June 15, 2015

How to replace an elliptical resistance motor

By Lyle Weischwill
How to replace an elliptical resistance motor

This DIY repair guide explains how to replace the resistance motor on an elliptical. The resistance motor controls pedal resistance by changing the distance between the C-magnet and the flywheel. If the resistance motor stops working, pedal resistance is the same regardless of the settings you select. Replace the resistance motor with the manufacturer-approved replacement part.

Follow these steps to replace the resistance motor in Weslo, ProForm, Lifestyler, NordicTrack and Image elliptical exercisers.

Quick links
Tools required
Work gloves
Slot screwdriver
Phillip screwdriver
Wire cutter
Wrench set
Allen wrench
Repair difficulty
Time required
30 minutes or less
Repair difficulty
Time required
30 minutes or less

Instructions

01.

Release the lower upright cover

Pry up the lower upright cover using a slot screwdriver.

Slide the lower upright cover up on the upright to release it from the side shields.

Pry the cover up to release.

Pry the cover up to release.

Slide the cover up.

Slide the cover up.

02.

Remove the left pedal arm

Remove the left pedal arm cover screw and pull the left pedal arm cover off.

Using an Allen wrench, remove the screw from the left crank arm by turning it clockwise because it is reverse threaded.

Pull the left pedal arm and washers off the crank arm shaft and push the pedal arm forward.

Remove the left pedal arm cover.

Remove the left pedal arm cover.

Remove the Allen screw.

Remove the Allen screw.

Pull the pedal arm off.

Pull the pedal arm off.

03.

Remove the left shield

Remove all the screws from the left and right side shields.

Remove the left shield.

Remove the screws.

Remove the screws.

Remove the left shield.

Remove the left shield.

04.

Release the resistance motor

Loosen but don't remove the top 2 resistance motor mounting screws.

Remove the bottom 2 resistance motor mounting screws and slide the resistance motor down and off.

Loosen the top screws.

Loosen the top screws.

Remove the bottom screws.

Remove the bottom screws.

Slide the motor off.

Slide the motor off.

05.

Disconnect the cable

Release the cable lock nut.

Release the cable from the frame bracket.

Release the cable from the motor housing.

Remove the cable from the motor pulley.

Unscrew the cable lock nut.

Unscrew the cable lock nut.

Release the cable from the frame.

Release the cable from the frame.

Release the cable from the motor housing.

Release the cable from the motor housing.

Remove the cable from the motor pulley.

Remove the cable from the motor pulley.

06.

Remove the resistance motor

Using a wire cutter, cut the wire harness retainer on the elliptical base to release the motor wires.

Disconnect the wire harness from the motor.

Remove the resistance motor.

Cut the wire harness retainer.

Cut the wire harness retainer.

Disconnect the motor harness connector.

Disconnect the motor harness connector.

07.

Install the new resistance motor

Plug the wire harness into the new motor.

Use a cable tie to strap the wire harness to the elliptical frame.

Reinstall the cable on the motor pulley.

Slide the cable into the slot on the motor housing

Slide the cable into the frame bracket slot.

Reinstall the cable lock nut.

Position the motor under the top 2 mounting screws and reinstall the bottom mounting screws.

Tighten the mounting screws.

Connect the new motor.

Connect the new motor.

Reinstall the cable on the motor pulley.

Reinstall the cable on the motor pulley.

Slide the cable into the motor housing.

Slide the cable into the motor housing.

Slide the cable into the frame bracket.

Slide the cable into the frame bracket.

Tighten the cable lock nut.

Tighten the cable lock nut.

Slide new motor under the top screws.

Slide new motor under the top screws.

Reinstall the bottom screws.

Reinstall the bottom screws.

08.

Reinstall the left shield

Line up the side shields.

Reinstall the shield mounting screws.

Reinstall the side shield.

Reinstall the side shield.

Reinstall the screws.

Reinstall the screws.

09.

Reinstall the left pedal arm

Push the left pedal arm over the end of the crank arm shaft.

Reinstall the D-washer on the crank arm shaft.

Slide the lock washer and flat washer on the Allen screw.

Reinstall the Allen screw into the crank arm and tighten it counterclockwise because it's reverse threaded.

Position the pedal arm cover over the crank arm shaft.

Reinstall the pedal arm mounting screw.

Reinstall the pedal arm.

Reinstall the pedal arm.

Reinstall the D-washer.

Reinstall the D-washer.

Reinstall the Allen screw.

Reinstall the Allen screw.

Reinstall the pedal arm cover and screw.

Reinstall the pedal arm cover and screw.

10.

Reinstall the lower upright cover

Slide the lower upright cover down the upright and snap it over the side shields.

Reinstall the upright cover.

Reinstall the upright cover.

Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.
Symptoms for elliptical machines

Choose a symptom to see related elliptical repairs.

Main causes: dirty heart rate sensors, wiring failure, bad control console
Main causes: weak batteries, loose wires, faulty control console
Main causes: faulty reed switch, reed switch needs adjustment, wiring failure, bad control console
Main causes: bad resistance motor, faulty control console, wiring failure
Main causes: dead batteries, power supply failure, bad wiring connections, faulty control console
Main cause: lack of lubrication on pivot points
Main causes: loose fastening bolts, damaged handle bars
Main causes: leveling feet need to be adjusted, loose frame bolts, unstable flooring
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