PATENT PENDING
Model No. WESY96400
Serial No.
Write the serial number in the space
above for reference.
USER'S MANUAL
Serial Number Decal (Under Seat)
QUESTIONS?
As a manufacturer, we are com-
mitted to providing complete
customer satisfaction. If you have
questions, or find that there are
missing or damaged parts, we
will guarantee you complete sat-
isfaction through direct assis-
tance from our factory.
TO AVOID UNNECESSARY
DELAYS, PLEASE CALL DIRECT
TO OUR TOLL-FREE CUSTOMER
HOT LINE. The trained techni-
cians on our customer hot line
will provide immediate assis-
tance, free of charge to you.
CUSTOMER HOT LINE:
1-800-999-3756
Mon.–Fri., 6 a.m.–6 p.m. MST
CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Save this manual
for future reference.
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IMPORTANT PRECAUTIONS
WARNING: To reduce the risk of serious injury, read the following important precautions before
using the home gym system.
1. It is the responsibility of the owner to ensure
that all users of the home gym system are
adequately informed of all precautions.
10. Always stand on a foot plate when perform-
ing an exercise that could cause the home
gym system to tip.
2. Read all instructions in this manual and in
the accompanying literature before using the
home gym system.
11. Keep your hands away from the leg press
upright when the military press arm is being
used. Your hand could become pinched
between the leg press upright and military
press arm.
3. Use the home gym system only on a level
surface. Cover the floor beneath the home
gym system for protection.
12. Make sure that the cables remain on the pul-
leys at all times. If the cables bind while you
are exercising, stop immediately and make
sure that the cables are on all of the pulleys.
4. Inspect and tighten all parts often. Replace
any worn parts immediately.
5. Keep small children and pets away from the
home gym system at all times.
13. Always disconnect the lat bar from the home
gym system when performing an exercise
that does not use the lat bar.
6. Never release the press arm, butterfly arms,
military press arm, leg lever, leg press plate,
lat bar or nylon strap while weights are
14. If you feel pain or dizziness at any time while
exercising, stop immediately and begin cool-
ing down.
raised. The weights will fall with great force.
7. Do not use the VKR station when either
weight stack is in use.
15. The home gym system is intended for home
use only. Do not use the home gym system in
any commercial, rental, or institutional set-
ting.
8. Always wear athletic shoes for foot protec-
tion.
9. Keep hands and feet away from moving parts.
WARNING: Before beginning this or any exercise program, consult your physician. This is especially
important for persons over the age of 35 or persons with pre-existing health problems. Read all
instructions before using. ICON assumes no responsibility for personal injury or property damage
sustained by or through the use of this product.
3
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BEFORE YOU BEGIN
Thank you for selecting the versatile WEIDER® PRO
9640 Home Gym System. The PRO 9640 offers a
selection of weight stations designed to develop every
major muscle group of the body. Whether your goal is
to tone your body, build dramatic muscle size and
strength, or improve your cardiovascular system, the
PRO 9640 will help you to achieve the specific results
you want.
Customer Service Department toll-free at 1-800-999-
3756, Monday through Friday, 6 a.m. until 6 p.m.
Mountain Time (excluding holidays). To help us assist
you, please note the product model number and serial
number before calling. The model number is
WESY96400. The serial number can be found on a
decal attached to the WEIDER® PRO 9640 (see the
front cover of this manual).
For your benefit, read this manual carefully before
using the WEIDER® PRO 9640 Home Gym System.
If you have additional questions, please call our
Before reading further, please review the drawing
below and familiarize yourself with the parts that are
labeled.
ASSEMBLED
DIMENSIONS:
Height: 76 in.
Width: 89 in.
Length: 64 in.
Lat Bar
High Pulley Station
VKR Arms
Military Press Arm
Backrests
Butterfly Arms
Press Arm
Leg Lever
Leg Press
Plate
Low Pulley
Station
Weight Stacks
Foot Plate
4
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ASSEMBLY
Before beginning assembly, carefully read the
following information and instructions:
• As you assemble the PRO 9640 be sure that all
parts are oriented as shown in the drawings.
• Place all parts of the PRO 9640 in a cleared area
and remove the packing materials; do not dis-
pose of the packing materials until assembly is
completed.
• Tighten all parts as you assemble them, unless
instructed to do otherwise.
THE FOLLOWING TOOLS (NOT INCLUDED) ARE
REQUIRED FOR ASSEMBLY:
• The assembly is broken into five stages: 1) frame
assembly, 2) arm assembly, 3) cable and pulley
assembly, 4) seat and backrest assembly, and 5)
VKR assembly. The hardware for each stage is
packaged separately.
• Two (2) adjustable wrenches
• One (1) standard screwdriver
• One (1) phillips screwdriver
• One (1) rubber mallet
• Wait until you begin each assembly stage to open
the parts bag labeled for that assembly stage.
• Lubricant, such as grease or petroleum jelly,
and soapy water will also be needed.
• For help identifying the small parts used in
assembly, use the PART IDENTIFICATION
CHART located in the center of this manual.
Note: Some small parts may have been pre-
attached for shipping. If a part is not in the parts
bag, check to see if it has been pre-attached.
Assembly will be more convenient if you have the
following tools: A socket set, a set of open-end or
closed-end wrenches, or a set of ratchet wrenches.
1. Before beginning assembly, be sure that
you have read and understand the infor-
mation in the box above.
1
Locate and open the parts bag labeled
“FRAME ASSEMBLY.”
Press two 2” Square Outer Caps (51) onto
the indicated locations on the Stabilizer (5).
Press a 2” Square Inner Cap (27) into the
end of the Base (4).
11
51
8
Insert six 5/16” x 2 1/2” Carriage Bolts (1) up
through the Stabilizer (5). Insert two 5/16” x
2 1/2” Carriage Bolts up through the Base
(4).
