How to assemble an elliptical trainer

A cross trainer arrives as a heavy main frame with the flywheel inside, two pedal arms, two swing arms, a mast and a console. It has more moving joints than a bike or treadmill, and each pivot needs its washers in the right order or the machine clicks and wears early.

Time
about 2 h 30 min
Difficulty
Hard
People
2 people
Steps
8

Tools needed

  • Allen keys (supplied)
  • Spanners (supplied)
  • Cross-head screwdriver
  • Spirit level

Parts to check first

Before you start, lay everything out on a soft surface (the flattened box works) and check it against the parts list in your manual.

  • Main frame with flywheel and crank
  • Front and rear stabilisers
  • Left and right pedal arms with foot plates
  • Console mast, swing arms and console
  • Pivot axles, wave washers, bolts and covers

Step by step

  1. Step 1: Unpack in the room where it will stand; lay the main frame on its side on the box cardboard to fit the stabilisers.

  2. Step 2: Bolt the front and rear stabilisers to the main frame, then stand the frame up with your helper and check it does not rock.

  3. Step 3: Stand the console mast in its socket, feeding the console cable up through the mast from the bottom, and start the mast bolts without tightening.

  4. Step 4: Slide each swing arm onto its pivot axle on the mast with the washers and wave washers in the exact order the manual shows, then fit the end bolt.

  5. Step 5: Connect each pedal arm to the lower end of its swing arm and to the crank or rail wheel at the back, again with every washer in place.

  6. Step 6: Fit the foot plates to the pedal arms, then mount the console, connect its cable and any heart-rate leads, and fit the batteries or power adapter.

  7. Step 7: Tighten the mast and all pivot bolts, turn the pedals through a full stroke by hand, and listen for clicks or rubbing before fitting the covers.

  8. Step 8: Level the machine with the adjustable feet and test at the lowest resistance before increasing it.

Common mistakes

  • Leaving out a wave washer at a pivot, which causes a clicking noise on every stride.
  • Crushing the console cable when the mast is lowered into its socket.
  • Overtightening pivot bolts until the arms stiffen instead of swinging freely.

Safety notes

  • Keep children's hands away from the moving pedal arms and flywheel; they keep turning after you step off.
  • Leave clear space around the machine as the manual specifies, and respect the user weight limit.
  • Check the pivot bolts after the first few sessions and regularly after that.

This is general guidance for this type of product. Your product's own manual comes first: follow its order, fittings and torque values where they differ from this page.

Updated 2026-09-30