REPLACE MOTOR & CABLE ASSEMBLY

INFORMATION: With the Cranks and Buoyancy Clips removed both Left-Hand and Right-Hand Buoyancy Modules are free and can be removed. Take care not to drop the Rear Buoyancy halves when pulling out the last clip. Dropping the Buoyancy parts may cause scratches and or other damage. Leaving the Clip in front of the seat tube to be removed last is recommended.

1. Remove Chain Ring

TOOLS REQUIRED

ID	Description	Task
JP00060	TOOL, LOCKING RING, ISIS, WITH CORE, STD	Remove Chain Ring Spider Lock Nut (Ring)
	19 mm Ring or Open-Ended Wrench	Remove Chain Ring Spider Lock Nut (Ring)

1.1 Loosen and remove the Lock Nut by rotating the round nut clockwise with the Locking Ring tool.

INFORMATION: Screw the tool core into the axle, place the main tool body with pins over the core and to engage the 8 Lock Nut holes. Using a 19 mm wrench, rotate the tool and nut clockwise to remove the lock nut. Use a long chain whip to hold the chain ring from rotating on the free spinning motor hub when loosening the Lock Nut.

 

 

1.2 Remove the Chain Ring Assembly by pulling off the Motor Drive Shaft Spline.

 

 

1. Work Instruction - Fit Motor and Cable Assembly.

TOOLS REQUIRED

ID	Description	Task
	M5 Hex Key	Fasten M6 Cap Screws
	10 MM Open/Combination Wrench	Fasten M6 Nylock Nut
HP00162	LOCTITE 242	Fasten M6 Cap Screw to Frame

INFORMATION: Read all information and refer to the supplied image for each step of the process before you proceed.

1.1 If not already done, transfer then loosely assemble Top Motor Mount Brackets with Water Cooling Outlet Bracket in the left aft position.

INFORMATION: The brackets are fitted with the short side at the front and the taller side at the rear.

1.2 Position the Motor & Cable Assembly in the Frame with the Cable facing forward passing on the left-hand side of the frame.



1.3 Apply Loctite 242 thread locker to the screw threads and loosely fit the four M6 Top Motor Mount Cap Screws with Washers to the Frame.

INFORMATION: To ensure alignment of the Drive Drain, the Top Motor Mount fasteners will be fastened later when both the LH and RH Lower Motor Mount Brackets are in place.

1.4 Position and hold the LH Lower Motor Mount Spacer (Anodized Red) between the Lower LH Motor Mount and Lower Motor Mount with the cooling hose passing behind the spacer.



1.5 Fit the Lower Motor Mount Screw (70 mm length M6 Stainless Steel) with SS washer. Sleeve with shoulder and Long Sleeve through the Lower Left-Hand Motor Mount bracket, Motor Mount Spacer and Lower Motor Mount.

INFORMATION: Ensure that the screw is pushed in all the way so that the end of the long sleeve appear on the right-hand side.

1.6 Insert the end of the Water Cooling Hose through the hole in the Water Cooling Bracket so that it makes contact with the Motor Cooling Fins.



1.7 Position a Motor Mount Spacer (anodized red color) onto the Lower Motor Mount Screw over the end of the Long Sleeve.



1.8 Fit the Lower Right-Hand Motor Mount Bracket with the curved side facing forward ensuring that the bracket holes align with that of the frame.



1.9 Loosely fit the Short Nylon Sleeve (with shoulder), M6 Stainless Steel Washer and M6 Stainless Steel Nylock Nut to the end of the Motor Mount Screw.



1.10 Apply Loctite, and loosely fit the M6 Aluminium Cap Screw and Washer to the bottom hole position of the Lower RH Motor Mount Bracket.