5
1
Attach the Base (4) to the Stabilizer (5) with
two 5/16” x 2 3/4” Bolts (11), two 5/16” Flat
Washers (8), and two 5/16” Nylon Locknuts
(3). Do not tighten the Nylon Locknuts
yet.
51
1
3
4
1
27
5
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2. Slide the VKR Upright (74) and the Leg Press
Upright (56) onto the indicated 5/16” x 2 1/2”
Carriage Bolts (1) in the Stabilizer (5). The
high side of the brackets on the VKR
2
27
27
Upright and Leg Press Upright should be
on the side shown. Hand-tighten four 5/16”
Nylon Locknuts (3) onto the Carriage Bolts.
Do not tighten the Nylon Locknuts yet.
87
91
High Sides
of Brackets
74
Press two 2” Square Inner Caps (27) into the
Leg Press Upright (56). Press a 2” Square
Inner Cap into the VKR Upright (74).
56
27
Attach the Rubber Bumper (91) to the Leg
Press Upright (56) with the #8 x 1/2” Self-tap-
ping Screw (87).
3
5
1
1
3. Slide the Front Upright (42) onto the 5/16” x
2 1/2” Carriage Bolts (1) in the Base (4).
Hand-tighten a 5/16” Nylon Locknut (3) onto
each Carriage Bolt. Do not tighten the
Nylon Locknuts yet.
3
Press a 1” Square Inner Cap (6) into the
Front Upright (42).
42
6
3
4
1
6
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4. Press a 2” Square Inner Cap (27) into the end
of the Top Frame (55). Press a 1 3/4” Square
Inner Cap (44) into each end of the crossbar
on the Top Frame. Press two 1” Round Inner
Caps (49) into the top of the crossbar.
11
4
49
55
44
8
27
3
Attach the Top Frame (55) to the VKR Upright
(74) and the Leg Press Upright (56) with two
5/16” x 2 3/4” Bolts (11) and two 5/16” Nylon
Locknuts (3).
Crossbar
44
3
Attach the Top Frame (55) to the Front
Upright (42) with two 5/16” x 2 3/4” Bolts (11),
two 5/16” Flat Washers (8), and two 5/16”
Nylon Locknuts (3).
11
56
42
74
5. Slide the Rear Seat Frame (100) onto the
indicated 5/16” x 2 1/2” Carriage Bolts (1) in
the Stabilizer (5). Hand-tighten two 5/16”
Nylon Locknuts (3) onto the Carriage Bolts.
5
1
100
3
Attach the other end of the Rear Seat Frame
(100) to the Leg Press Upright (56) with two
5/16” x 2 3/4” Bolts (11), two 5/16” Flat
11
56
Washers (8), and two 5/16” Nylon Locknuts (3).
8
Attach the Handle (82) to the Rear Seat
Frame (100) with two 5/16” x 2 1/2” Carriage
Bolts (1) and two 5/16” Nylon Locknuts (3).
3
3
82
Tighten all Nylon Locknuts used in steps
1–5.
5
1
6. Set two Weight Bumpers (19) on the bracket
on the Base (4) as shown. Set two Weight
Bumpers (19) on the bracket on the Stabilizer
(5).
6
Pin
Grooves
Stack eight Weights (25) onto each set of
Weight Bumpers (19). Be sure that the pin
grooves are all on the same side of each
stack of Weights.
25
25
Pin
Grooves
19
5—Bracket
Be careful not to tip either stack of
Weights (25) until step 8 is complete.
19
4—Bracket
7
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7. Press a Weight Tube Bumper (64) into the
end of a Weight Tube (63). Insert the Weight
Tube into the front stack of Weights (25). Be
sure that the pin on the Weight Tube is sit-
ting in the pin grooves in the top Weight.
7
Holes
62
Lubricate the inside of the holes in a Top
Weight (65). Set the Top Weight onto the front
stack of Weights (25). Insert both Long
Weight Guides (62) into the stack of Weights.
Be sure that the holes in the Weight
Guides are at the top, as shown.
65
Lubricate
Pin
63
64
Pin Grooves
25
8. Press a Weight Tube Bumper (64) into the
end of the other Weight Tube (63). Insert the
Weight Tube into the rear stack of Weights
(25). Be sure that the pin on the Weight
Tube is sitting in the pin grooves in the top
Weight.
8
Holes
73
Lubricate the inside of the holes in the other
Top Weight (65). Set the Top Weight onto the
rear stack of Weights (25). Insert both Short
Weight Guides (73) into the stack of Weights.
Be sure that the holes in the Weight
Guides are at the top, as shown.
Lubricate
65
Pin
63
64
Pin Grooves
25
8
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9. Attach the upper ends of the Short Weight
Guides (73) to the Top Frame (55) with a 5/16”
x 6” Bolt (60), two 1/2” x 3/4” Spacers (61), and
a 5/16” Nylon Locknut (3).
9
61
61
3
3
55
60
Attach the upper ends of the Long Weight
Guides (62) to the Top Frame (55) with a 5/16”
x 6” Bolt (60), two 1/2” x 3/4” Spacers (61), and
a 5/16” Nylon Locknut (3).
73
60
62
10. Locate and open the parts bag labeled
10
27
95
“ARM ASSEMBLY.”
Welded
Tube
Be sure there is a Bushing (98) in each side of
the Stabilizer (5). Press a 2” Square Inner Cap
(27) into each end of the Leg Press Arm (96).
97
96
5
Lubricate a 3/8” x 3 1/4” Bolt (67). Attach the
Leg Press Arm (96) to the Stabilizer (5) with the
Bolt and a 3/8” Nylon Locknut (21). Do not over-
tighten the Nylon Locknut. The Leg Press
Arm must be able to pivot freely.
21
27
67—Lubricate
27
Align the welded tubes on the Leg Press Plate
(95) with one set of holes in the Leg Press Arm
(96). Attach the Leg Press Plate to the Leg
Press Arm with the Press Pin (97).
