces produced by any of that. Speaking of weight plate tabs, check them on a regular basis (say, monthly) for damage, or after any accidental drop. If the tabs are damaged the plates can fall from the handle even if your discs are fine. Lengthy comment, but I hope it saves you some unnecessary grief in the future. Cheers, Joe

[@KevinPon.]

Thank you Joe! Very detailed and informative!👍🏻🍻 I've seen your set of dumbbells. They are one of a kind! They're like unbreakable. Much rather have that then these plastic disc.

[@maxmardig]

By far one of the most useful comments I've ever read.

[@AAmtb]

Question on #8 and 9: when I unthreaded the nut, it was on there pretty tight. But when putting everything back, I noticed that if I tightened the nut pretty tight (like when I disassembled) the dials wouldn't turn at all. I had to back them out enough that nut adjustment tension on the ratchet was pretty easy. Don't know if the initial unscrewing was just tight and needed to be broken loose.

[@KevinPon.]

Yes you're right. It can't be over tightened or else the dials will be too difficult to turn 🍻

[@AverageJoeInnovationsLLC]

@@AAmtb Kevin nailed it. I would add that these nuts usually have thread lock on them. You may have noticed a whitish/blue/red/green powder residue when removing the nut for the first time. A major improvement over the 552 Series 1 that often seemed to be assembled with an impact wrench and thread lock. But the factories go overboard with it. It is not uncommon for someone to have to use a large 2ft breaker bar to break the end bolt/nut free. When reassembling, apply some fresh thread lock. A dab is enough. You're just preventing the nut from working its way loose over time due to the friction of rotating the dial counterclockwise.

[@kwynw9402]

Thank you soooooo much! I was so bummed out. I thought my dumbbells were gone. You and one other video saved me hundreds of dollars and hours of searching to even find a a set. Amazing. Thank you!!!!!

[@KevinPon.]

You're very welcome my friend! 😁🍻

[@kellyrench8173]

Thanks for this video - you’re a lifesaver! One of my dad’s dumbbells stopped working a couple years ago (two discs got stuck on the dumbbell bc my brother put them on backwards 😂) and he never had time to look into fixing it, so I did! Couldn’t figure out a solution after watching several vids and googling a bunch, until your video! My dad said he’s gonna go put his balls on the shelf bc his daughter fixed something he couldn’t 😌💁🏼‍♀️ haha so anyway, thanks again! You the real mvp.

[@KevinPon.]

😂😂 that's a funny story! You're most welcome Kelly! I'm very happy to hear that I was able to assist you. 😎😁

[@conanmchugh]

Thanks Kevin. Your video just saved me some $$$!!!

[@mo.6ix]

Dude you helped me save my 1090, didn't realize it was such an easy fix!!! Cheers!!

[@KevinPon.]

Glad to hear man!! 🍻

[@jdawg93]

You are a lifesaver man

[@davecornett7604]

Worked like a charm!! Well done.

[@KevinPon.]

Awesome news Dave and thank you! 🍻

[@jadenjones8246]

Just saved me so much time bro. Thank you!

[@KevinPon.]

My pleasure bro 🍻

[@betoesca71]

Thank you for the great detailed video. I was able to repair my dumbbells

[@KevinPon.]

Awesome! 🍻🍻

[@st4rbuk]

Thanks Kevin! My bow flex was selecting the wrong weight but after putting it back together again it’s perfect.

[@KevinPon.]

Perfect! Glad to hear!

[@racer8422]

Good job! Thank you for the upload!

[@KevinPon.]

You're very welcome Vic 😎🍻

[@Thenewyorkdolley1]

Perfect instructions for this job!

[@KevinPon.]

Thanks Ryan! 🍻

[@lemonthylton1243]

Great information and video fixed my dumbbells thanks

[@KevinPon.]

Awesome!! You're very welcome 🍻

[@lhancock123]

Mine aren't the same model as yours but went together the exact same way. Very helpful video. Thanks.

[@KevinPon.]

Perfect, glad to hear Len! 😁🍻

[@mr_skywalkingpimp4067]

Perfect! Thank you.

[@KevinPon.]

Happy to help! 🍻

[@nickh2166]

Thank you!!!!!

[@briangrana982]

Very helpful ... thank you!

[@KevinPon.]

My pleasure Brian! 😎🍻

[@JackyTran]

Very helpful, thank you 🙏

[@KevinPon.]

You're very welcome Jacky! 🍻

[@johnsaucedo1131]

Excellent video, bro!

[@KevinPon.]

Why, thank you! 😎🍻

[@SuperLaura516]

What a huge help you were! Thanks for making this video. I thought I had to replace the whole thing for $400 then found a single for $200 then just the handle for $59 but ended up just replacing a #2 disc for only $15 with shipping. KZbin and Etsy are the best!! Thanks again!!!

[@KevinPon.]

You're very welcome Laura! Glad I could help 😁 🍻

[@ferrettigroupaustralia402]

Hey guys, where is best place to purchase parts??

