Bowflex Recalls Nearly 4 Million Adjustable Dumbbells Over Injury Risk

What happened

On 5 June 2025, Johnson Health Tech Trading voluntarily recalled approximately 3,844,200 BowFlex SelectTech adjustable dumbbells — specifically the 552 (adjusting from 5 to 52.5 lb) and the 1090 (10 to 90 lb) — after reports that weight plates could detach from the handle during use. The action was taken in cooperation with the US Consumer Product Safety Commission and carries official recall number 25-311.

The company cited "reports that the weight plates can dislodge from the handle during use, posing an impact hazard." Both models use manual adjustment knobs to select resistance and are sold in black, with handles, weight plates, and a moulded plastic tray.

The scale of the problem

This is one of the largest fitness equipment recalls in recent memory. The 3.8 million-plus units were sold over a remarkable 20-year window — from as early as 2004 right through to May 2025 — through Johnson Fitness & Wellness, DICK'S Sporting Goods, Best Buy, Bowflex.com, and Amazon.com in the United States.

Crucially, the vast majority of the affected products were not sold by the company issuing the recall. According to the CPSC, over 95% of recalled units were sold by Nautilus Inc. — the company that originally manufactured BowFlex products — which is no longer in business. Nautilus filed for bankruptcy in March 2024 and was acquired by Johnson Health Tech Trading in April 2024 for $37.5 million. Nautilus had rebranded itself as BowFlex in 2023, shortly before its collapse.

The CPSC acknowledged the unusual situation directly:

"Despite having no obligation to do so, Johnson Health Tech Trading is stepping up to provide a remedy to customers who purchased recalled dumbbells from Nautilus."

Injuries: what the reports show

Nautilus logged 337 incidents and 111 injuries before the brand changed hands. Since acquiring BowFlex, Johnson Health Tech Trading received a further 12 incident reports, though it reported no additional injuries. In total, the CPSC confirmed more than 100 injuries, including concussions, broken toes, bruises, and scrapes.

Individual incidents underscore the seriousness of the hazard. In 2021, a SelectTech 552 owner reported a plate fell onto his eye, causing bruising and pain. In 2023, a 1090 owner reported a dumbbell fell from its handle onto his foot, resulting in bleeding and severe swelling.

This is also not the first time BowFlex's adjustable dumbbells have been subject to a recall. In 2012, Nautilus recalled the 1090 model after the weight selector dial was found to fail, causing plates to fall when the dumbbell was lifted. That recall followed 16 problem reports resulting in three injuries — a far smaller episode than the current action.

Who gets what: the US remedy

The remedy available to US consumers varies depending on when and where they purchased:

• Bought from Johnson Health Tech Trading (after 23 April 2024): Eligible for a replacement dumbbell from the new BowFlex Results Series 552 or 1090.
• Bought from BowFlex Inc./Nautilus (before May 2024): Entitled to a prorated refund voucher — worth between $20 and $95 — redeemable only at BowFlex.com, plus a one-year JRNY digital fitness membership. Consumers can request conversion to a Visa gift card instead.
• Bought from Costco: Can return the product to any Costco store for a full refund.

Consumer Reports stated that the company's remedy is insufficient for pre-2024 buyers. Given that a replacement set retails for $429 to $799, a maximum voucher of $95 has drawn multiple formal complaints, with critics calling it "effectively worthless." Johnson Health Tech Trading is contacting known purchasers directly and issuing pre-paid shipping labels for the return of handles and bases.

"We are working diligently to reach owners of the 552 and 1090 dumbbells — regardless of whether the units were purchased from the now defunct Nautilus or from our company."

The legal fallout

A class action lawsuit — Cosin v. Johnson Health Tech Retail, Inc. (case no. 3:25-cv-05085) — was filed on 16 June 2025. However, on 12 August 2025, US Bankruptcy Court Judge Andrew B. Altenburg Jr. shut down the class claims, ruling that BowFlex's court-approved bankruptcy plan and sale barred such litigation, releasing the companies from liability.

What UK owners should do right now

This is where the picture becomes less clear for British buyers. The recall is a US Consumer Product Safety Commission action. As of the date of this article, no matching recall notice from the UK's Office for Product Safety and Standards has been confirmed, and BowFlex's UK website carries no visible recall disclosure. The equivalent UK model, the SelectTech 552i, carried an RRP of £549.99, with a price of £337.99 seen at Johnson Fitness UK at the time of reporting.

No UK-specific refund or registration process has been confirmed. US contact details — recall@bowflex.com and www.bowflex.com/recalls — are publicly available, and UK owners with concerns should contact the brand directly while monitoring for any OPSS announcement.

The recommended guidance in the meantime is straightforward: stop using any SelectTech 552 or 1090 model immediately, and purchase current stock only from an authorised UK retailer — bowflex.co.uk, Johnson Fitness UK, Decathlon UK, or Fitness Superstore — rather than unverified third-party marketplace listings.