98
11
17
Pulleys
must be on
this side
11. Press a 1” x 7/8” Plastic Bushing (90) onto
each welded spacer on the Press Frame (17).
Slide the Press Frame into place onto the Base
(4). Note: This will be a tight fit. The Plastic
Bushings should fit on each end of the indi-
cated tube in the Base. Make sure that the
pulleys are on the side shown.
59—Lubricate
21
Welded Spacers
90
4
Tube
Lubricate the 3/8” x 8” Bolt (59). Attach the
Press Frame (17) to the Base (4) with the Bolt
and a 3/8” Nylon Locknut (21).
9
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12. Press a 1” Round Inner Cap (49) into one of
the Press Arms (46). Press a 1 3/4” Square
Inner Cap (44) into the Press Arm.
12
44
49
Attach the Press Arm (46) to one side of the
Press Frame (17) with two 5/16” x 2 1/2” Bolts
(22) and two 5/16” Nylon Locknuts (3).
46
22
Assemble the other Press Arm (46) in the
same manner.
46
3
17
13. Identify the Right Arm (48) and the Left Arm
(47). Note the position of the welded bracket
on each Arm. Arm identification is very
important for step 14.
31
50
86
13
31
50
47
Welded
Brackets
Attach a “V”-Pulley (50) and a Long Cable
Trap (31) to the Right Arm (48) with a 3/8” x
2 1/2” Bolt (86) and a 3/8” Nylon Locknut (21).
Do not tighten the Nylon Locknut yet.
21
Attach a “V”-Pulley (50) and a Long Cable
Trap (31) to the Left Arm (47) in the same
manner.
48
14. Lubricate both axles on the Top Frame (55).
14
Bracket
55
Slide the Right Arm (48) onto the right axle.
Note: Be careful not to confuse the Right
Arm with the Left Arm (47); refer to step 13
to identify the Right Arm. Be sure that the
upper end of the Right Arm is behind the
indicated bracket on the Top Frame (55).
47
Lubricate
Axle
Tap two 1” Retainers (69) and a 1” Round
Cover Cap (70) onto the axle. Be sure that
the teeth on the Retainers bend toward the
Round Cover Cap, as shown in the inset
drawing.
48
69
45
70
Attach the Left Arm (47) in the same manner.
44
Press 1 3/4” Square Inner Caps (44) into the
lower ends of the Right and Left Arms (47,
48). Wet the lower end of each Arm with
soapy water. Slide a 10” Pad (45) onto the
lower end of each Arm.
44
45
Axle
69
70
10
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15. See the inset drawing. Attach the Military
Press Arm (84) to the Pivot Arm (101) with
two 5/16” x 2 1/4” Bolts (33) and two 5/16”
Nylon Locknuts (3).
15
32
49
32
Press two 1 1/2” Square Inner Caps (32) into
the indicated end of the Military Press Arm
(84). Press two 1” Round Inner Caps (49) into
the Military Press Arm. Slide two 5” Plastic
Grips (83) onto the Military Press Arm.
21
74
84
83
101
67
Attach the Military Press Arm (84) to the VKR
Upright (74) with a 3/8” x 3 1/4” Bolt (67) and
a 3/8” Nylon Locknut (21).
56
33
101
84
3
16. Locate and open the parts bags labeled
16
“CABLE ASSEMBLY” and “PULLEYS.”
23—79”
During steps 16 through 36, refer to the
CABLE DIAGRAMS on pages 26–27 of this
manual to verify proper cable routing. Before
beginning this section, fully unwind the four
Cables. Identify the four Cables by comparing
the lengths and ends of the Cables. The
approximate length of each Cable is listed (in
inches) after the key number in the drawing.
58—147”
72—194”
99—63”
IMPORTANT: While assembling the cables,
do not overtighten the bolts and nuts
attaching the pulleys. The pulleys must be
able to turn freely.
17
21
58
55
17. Locate the High Cable (58). Wrap the High
Cable around a 3 1/2” Pulley (15). Attach the
Pulley to the Top Frame (55) with a 3/8” x
3 3/4” Bolt (88) and a 3/8” Nylon Locknut (21).
Be sure that the end of the Cable with the
ball is on the indicated side of the Pulley
and that the Cable is between the Pulley
and the hook.
88
15
Ball
Hook
11
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18. Wrap the High Cable (58) around a “V”-Pulley
(50). Attach the “V”-Pulley and a Long Cable
Trap (31) to the indicated bracket on the Front
Upright (42) with a 3/8” x 2 1/2” Bolt (86) and
a 3/8” Nylon Locknut (21). Be sure that the
Long Cable Trap is positioned to hold the
Cable in place.
18
86
31
50
58
Bracket
42
21
19. Route the High Cable (58) around the “V”-
Pulley (50) on the Left Arm (47). Be sure that
the Cable is in the groove of the Pulley
and that the Long Cable Trap (31) is posi-
tioned to hold the Cable in place. Tighten
the 3/8” x 2 1/2” Bolt (86) and the 3/8” Nylon
Locknut (not shown).
19
31
86
50
58
47
86
20. Route the High Cable (58) around the “V”-
Pulley (50) on the Right Arm (48). Be sure
that the Cable is in the groove of the “V”-
Pulley and that the Long Cable Trap (31) is
turned to hold the Cable in place. Tighten
the 3/8” x 2 1/2” Bolt (86) and the 3/8” Nylon
Locknut (not shown).
20
50
31
58
48
21. Attach the Pulley Bracket (20) to the Top
Frame (55) with the 5/16” x 5” Bolt (68) and a
5/16” Nylon Locknut (3). Do not overtighten
the Nylon Locknut; the Pulley Bracket
must be able to move freely.