[@KevinPon.]

You can try looking on Ebay or etsy 🍻

[@ferrettigroupaustralia402]

@@KevinPon. Cheers mate and thanks for the video

[@davidross4036]

Thanks, guy. These things are PRICEY! Had a bad moment when the ball bearings fell out but…all good, thanks to you.

[@KevinPon.]

You're very welcome David! Glad I could help 🍻

[@AAmtb]

bowflex wont sell replacement plates, and i wasn't shelling out $150 for a new handle. an ebay part and an awesome video had me up and running. great vid!

[@KevinPon.]

Thank you! Yeah it's too bad bowflex stopped selling replacement parts but thank god for Ebay!

[@jpcal1988]

you are my hero thank you so much

[@KevinPon.]

😂 happy to help 🍻

[@rameygentry4836]

Thank you for this video!!! You saved my dumbbells and me from an absolute meltdown😂 and now I feel like I can fix anything (anybody need a handyman? ) LOL

[@KevinPon.]

😂 you're very welcome! 🍻

[@upystudio7373]

Great turorial bro..nice sharing👍👍

[@KevinPon.]

Thank you bro!

[@jamesreid8817]

THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU THANK YOU

[@KevinPon.]

😂 you're very welcome! 🍻

[@WoodakaDiddy]

Thanks I just got a good deal on some used 1090s for $350 a pair but one of them has a cracked disc 5

[@KevinPon.]

Good deal!!

[@mrudangpatel8132]

Greta video dude!...I'm from UK and have these q090 dumbells with exact same issue but where can I get the replacement pm broken discs from????

[@KevinPon.]

Thanks man! I ordered my parts from Ebay. It's hard to find parts.

[@BigEth17]

Hi! Thanks for the video! I'm trying to use the ratchets now and haven't been able to loosen the bolts on the ends. Were yours pretty easy to loosen/turn? Thanks again!

[@KevinPon.]

Hey BigEth17, you're welcome! Remember to set your ratchets "both" to turn the nuts counterclockwise. Mine came off pretty easy. Hope you'll be able to get yours off 🍻

[@acmotz]

Thanks for this, very helpful! When I was first removing the plate, a very small nut fell out but I don't know from where. Any idea where this might have come from? It's about 5mm wide. Thanks!

[@KevinPon.]

No problem Adam. I believe it's a small steel ball that fell out and is about 5mm. There's no nuts in my video 🍻

[@catherinestauber9228]

Hi Kevin! Do you have any tips or tutorials on replacing the red handle tab? I'm assuming I'll need to disassemble half of the dumbbell (pop off end cap, loosen the end nuts, remove the mini plates) and then remove the silver plate of the 6th plate to unscrew and replace the red tab. Any advice you might have is greatly appreciated!!

[@daniellepeterson9013]

Yes--I was actually just wondering this too!!

[@KevinPon.]

Hi Catherine! Yes you are absolutely correct! If you're lucky, the side that you want to replace. Hopefully that's the side that the nut will unscrew off. If it's not the side side you're hoping for then you will have to take everything apart. Cheers :)

[@Peaorth]

Is the socket size the same for the 552 series 2? I haven't been able ro find the socket size anywhere.

[@KevinPon.]

Hello, I believe it is. There's a guy named AverageJoeInnnovations if you scroll down in the comments. He might be able to confirm it. He fixes and mods Bowflex's dumbbells 🍻

[@jamessaavedra7003]

Hi I followed your directions thanks and had to replace 3 broken discs. When I reassembled I was able to turn the dials by depressing the button as Joe commented but when I put the handle back in the rack it was difficult to push the handle down and the dials wouldn't turn. Any suggestions?

[@KevinPon.]

Hmm I know 1 reason why the dials isn't turning as they used to it's because the end nuts are over tightened. Loosen them a bit and then they should turn freely 🍻

[@jamessaavedra7003]

@@KevinPon. Thanks for the quick response Kevin. That seems to have fixed the problem. Much appreciated!!

[@ee7369]

Where can I find disc 5 for 1090? They don’t have those on Amazon?

[@KevinPon.]

eBay will be your next best place 🍻

[@carywhitehurst365]

Do you know if bowflex 552 handle is interchangeable with 1090? 1090 handle is kind of annoying

[@KevinPon.]

Hello there, sorry it is not interchangeable. I know what you mean. I wear gloves when I use the 1090 🍻

[@XO.Clinic]

My plastic plates that hold the weights in have snapped, can you buy replacements?

[@KevinPon.]

Try finding them on eBay. I heard etsy may sell replacement parts as well 🍻

[@jprince19]

I looked I believe I just need disc 3 I have series 552 version 1… I’m having a hard time finding disc 3 for purchase. Can u help?

[@KevinPon.]

www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313&_nkw=bowflex+552+disc+3&_sacat=0

[@luckyk5]

Kevin - any tip to preventing this to happen I just bought a set of 1090 and would like to get tips on keep them operational with proper care.

