Russ' Do It Yourself Home Workshop

Finding Fixes to Just About Anything and Everything

Disassembly and Assembly of a LifeFitness x5i Elliptical

Posted by Russell Wright on July 4, 2010

Here are some pics and procedures for taking apart your x5i and reassembling it.  It’s not comprehensive, but it will give you the main idea if you need to take it apart for any reason.

The bottom shroud that wraps around the back end of the machine can be removed without taking anything else off.  It is held in place with six machine screws and, once they are removed, you simply pull it back to remove it.  The power jack is attached to the metal frame, so it doesn’t get in the way of the removal of the shroud.


If you want to remove the long “arms” on the elliptical you need to remove the bolts (9/16”) at the front and back of the arms by first removing the covers.  Each cover half is held in place with a single machine screw.  You can take either side out first, as the order doesn’t matter.  This will expose a bolt with a self-locking nut that can easily be removed.  Here are some pictures, but they are not very good.  Hopefully you get the idea.





Once you have these bolts removed, you need to remove the bolt holding the stride length adjustment mechanism on the crank.  This bolt is accessed by removing a plug that covers it.


Now you can remove the 9/16” bolt, lock washer and flat washer that hold the mechanism on the crank.  I found that using a magnet to retrieve the hardware from the hole was very handy. 


After removing the stride length adjustment mechanism, you can remove four machine screws that hold on a plastic cover.


Once the cover is out of the way, you can remove the two screws that hold the metal plate on the crank and then remove the bolt that clamps the crank on to the flywheel.  To pull the crank off the flywheel, you may need some kind of puller.  I used a sliding hammer/puller that is used for doing bodywork.  These things have a knack for being wedged on so this may be the hardest part of the disassembly unless you have a puller to help you remove it.


Now you can finally remove all the screws that hold one half of the shroud in place.  These are a mixture of machine screws that attach the shroud to the frame and plastic/wood screws that screw into the other half of the plastic shroud.  Once you remove all the screws on a given side (this is the left side we’re working on) you should be able to remove half the shroud and expose the innards. 

To expose the other side simply repeat the process.  It’s a lot of screws, but nothing very difficult.


4 Responses to “Disassembly and Assembly of a LifeFitness x5i Elliptical”

  1. […] I received my “repaired” console ($350) while I was out of town and installed it today.  While it was out being repaired I purchased a replacement 9 volt, 1 amp adapter on eBay for about $10, so I know that I won’t be damaging the new console with a bad power supply.  The installation went quickly and without incident.  Everything came up and worked.  From what I can tell though, the console was brand new.  At least all the plastic parts and keyboard were new.  There was a new PROM installed on the board, so I’m not sure if they used the same circuit board or not and I didn’t attempt to determine whether it was the same one.  The part that took me the longest was putting the machine back together again, as I had taken some of it apart while troubleshooting (which I’ve documented here).  […]

  2. Disassembly and Assembly of a LifeFitness x5i Elliptical…

    I found your entry interesting do I’ve added a Trackback to it on my weblog :)…

  3. Peter said

    where did you get your repaired console? My console has not worked for about 5 years – and the local shop says they no longer support it – the machine works but without resistance – I am about to junk it – unless I can repair it – seems I had the same problem you encountered?

    • Russell Wright said

      I was able to get one…probably one of the last ones…by contacting the company directly. There are others who have successfully removed the skin on the console and effected a repair.

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