21
20
68
55
See the inset drawing. Route the High Cable
(58) around the 3 1/2” Pulley (15) attached to
the Pulley Bracket (20). Tighten the 3/8” x 2”
Bolt (12) and a 3/8” Nylon Locknut (not
shown). Be sure that the Cable is in the
groove of the Pulley and that the Cable
Trap (66) is turned to hold the Cable in
place.
66
12
15
3
58
12
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22. See the inset drawing. Attach a 3 1/2” Pulley
(15) and a Cable Trap (66) to the upper hole in
a Long “U”-Bracket (57) with a 3/8” x 2” Bolt
(12) and a 3/8” Nylon Locknut (21). Be sure
that the Cable Trap is inside the Long “U”-
Bracket. Note: This may come pre-assem-
bled.
22
58
66
15
15
21
57
Route the High Cable (58) through the Long
“U”-Bracket (57) and the 3 1/2” Pulley (15)
shown in the inset drawing. Be sure that the
Cable is in the groove of the Pulley and that
the Cable and Pulley move smoothly.
58
12
12
57
23. Wrap the High Cable (58) around a 3 1/2”
Pulley (15). Attach the Pulley to the bracket on
the Top Frame (55) with a 3/8” x 2” Bolt (12)
and a 3/8” Nylon Locknut (21). Be sure that
the Cable is in the groove of the Pulley and
that the Cable and Pulley move smoothly.
23
Bracket
58
55
15
21
24. Note: This assembly step shows how to
complete the assembly of several pre-
attached parts.
24
The 5/8” x 9/16” Spacer (7) has been pre-
attached on the outside of the 3 1/2” Low
Pulley (76) for shipping purposes. Remove the
3/8” Nylon Locknut (21), the Spacer, and the
Pulley from the 3/8” x 3 3/4” Bolt (88). Do not
remove the Bolt. The Bolt has been shown
removed for part identification.
Reattach the 3 1/2” Low Pulley (76), with the
5/8” x 9/16” Spacer (7) between the Pulley and
the Press Frame (17). Do not tighten the 3/8”
Nylon Locknut (21) yet. Be sure that the
3/8” x 3 3/4” Bolt (88), the 3/8” Flat Washer
(9), the 5/8” x 9/16” Spacer (7), the 3 1/2”
Low Pulley (76), and the 3/8” Nylon Locknut
(21) are oriented as shown.
9
88
7
17
76
21
13
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25. Locate the Low Cable (23). Route the Low
Cable under the 3 1/2” Low Pulley (76)
25
attached to the lower hole in the Press Frame
(17). Be sure that the end of the Cable with
the ball is on the indicated side of the
Press Frame and that the Cable is between
the Pulley and the crossbar on the Press
Frame. Tighten the 3/8” Nylon Locknut (21)
and the 3/8” x 3 3/4” Bolt (not shown).
21
76
23
Ball
17
Crossbar
26. Route the Low Cable (23) around the 3 1/2”
Pulley (15) attached to the lower hole in the
Front Upright (42). See the inset drawing.
Be sure that the Cable Trap (66) is turned
to hold the Cable in place and that the
Cable is routed around the Pulley as
shown. Tighten the 3/8” Nylon Locknut (21)
and the 3/8” x 3 3/4” Bolt (88).
23
88
42
26
15
42
15
66
Inset shows view
from other side
21
23
27. Route the Low Cable (23) around the 3 1/2”
Pulley (15) attached to the upper hole in the
Press Frame (17). Be sure that the Cable
Trap (66) is turned to hold the Cable in
place and that the Cable is routed around
the Pulley as shown. Tighten the 3/8” Nylon
Locknut (21) and the 3/8” x 3 1/2” Bolt (not
shown).
27
23
15
21
66
17
28. Route the Low Cable (23) around the 3 1/2”
Pulley (15) attached to the upper hole in the
Front Upright (42). See the inset drawing.
Be sure that the Cable Trap (66) is turned
to hold the Cable in place and that the
Cable is routed around the Pulley as
shown. Tighten the 3/8” Nylon Locknut (21)
and the 3/8” x 3 3/4” Bolt (88).
15
28
23
88
42
23
15
42
21
66
Inset shows view
from other side
14
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29. Attach the end of the Low Cable (23) to the
Long “U”-Bracket (57) with a 1/4” Nylon
Locknut (2) and a 1/4” Flat Washer (10). Do
not completely tighten the Nylon Locknut.
It should be threaded onto the end of the
Cable so only a couple of threads are
showing above the Nylon Locknut, as
shown in the inset drawing.
29
57
2
2
10
23
10
57
23
30
30. Attach the High Cable (58) to a Small “U”-
Bracket (71) with a 1/4” Nylon Locknut (2) and
a 1/4” Flat Washer (10). Do not completely
tighten the Nylon Locknut. It should be
threaded onto the end of the Cable only a
couple of turns, as shown in the inset
drawing.
58
Attach the Small “U”-Bracket (71) to the indi-
cated Weight Tube (63) with a 5/16” x 1 3/4”
Bolt (24) and a 5/16” Nylon Locknut (3).
3
24
71
63
10
2
58
10
71
31
2
31. Locate the Military Press Cable (72). Attach
the Military Press Cable to the other Small
“U”-Bracket (71) with a 1/4” Nylon Locknut (2)
and a 1/4” Flat Washer (10). Do not com-
pletely tighten the Nylon Locknut. It
should be threaded onto the end of the
Cable only a couple of turns, as shown in
the inset drawing.
72
71
3
24
63
72
10
10
2
Attach the Small “U”-Bracket (71) to the indi-
cated Weight Tube (63) with a 5/16” x 1 3/4”
Bolt (24) and a 5/16” Nylon Locknut (3).
71
2
15
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32. Wrap the Military Press Cable (72) around a
3 1/2” Pulley (15). Attach the Pulley to the Top
Frame (55) with a 3/8” x 2” Bolt (12) and a
3/8” Nylon Locknut (21).