[@KevinPon.]

Hi Raj, I bought this set used. I assume the previous person dropped them on the floor. That's the only way that these break 🍻

[@luckyk5]

@@KevinPon. thanks for your feedback, I bought mine brand new so will definitely evade dropping them.

[@ericbrazau6533]

Were to buy the plastic disks. I put the weight down hard "crack"

[@KevinPon.]

eBay is where I found my replacements

[@alessiopozzi6812]

Hi Kevin, where can i find those replacement peaces for the dumbbells??? thank you!!

[@KevinPon.]

Hi Alessio, the only place I was able to find them was on Ebay 🍻

[@alessiopozzi6812]

@@KevinPon. can u please link them if u still remember where to find them and if they still available?? thank u vary much i just broke mine and i don't know how to find the discs for my dumbbells they are the same as yours

[@KevinPon.]

@@alessiopozzi6812 www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1311&_nkw=bowflex+1090+replacement+disc&_sacat=0

[@toddtucker709]

Thanks Kevin. Where can I get parts. I have the older version of the BD1090.

[@KevinPon.]

I was able to find parts on Ebay. On the Bowflex website, I found nothing. They have a 1-800 number but I didn't try calling.

[@toddtucker709]

@@KevinPon. Thank you Kevin! I did get in touch with Bowflex/Nautilus. Long wait times due to COVID-19, but good customer service otherwise. Their philosophy in a nutshell is; they don’t trust us to replace parts within the handle assembly. They only sell the complete handle units for about $160 incl S&H. I followed your excellent instructions and the disassembly went quickly and easily. Replacing the individual parts is the way to go because even though it is a great product, it is susceptible to damage. Even if you don’t drop your weights, “stress fractures” can result from repeated use in the plastic joints in the discs that hold the weights in the handle. Thanks again!

[@KevinPon.]

That is awesome!! Mission accomplished! 🍻 you're very welcome Todd, happy to help 😁

[@jprince19]

Hi I have the bowflex 552 version 1 where I broke 1 disc… is this for that version? And can u send link to where on eBay I can purchase? Thanks

[@KevinPon.]

www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313&_nkw=bowflex+552+disc+3&_sacat=0

[@jprince19]

Thanks and just verifying this shows how to fix for version 1 correct?

[@dankelly]

Where do you buy replacement discs?

[@KevinPon.]

I was only able to locate them on Ebay.

[@klvanallen3]

Where did you get the replacement plates?

[@KevinPon.]

I found mine on eBay. I heard etsy sells them too 🍻

[@sheafrank4816]

Damn kev you you probably curled that weight so fast the g force broke the thing

[@KevinPon.]

😂😂😂

[@AA-iq7pp]

Question: My dumbbells are at my home up north, but I need to replace the disc that allows me to use 40lbs of weight. Does anyone know what disc i need to order/replace? i would like to order it so I have it and can repair as soon as i get them back

[@KevinPon.]

It's disc #5. You can shine a light and you can see the numbers on the side 🍻

[@AA-iq7pp]

thank you very much@@KevinPon.

[@nathanhyde2079]

How'd you break a disc? I've had my 1090 set since 2006 and they still work like when I bought them.

[@KevinPon.]

I bought these used and found out they were broken... Seller lied to me :(

[@nathanhyde2079]

@@KevinPon. oh ok, that's a bummer, you know they must have been dropped. Hope you got a deal at least. My honest experience with these is that they surpassed my expectations, but they were expensive.

[@KevinPon.]

Thankfully I picked them at a fairly good deal. It came with the rack which was a bonus. I'm very happy with the product as well and they work great 🍻

[@joeroberts4608]

I've had me 90 pounders for about three years. Love them, but I dropped them from about a foot off the ground, for the first time, with 85 lbs loaded each dumbbell. Now I can't get either of them to load on even weight (10, 20, 30, 40 etc.), the smallest plate won't load up. Any idea how these might be repaired?

[@KevinPon.]

What you are saying. It sounds like you can't turn the dial. The dial is when turns all the disc together. The disc has these lips in the edges. That's what holds the different weights from falling. Are you able to rotate the dial?

[@joeroberts4608]

I looked at them closer, after some research. I cracked roughly half the total discs on the dumbbells. Ordered new parts, not a cheap repair. LOL @@KevinPon.

[@JaredRoberts-qi8kb]

Where are y’all getting replacement parts from? Are you buying direct from bowflex? A third party vendor?

[@KevinPon.]

I got mine from eBay. But I've seen some on Amazon and etsy from time to time 🍻

[@JaredRoberts-qi8kb]

Thank you sir

[@ericbrah7643]

Where would I buy these parts?

[@KevinPon.]

@@ericbrah7643 eBay or Etsy 🍻

[@SSModi852]

Yeah, weight falling on the face is dreadful. I will stick with my dumbells with bar and nuts.

[@arthurdebare2439]

Don't buy these dumbells waste of money