Analysis of a NordicTrack rower with nonfunctional magnetic resistance and a simple fix I developed. The improvement is amazing.

Background:
I just got this NordicTrack RW900 rower and the magnetic resistance does nothing at all. On the highest setting (26) you can easily row pulling on the handle delicately with just 2 fingers of one hand! Many people are having this same problem. Is it a manufacturing defect welding the magnet mount in the wrong position? Is it a design flaw? Support was friendly but ultimately useless. After 8 phone calls (waiting 30 min on hold each time) 5 remote video support sessions, and one onsite technician visit replacing tons of parts that obviously did not need to be replaced NordicTrack declared that this rower was functioning as designed and there was nothing to fix. Really, if nothing was wrong then why were they willing to replace so many parts? I will be sure to pay extra for the extended NordicTrack warranty ... NOT!

The Fix:
Simple modification to the plastic magnet mount to make the magnet position finely adjustable to get closer to the metal strip on the fan.

Parts List for this fix:
- 2 pan head phillips machine screws - M4 diameter - 0.70 thread x 40mm long
- 4 M4 lock nuts
- 2 small, very thin flat washers
- Loctite blue threadlock for the rounded lock nuts holding the magnet in and the screws holding the magnet mount onto the frame
- JB Weld 2-part epoxy to reattach the magnets if they break loose

Required Tools:
- screwdriver / socket wrench / misc allen wrenches
- crank puller for removing the fans
- 4mm drill bit
- bench grinder (for rounding 2 of the lock nuts)

Fix Process:
- remove plastic cover around fans
- remove left fan using a crank puller (left side when looking from the rower seat)
- remove magnet mount
- be careful not to bump the magnets or let them stick to the frame, the glue might break loose
- remove the magnet from the plastic mount with 2 screws
- drill 4mm holes all the way through the plastic mount where the existing 2 holes are
- clip the plastic ridges around the holes on the back so a washer can fit in
- bench grind 2 of the lock nuts to be rounded
- screw a lock nut almost all the way onto each of the 2, 4mm pan-head screws
- place a washer onto each screw
- insert the pan-head screws with locknut and washer into the back of the plastic magnet mount
- place the magnet back on the mount over the ends of the screws
- use Loctite blue on the very end of the pan-head screws
- using pliers, screw the rounded locknuts onto the pan-head until thread barely protrudes
- if you screw the rounded locknuts on too far, the screws may damage the metal strip on your fan
- if you goofed and broke the 2 magnets off of the metal strip, JB Weld epoxy them back on now
- if you used epoxy, let it cure for 24 hrs
- attach the magnet mount back onto the rower and use Loctite blue on the 2 screws
- adjust the magnet position until it is parallel to the metal strip on the fan
- get the magnet very close but make sure it does not rub the metal when rowing
- if it is too hard to row, increase the distance. if it is too easy to row, reduce the distance

Special case for too much resistance:
Some people have way too much resistance with an unmodified magnet mount. For them, the solution is even easier: No need to modify the mount at all. Simply place a washer between the mount and the welded metal bracket on the frame keeping the magnet mount just a bit further away from the fan. Keep adding very thin washers if the magnetic resistance is too much. If you have gone more than 0.1 inch then something different is wrong.

Notes:
The fans on this rower do not spin true and it is very important that the magnet side fan spin as true as possible. Try removing it with a crank puller and when re-installing very gently tap it with a rubber mallet to get the best alignment possible. With many attempts and some luck you can get it very close.

Warning:
If they do send you a replacement fan you need to be careful and make sure a crank puller is able to thread into it before you install it. I received one with mangled internal threads. That has nothing to do with install, only removal so you might not see that until it is too late and the fan is crazy hard to get off when you are unable to thread a crank puller into it. Ugh, can they make this any worse!

Summary:
This design has serious issues. NordicTrack should be embarrassed. I regret buying this hardware but I do like the IFIT workouts and it is finally working.

Let's start calling them BorgicTrack ... because they think resistance is futile.