32
55
15
See the inset drawing. Wrap the Long Cable
(72) around a 3 1/2” Pulley (15). Attach the
Pulley and a Cable Trap (66) to the bracket
on the Stabilizer (5) with a 3/8” x 2” Bolt (12)
and a 3/8” Nylon Locknut (21). Be sure that
the Cable Trap is turned to hold the Cable
in place.
21
12
72
72
Bracket
21
12
15
66
5
33. Wrap the Military Press Cable (72) around a 3
1/2” Pulley (15). Attach the Pulley and a
Cable Trap (66) to the Pivot Arm (101) with
the 3/8” x 3 3/4” Bolt (88), a 3/8” Flat Washer
(9), and a 3/8” Nylon Locknut (21). Be sure
that the Nylon Locknut is on the side
shown and that the Cable Trap is posi-
tioned to hold the Cable in place.
33
88
15
66
9
101
72
21
16
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34. See inset drawing A. Attach a 3 1/2” Pulley
(15) and a Cable Trap (66) to the upper hole
in the Long “U”-Bracket (57) with a 3/8” x 2”
Bolt (12) and a 3/8” Nylon Locknut (21). Be
sure that the Cable Trap is inside the Long
“U”-Bracket. (Note: This may come pre-
assembled.)
34
15
A
66
21
57
12
Route the Military Press Cable (72) through
the Long “U”-Bracket (57) and the 3 1/2”
Pulley (15). Be sure that the Cable is in the
groove of the Pulley and that the Cable
and Pulley move smoothly.
B
101
11
8
See inset drawing B. Slide a 5/16” Flat
Washer (8) onto a 5/16” x 2 3/4 Bolt (11).
Insert the Bolt through the Pivot Arm (101)
from the indicated side. Tighten a 5/16” Nylon
Jam Nut (93) onto the Bolt. Slide the end of
the Military Press Cable (72) onto the end of
the Bolt. Thread another 5/16” Nylon Jam Nut
onto the Bolt. Do not fully tighten the sec-
ond Jam Nut. There must be room
57
15
72
93
72
between the two Jam Nuts for the end of
the Cable to pivot.
35. Locate the Leg Press Cable (99). Attach the
end of the Leg Press Cable to the Long “U”-
Bracket (57) with a 1/4” Nylon Locknut (2) and
a 1/4” Flat Washer (10). Do not completely
tighten the Nylon Locknut. It should be
threaded onto the end of the Cable only a
couple of turns, as shown in the inset
drawing.
35
Wrap the Leg Press Cable (99) around a
3 1/2” Pulley (15). Attach the Pulley to the Leg
Press Upright (56) with the 3/8” x 3 1/2” Bolt
(16), a 3/8” Flat Washer (9), and a 3/8” Nylon
Locknut (21). The ball on the Cable must be
on the indicated side of the Pulley. Be sure
that the Cable and Pulley move smoothly
and that the Cable is between the Pulley
and the welded rod.
2
10
56
57
15
Ball
16
9
99
21
Welded
Rod
2
10
57
99
17
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36. Attach the Press Bracket (94) to the Leg
Press Arm (96) with a 5/16” x 3” Bolt (75) and
a 5/16” Nylon Locknut (3).
36
Wrap the Leg Press Cable (99) around a 3 1/2”
Pulley (15). Attach the Pulley to the Press
Bracket (94) with the 3/8” x 2” Bolt (12) and a
3/8” Nylon Locknut (21).
96
12
Slide a 5/16” Flat Washer (8) onto a 5/16” x
2 3/4” Bolt (11). Insert the Bolt through the
lowest hole in the Rear Seat Frame (100)
from the indicated side. (Note: The three
holes are for cable adjustment.) Tighten a
5/16” Nylon Jam Nut (93) onto the Bolt. Slide
the end of the Leg Press Cable (99) onto the
end of the Bolt. Thread another 5/16” Nylon
Jam Nut onto the Bolt. Do not fully tighten
the second Jam Nut. There must be room
between the two Jam Nuts for the end of
the Cable to pivot.
3
11
8
94
75
99
15
21
100
93
37. Locate and open the parts bag labeled
37
“SEAT ASSEMBLY.”
85
56
Insert a 1/4” x 2 1/2” Carriage Bolt (92)
through the center hole in a Seat Plate (37).
Attach the Seat Plate to the Rear Backrest
(85) with two 1/4” x 1/2” Screws (18).
37
92
18
Insert the 1/4” x 2 1/2” Carriage Bolt (92)
through the indicated hole in the Leg Press
Upright (56). Tighten a 1/4” Nylon Locknut (2)
with a 1/4” Flat Washer (10) onto the Carriage
Bolt. Attach the top of the Rear Backrest (85)
to the Leg Press Upright with a 1/4” x 2 1/2”
Screw (43) and a 1/4” Flat Washer (10).
10
43
2
38
13
38. Attach one end of a Seat (13) to the Rear
Seat Frame (100) with two 1/4” x 1/2” Screws
(18). Attach the other end of the Seat to the
Rear Seat Frame with a 1/4” Flat Washer (10)
and a 1/4” x 2 1/2” Screw (43).
18
10
43
100
18
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39. Attach the Front Backrest (41) to the Front
Upright (42) with two 1/4” x 2 1/2” Screws
(43) and two 1/4” Flat Washers (10). The
Backrest must be oriented as shown.
39
42
41
10
43
40. Press a 1 1/2” Square Inner Cap (32) into the
Front Seat Frame (36).
Thick
End
Insert a 1/4” x 2” Carriage Bolt (38) through
the center hole in the Seat Plate (37). Attach
the Seat Plate to the Seat (13) with two 1/4” x
1/2” Screws (18).
