What Does The BowFlex Adjustable Dumbbell Recall Mean For Consumers?

On June 5, 2025, Johnson Health Tech Trading voluntarily recalled two models of BowFlex adjustable dumbbells—the 552 (52.5 lb) and 1090 (90 lb)—after reports that their weight plates could unexpectedly detach during use, posing serious impact hazards. The recall affects a staggering approximately 3,844,200 units sold between 2004 and May 2025.

This recall is being conducted in cooperation with the U.S. Consumer Product Safety Commission (CPSC). It spans two generations of ownership:

• Nautilus Inc. (later BowFlex Inc.), which sold about 3.7 million units from 2004 to April 2024.
• Johnson Health Tech Trading, which sold the remaining units between May 2024 and May 2025 after acquiring BowFlex assets in April 2024.

Scope of the Problem Regarding BowFlex Weights

Total incidents: Over 350 reports of plate dislodgements—12 for units sold by Johnson Health Tech and 337 for prior BowFlex/Nautilus units.

Injuries reported: At least 111 injuries, including concussions, abrasions, contusions, and broken toes. Many injuries resulted from malfunctioning 552 and 1090 series dumbbells.

Real-life consequence: One report described users experiencing “concussions & broken toes” after plates detached unexpectedly mid-use. These are serious injuries, underscoring the gravity of a mechanical defect in heavy workout equipment.

Key Recall Statistics at a Glance

Details About the Product Defect

• Defect mechanism: The metal weight plates may dislodge from the adjustable handle during exercise—posing an impact hazard.
• Affected models: BowFlex 552 (adjustable from 5–52.5 lb) and 1090 (10–90 lb), both sold as single units or in pairs with stands/trays.
• Affected serial numbers: Precise serial number ranges are listed under the recall notice (too extensive to include fully here).

The issue appears tied to either design or quality control faults predating the current manufacturer. Nearly all incidents stemmed from units produced under Nautilus/BowFlex before Johnson Tech’s acquisition.

Manufacturer Response

Despite BowFlex’s Chapter 11 bankruptcy in March 2024, Johnson Health Tech acquired its assets (including iconic dumbbell lines) for $37.5 million in April 2024. In a move described as “voluntary” by the CPSC, Johnson Health Tech has assumed responsibility and initiated the recall for both legacy and newer units.

Remedies offered vary depending on when and from whom the dumbbells were purchased:

• Purchased from Johnson Health Tech (post-April 23, 2024):
  • Option for a replacement dumbbell (current BowFlex Results Series 552/1090), or
  • A voucher refund equivalent to the original purchase price, plus a 1-year JRNY app subscription.
• Purchased from BowFlex/Nautilus (pre-April 23, 2024):
  • Prorated voucher refund, plus 1-year free JRNY membership.
• Note: Vouchers are redeemable only at BowFlex.com, but customers can request conversion to a Visa gift card instead.

Additionally, consumers may return handles and bases using a provided prepaid label; weight plates are not required to be returned and can be disposed locally.

What You Should Do If You Own Recalled BowFlex Dumbbells

If you own a BowFlex 552 or 1090 adjustable dumbbell, follow these steps immediately:

1. Stop using the product to avoid potential plate detachment and injury.
2. Identify your model/serial number (found on the plastic tray’s bottom sticker) and check recall eligibility via CPSC or BowFlex’s recall page cpsc.gov.
3. Submit a claim online via the BowFlex recall portal at BowFlex.com/recalls, or contact Johnson Health Tech at 800‑209‑3539 (Mon–Fri, 8 a.m.–7 p.m. CT); you’ll need:
   • Name, contact info, serial number(s), and a picture of the unit.
   • Proof of purchase if bought April 23, 2024 or later.
4. Arrange product return: The company will mail a prepaid label and return box; you’re expected to include only the handle and base.
5. Choose and receive your remedy:
   • Post-April 2024 buyers can opt for replacements or full-price vouchers.
   • Earlier buyers receive prorated vouchers.
   • All eligible buyers get a 1‑year JRNY fitness subscription

If vouchers don’t suit you or redemption is challenging, you can request a Visa gift card instead.

What to Do If You’ve Been Injured by a Recalled BowFlex Dumbbell

If you’ve been hurt while using one of the recalled BowFlex 552 or 1090 adjustable dumbbells—whether due to a falling weight plate, malfunctioning selector dial, or sudden detachment—it’s important to take immediate steps to protect your health and legal rights.

1. Seek Medical Attention Immediately

First and foremost, your health is the top priority. Even if an injury seems minor—like a bruise or strain—get evaluated by a doctor. Some injuries, such as concussions, herniated discs, or internal injuries, may not present obvious symptoms right away.

Make sure your medical visit is well documented, as this will serve as key evidence if you decide to pursue a legal claim.

2. Preserve the Evidence

Do not discard or return the dumbbell set before documenting it thoroughly. Take the following steps:

• Photograph the dumbbell from multiple angles, especially the damaged area.
• Note the model and serial number (located on the product tray or handle).
• Retain receipts, original packaging, and any correspondence with BowFlex or Johnson Health Tech.
• If possible, video-record the failure or describe the sequence of events leading up to the injury in writing.

This evidence could be vital to proving your case and showing the connection between the product defect and your injury.

3. Report the Incident

You should report the injury to:

• Johnson Health Tech / BowFlex via their recall website or hotline.
• The U.S. Consumer Product Safety Commission (CPSC) by filing an incident report online at www.saferproducts.gov.

These reports help alert regulators to the full extent of the problem and may support your individual claim or a broader class action.

4. Speak to an Experienced Illinois Product Liability Attorney

If you suffered a significant injury—such as a broken bone, concussion, or long-term impairment—you may have a claim for:

• Medical expenses
• Lost wages or lost earning capacity
• Pain and suffering
• Emotional distress
• Punitive damages (in cases of gross negligence)

BowFlex and Johnson Health Tech may be liable under product liability laws, which hold manufacturers responsible for injuries caused by defective products. A dedicated Illinois defective product injury attorney can help you evaluate your case, gather necessary evidence, and fight for the compensation you deserve.

5. Avoid Signing Anything Without Legal Advice

In some cases, manufacturers may offer compensation in exchange for a release of liability. Do not sign any documents or accept a settlement until you’ve spoken with an attorney. Signing a release may prevent you from seeking full compensation down the line.

Contact the 5-Star Rated Illinois Defective Product Lawyers at John J. Malm & Associates

If you’re a BowFlex 552 or 1090 owner, take action now: check your serial number, stop use, and file your claim. While Johnson Health Tech’s remedy may not fully compensate all consumers, they’re offering vouchers, replacements, and a JRNY subscription—and you’re protected by the CPSC oversight.

At a bigger-picture level, this recall reminds us that:

• Fitness gear with moving parts carries unique failure risks.
• Safety should remain paramount—even in bankruptcy or rebranding contexts.
• Consumer voices and watchdog groups play a vital role in accountability.

Your health and safety matter. If you’ve been injured by a defective BowFlex Adjustable Weight, contact John J. Malm & Associates for a free consultation. Let our knowledgeable product liability attorneys help you get the compensation you deserve.