40
13
Insert the 1/4” x 2” Carriage Bolt (38) through
the indicated hole in the Front Seat Frame
(36). Tighten a 1/4” Nylon Locknut (2) with a
1/4” Flat Washer (10) onto the Carriage Bolt.
38
37
32
18
Attach the other end of the Seat (13) to the
Front Seat Frame (36) with a 1/4” Flat
Washer (10) and a 1/4” x 2” Machine Screw
(81).
36
10
81
2
41. Press a 1 1/2” Square Inner Cap (32) into the
Leg Lever (29).
41
Lubricate the 5/16” x 2 1/4” Bolt (33). Attach
the Leg Lever (29) to the Front Seat Frame
(36) with the Bolt and a 5/16” Nylon Locknut
(3).
36
3
33
Insert the 5/16” x 2” Eyebolt (35) into the Leg
Lever (29) from the direction shown. Tighten a
5/16” Nylon Locknut (3) with a 5/16” Flat
Washer (8) onto the Eyebolt.
29
8
35
3
32
42. Rest the Front Seat Frame (36) on the indi-
cated pin in the Front Upright (42). Attach the
Front Seat Frame to the Front Upright with a
5/16” x 2 3/4” Carriage Bolt (14) and the Seat
Knob (40).
42
42
40
36
14
Pin
19
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43. Press two 3/4” Round Inner Caps (34) into
each Pad Tube (28).
43
Insert a Pad Tube (28) into the Seat Frame
(36). Slide a Foam Pad (30) onto each end of
the Pad Tube.
30
34
28
Insert the other Pad Tube (28) into the Leg
Lever (29). Slide a Foam Foam Pad (30) onto
each end of the Pad Tube.
34
29
30
44. Locate and open the parts bag labeled
44
“VKR ASSEMBLY.”
75
80
Press 1 1/2” Square Inner Caps (32) into the
ends of the Left VKR Arm (79) and the Right
VKR Arm (80).
3
74
79
Attach the Left VKR Arm (79) and the Right
VKR Arm (80) to the VKR Upright (74) with
two 5/16” x 3” Bolts (75) and two 5/16” Nylon
Locknuts (3).
32
45. Attach the VKR Backrest (77) to the VKR
Upright (74) with two 1/4” x 2 1/2” Screws (43)
and two 1/4” Flat Washers (10).
45
Attach a VKR Armrest (78) to the Right VKR
Arm (80) with two 1/4” x 2” Machine Screws
(81) and two 1/4” Flat Washers (10).
78
74
43
10
Attach a VKR Armrest (78) to the Left VKR
Arm (79) in the same manner.
10
80
79
81
78
77
20
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46. Remove the adhesive backing from the PRO 9640 decal and apply it to the Front Upright (42) under the
“WEIDER” nameplate as shown.
46
WEIDER
Nameplate
42
PRO 9640
Decal
47. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in
HOW TO USE THE HOME GYM SYSTEM, beginning on page 22 of this manual.
Before using the home gym system, pull each cable a few times to be sure that the cables move smoothly
over the pulleys. If one of the cables does not move smoothly, find and correct the problem. IMPORTANT: If
the cables are not properly installed, they may be damaged when heavy weight is used. See the
CABLE DIAGRAMS on page 26 and 27 of this manual for proper cable routing. If there is any slack
in the cables, you will need to remove it by tightening the cables. See TROUBLE-SHOOTING AND
MAINTENANCE on page 25.
21
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HOW TO USE THE HOME GYM SYSTEM
The instructions below describe how each part of the home gym system can be adjusted. Refer to the exercise
poster accompanying this manual to see how the home gym system should be set up for each exercise.
IMPORTANT: When attaching the lat bar or nylon strap, make sure that the attachments are in the cor-
rect starting position for the exercise to be performed. If there is any slack in the cables or chain as an
exercise is performed, the effectiveness of the exercise will be reduced.
CHANGING THE WEIGHT SETTING
The PRO 9640 features two weight stacks. The front
weight stack is connected to the upper and lower pul-
leys, the press arm, and the butterfly arms. The rear
weight stack is connected to the military press arm
and leg press.
26
25
To change the weight setting of either weight stack,
insert a Weight Pin (26) under the desired Weight
(25). Insert the Weight Pin until the bent end of the
Weight Pin is touching the Weights, and turn the bent
end downward. The weight setting of either weight
stack can be changed from 6.5 pounds to 106.5
pounds, in increments of 12.5 pounds. Note: Due to
the cables and pulleys, the amount of resistance
at each exercise station may vary from the weight
setting. Use the WEIGHT RESISTANCE CHART on
page 24 to find the approximate amount of resis-
tance at each weight station.
25
26
52
ATTACHING THE LAT BAR OR NYLON STRAP TO
THE HIGH PULLEY STATION
53
Attach the Lat Bar (54) to the High Cable (58) with a
Cable Clip (53). For some exercises, the Chain (52)
should be attached between the Lat Bar and the High
Cable with two Cable Clips. Adjust the length of the
Chain between the Lat Bar and the High Cable so
the Lat Bar is in the correct starting position for
the exercise to be performed.
58
53
54
The Nylon Strap (39) can be attached in the same
manner.
39
ATTACHING THE LAT BAR OR NYLON STRAP TO
THE LOW PULLEY STATION
23
53
52
Attach the Lat Bar (54) to the Low Cable (23) with a
Cable Clip (53). For some exercises, the Chain (52)
should be attached between the Lat Bar and the Low
Cable with two Cable Clips. Adjust the length of the
Chain between the Lat Bar and the Low Cable so
the Lat Bar is in the correct starting position for
the exercise to be performed.
53
39
The Nylon Strap (39) can be attached in the same
manner.
54
22
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ATTACHING AND REMOVING THE SEAT
40
36
13
To attach the Seat (13), set the bracket on the Seat
Frame (36) onto the indicated pins on the Front
Upright (42). Attach the Seat Frame to the Front
Upright with the 5/16” x 2 3/4” Carriage Bolt (14) and
the Seat Knob (40).
42
For some exercises, the Seat (13) must be removed.
First, be sure that the chain is not attached to the leg
lever. Next, remove the Seat Knob (40) and the 5/16”
x 2 3/4” Carriage Bolt (14) from the Seat Frame (36).
Lift the Seat Frame off the Front Upright (42).
14
ATTACHING THE LEG LEVER TO THE LOW
PULLEY STATION
To use the Leg Lever (29), the seat must be attached
to the front upright (see ATTACHING AND REMOV-
ING THE SEAT above).
53
29
35
52
Attach one end of the Chain (52) to the Short Cable
(23) with a Cable Clip (53). Attach the other end of
the Chain to the Eyebolt (35) with a Cable Clip.
53
23
ADJUSTING THE LEG PRESS PLATE
Remove the Press Pin (97) from the Leg Press Plate
(95) and the Leg Press Arm (96).
95
Welded
Tube
Align the welded tubes on the Leg Press Plate (95)
with the desired set of holes in the Leg Press Arm
(96). Re-insert the Press Pin (97) through the welded
tubes on Leg Press Plate and the holes in the Leg
Press Arm.
97
96
23
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WEIGHT RESISTANCE CHART
This chart shows the approximate weight resistance at each weight station. “Top” refers to the 6.5 lb. top weight.
The other numbers refer to the 12.5 lb. weight plates. The butterfly arm resistance listed is the resistance for
each butterfly arm.
WEIGHT
PLATES
PRESS
ARM
(lbs.)
BUTTERFLY
ARM
LEG
LEVER
(lbs.)
HIGH
PULLEY
(lbs.)
LOW
PULLEY
(lbs.)
MILITARY
PRESS ARM
(lbs.)
LEG
PRESS
(lbs.)
(lbs.)
Top
1
20
45
10
22
33
42
48
60
69
79
91
15
36
16
30
30
29
50
40
60
80
2
70
54
52
100
130
170
200
255
270
320
72
146
166
210
240
268
325
360
3
99
75
68
95
4
128
153
184
204
247
96
87
120
140
160
180
205
5
115
137
146
176
100
120
135
155
6
7
8
The actual resistance at each weight station may vary due to differences in individual weight plates, as
well as friction between the cables, pulleys, and weight guides.
24
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TROUBLE-SHOOTING AND MAINTENANCE
Inspect and tighten all parts each time you use the home gym system. Replace any worn parts immediately. The
home gym system can be cleaned using a damp cloth and mild non-abrasive detergent. Do not use solvents.
TIGHTENING THE CABLES
Woven cable, the type of cable used on the home gym system, can stretch slightly when it is first used. If there
is slack in the cables before resistance is felt, the cables should be tightened. If any slack is felt when using the
front weight stack, both the High Cable (58) and the Low Cable (23) will need to be tightened. If any slack is felt
when using the rear weight stack, both the Military Press Cable (72) and the Leg Press Cable (99) will need to
be tightened.
To tighten the cables, insert the weight pin into the middle of
the weight stack. Slack can be removed from these cables
1
15
several ways:
66
•
See drawing 1. Tighten the 1/4” Nylon Locknut (2) that
connects the end of the Low Cable (23) to the Long “U”-
Bracket (57).
21
57
12
The Leg Press Cable (99) can be tightened in the same
manner.
2
23 or 99
•
See drawing 1. Move the 3 1/2” Pulley (15) to the other
hole in one of the Long “U”-Brackets (57). Remove the
3/8” Nylon Locknut (21) and the 3/8” x 2” Bolt (12) from
the Cable Trap (66), Pulley, and Long “U”-Bracket. Re-
attach the Pulley and Cable Trap. Be sure that the Cable
Trap is in the proper position and that the Cable and
Pulley move smoothly.
2
72
2
58
71
71
The other Long “U”-Bracket (57) can be adjusted in the
same manner.
2
•
See drawing 2. Tighten the 1/4” Nylon Locknut (2) that
connects the end of the High Cable (58) to the Small “U”-
Bracket (71).
3
The Military Press Cable (72) can be tightened in the
same manner.
96
100
11
•
See Drawing 3. If additional slack is felt while using the
Leg Press Arm (96), then the end of the Leg Press Cable
(99) must be moved to the next hole in the Rear Seat
Frame (100). Remove the 5/16” x 2 3/4” Bolt (11), the
5/16” Washer (8), the end of the Cable, and both 5/16”
Nylon Jam Nuts (93) from the Rear Seat Frame. Re-
attach the Bolt, the Washer, the end of the Cable, and
both Nylon Jam Nuts to the next hole in the Rear Seat
Frame.
8
99
93
93
Do not overtighten the cables. The top weight will be lifted off the weight stack.
If a cable tends to slip off the pulleys often, it may have become twisted. Remove the cable and re-install it.
If the cables need to be replaced, see ORDERING REPLACEMENT PARTS on the back cover of this manual.
25
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CABLE DIAGRAMS
The cable diagrams on these pages show the proper routing of the High Cable (58), the Low Cable (23), the
Military Press Cable (72), and the Leg Press Cable (99). Use the diagrams to be sure that the four cables and
the cable traps have been assembled correctly. If the cables have not been correctly routed, the home gym sys-
tem will not function properly and damage may occur. The insets show the proper positioning of the cable traps.
The cable traps should be positioned so that the cables will not come off the pulleys. Be sure that the cable
traps do not touch or bind the cables.
High Cable (58) and Low Cable (23)
2
3
1—High Pulley
7
5
4
TOP VIEW
High Cable (58)
6
5—Long “U”-Bracket
Low Cable (23)
Front Weight Stack—
8
4
3
1—Low Pulley
2
26
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Military Press Cable (72) and Leg Press Cable (99)
2
Military Press Cable (72)
6—Pivot Arm
4
5
1—Long “U”-Bracket
3
2
Rear Weight Stack—1
4—Rear Seat Frame
3
Leg Press Cable (99)
27
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ORDERING REPLACEMENT PARTS
To order replacement parts, simply call our Customer Service Department toll-free at 1-800-999-3756, Monday
through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays). To help us assist you, please be pre-
pared to give the following information:
1. The MODEL NUMBER of the product (WESY96400).
2. The NAME of the product (WEIDER® PRO 9640 Home Gym System).
3. The SERIAL NUMBER of the product (see the front cover of this manual).
4. The KEY NUMBER and DESCRIPTION of the part(s) (see the PART LIST and EXPLODED DRAWING
attached at the center of this manual).
Part No. 135891 F04109-C R1296A
Printed in Canada © 1996 ICON Health & Fitness, Inc.
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REMOVE THIS PART IDENTIFICATION
CHART FROM THE MANUAL
This chart is provided to help you identify the small parts used in assembly. Important: Some parts
may have been pre-assembled for shipping purposes. If you cannot find a part in the parts bags,
check to see if it has been pre-assembled. The number in parenthesis below each part refers to the
key number of the part. The second number refers to the quantity needed for assembly.
Please Note: The assembly is divided into five stages: 1) frame
assembly, 2) arm assembly, 3) cable and pulley assembly, 4) seat and
backrest assembly, and 5) VKR assembly. The hardware for each
stage is packaged separately. WAIT UNTIL YOU BEGIN EACH
ASSEMBLY STAGE TO OPEN THE PARTS BAG LABELED FOR THAT
ASSEMBLY STAGE.
WESY96400 R1296A
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1/2" x 3/4" Spacer (61)–4
5/16" x 2" Eyebolt (35)—1
3/4" Round Inner Cap (34)–4
1" Round Inner Cap (49)–8
1" Round Cover Cap (70)–2
1" Square Inner Cap (6)–1
1 3/4" Square Inner Cap (44)–6
1 1/2" Square Inner Cap (32)–6
2" Square Inner Cap (27)–8
2" Square Outer Cap (51)–2
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3 / 8 " x 8 " B o l t ( 5 9 ) – 1
5 / 1 6 " x 6 " B o l t ( 6 0 ) – 2
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REMOVE THIS PART LIST/EXPLODED
DRAWING FROM THE MANUAL!
81
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PART LIST—Model No. WESY96400
R1296A
Key No. Qty.
Description
Key No. Qty.
Description
1
2
3
4
5
6
7
8
10
6
34
1
1
1
1
9
6
17
10
7
2
1
13
2
1
6
4
1
20
4
1
2
16
2
8
2
1
4
3
6
3
4
1
1
2
1
1
1
1
1
6
6
2
2
1
1
8
3
2
1
5/16” x 2 1/2” Carriage Bolt
1/4” Nylon Locknut
5/16” Nylon Locknut
Base
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
#
3
1
1
1
2
1
1
2
4
2
2
2
2
8
2
1
4
2
2
1
2
1
3
1
1
2
1
1
5
1
10
1
1
3
1
5
2
2
1
1
4
1
1
1
1
2
1
1
1
1
1
Cable Clip
Lat Bar
Top Frame
Leg Press Upright
Long “U”-Bracket
High Cable
Stabilizer
1” Square Inner Cap
5/8” x 9/16” Spacer
5/16” Flat Washer
3/8” Flat Washer
1/4” Flat Washer
5/16” x 2 3/4” Bolt
3/8” x 2” Bolt
3/8” x 8” Bolt
5/16” x 6” Bolt
1/2” x 3/4” Spacer
Long Weight Guide
Weight Tube
Weight Tube Bumper
Top Weight
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Seat
5/16” x 2 3/4” Carriage Bolt
3 1/2” Pulley
3/8” x 3 1/2” Bolt
Press Frame
1/4” x 1/2” Screw
Weight Bumper
Pulley Bracket
3/8” Nylon Locknut
5/16” x 2 1/2” Bolt
Low Cable
5/16” x 1 3/4” Bolt
Weight
Weight Pin
2” Square Inner Cap
Pad Tube
Leg Lever
Cable Trap
3/8” x 3 1/4” Bolt
5/16” x 5” Bolt
1” Retainer
1” Round Cover Cap
Small “U”-Bracket
Military Press Cable
Short Weight Guide
VKR Upright
5/16” x 3” Bolt
3 1/2” Low Pulley
VKR Backrest
VKR Armrest
Left VKR Arm
Right VKR Arm
1/4” x 2” Machine Screw
Handle
5” Plastic Grip
Military Press Arm
Rear Backrest
3/8” x 2 1/2” Bolt
#8 x 1/2” Self-tapping Screw
3/8” x 3 3/4” Bolt
1 1/8” x 2 1/2” Plastic Bushing
1” x 7/8” Plastic Bushing
Rubber Bumper
Foam Pad
Long Cable Trap
1 1/2” Square Inner Cap
5/16” x 2 1/4” Bolt
3/4” Round Inner Cap
5/16” x 2” Eyebolt
Front Seat Frame
Seat Plate
1/4” x 2” Carriage Bolt
Nylon Strap
Seat Knob
Front Backrest
Front Upright
1/4” x 2 1/2” Screw
1 3/4” Square Inner Cap
10” Pad
1/4” x 2 1/2” Carriage Bolt
5/16” Nylon Jam Nut
Press Bracket
Leg Press Plate
Leg Press Arm
Press Pin
Bushing
Leg Press Cable
Rear Seat Frame
Pivot Arm
Press Arm
Left Arm
Right Arm
1” Round Inner Cap
“V”-Pulley
User’s Manual
Exercise Poster
2” Square Outer Cap
Chain
#
Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.
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EXPLODED DRAWING—Model No. WESY96400
R1296A
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