1.11 Temporarily fit two M6 screws loosely into the remaining hole positions to ensure alignment of the components.



1.12 With place holder screws loosely fitted in, fasten all motor mount fasteners to a torque value of 5 Nm.

1.13 Remove the two screws that were temporarily fitted to assist with alignment of the Lower RH Motor Mount Bracket.

1. Fit Drive Gear Assembly

TOOLS  REQUIRED

ID	Description	Task
	Tef-Gel	Assemble Drive Gear Assembly to Top Gearbox Input Shaft
	M4 Hex Key	Fit M6 Torque Plate Countersink Head Screw
	Loctite 243 Thread Locking Compound	Fit M6 Torque Plate Countersink Head Screw
	Torque Wrench	Fasten M6 Torque Plate Countersink Head Screw

1.1 Apply Tef-Gel (or equivalent lubricant) to the Top Gearbox Input Shaft. Insert the Drive Gear Assembly with the Sprocket internal spline fitting onto the external spline of the Top Gearbox Input Shaft.

1.2 Apply Loctite 243 (or equivalent thread locker) to the thread and assemble the M6 Torque Plate Screw through the Torque Plate and Lower Right-Hand Motor Mount to engage with the threaded boss on the Frame. Fasten to 5 Nm. [Tools: M4 Hex, Torque Wrench]

INFORMATION: The M6 Torque Plate Screw has a countersink head and thread length 35mm. Do not exchange for a shorter length screw.

1. Fit Chain Tensioner Bracket with Pulley

TOOLS & JIGS REQUIRED

ID	Description	Task
	M5 Hex Key	Fasten M6 Cap Screw

1.1 Position the Bracket with Pulley so that the screw holes align.

 

1.2 Apply Tef-Gel (not Loctite) to the threads and Insert the M6 x 35mm Cap Screws with 18 mm OD washers. Do not fasten fully to allow for Chain tension adjustment in a following step.

INFORMATION: Using lubricant rather than Loctite in this location is required to facilitate Chain adjustment to compensate for normal wear. The M6 Chain Tensioner Bracket screws have a length of 35 mm and must not be replaced with shorter length screws. Using shorter screws may cause damage to the threads in the XE-1 Frame.

1.  Fit Chain Ring Assembly

TOOLS REQUIRED

ID	Description	Task
JP00060	TOOL, LOCKING RING, ISIS, WITH CORE, STD	Remove Chain Ring Spider Lock Nut (Ring)
	19 mm Ring or Open-Ended Wrench	Remove Chain Ring Spider Lock Nut (Ring)
	Generic round bar or Cassette Removal Tool with long chain whip.	Hold Chain Ring to prevent it from rotating when tightening Chain Ring Spider Lock Nut

 

INFORMATION: Inspect the Chain Ring for excessive wear. For the Chain Ring, Chain, and Sprocket to work well together all components must have a similar pitch (state of wear).

1.1 Place the Chain Ring Assembly onto the Motor Drive Shaft Spline.

1.2 Place the Lock Nut onto the Motor Drive Shaft and fasten by rotating the round Lock Nut anti-clockwise. [Tools: TOOL, LOCKING RING, ISIS, WITH CORE, STD].

INFORMATION: Screw the tool core into the axle, place the main tool body with pins over the core and to engage the 8 Lock Nut holes. Using a 19 mm wrench, rotate the tool and Lock Nut anti-clockwise to fasten. Use a round bar or Cassette Removal Tool with long chain whip to stop the Chain Ring from spinning while tightening.

1.  Fit Rear Buoyancy

1.1 Position and hold Left-Hand Rear Buoyancy Module.

 

 

1.2 Position and hold Right-Hand Rear Buoyancy Module.

 

INFORMATION: As soon as the two Rear Buoyancy halves are in position, insert one of the Buoyancy Clips (white clip in front of the Seat Tube is a good option) so that the assembly is self-supported.

1.3 Insert all seven Buoyancy Clips (4 short white, 1 short black, 2 long black) to complete the assembly.

INFORMATION: Corresponding with the black and white colours of the Rear Buoyancy, four short white clips are fitted around the front, two long black clips at the rear and one short black clip is fitted on top behind the Seat Tube Clamp.

 

1. Fit Pedal Crank Arms LH and RH

TOOLS REQUIRED

ID	Description	Task
	Hex Key 8 mm	Remove Crank Bolts
	Torque Wrench (20 – 60 Nm)	Fasten Crank Bolts (50 Nm)
	Rubber Mallet	Assemble Crank Arms to Motor Drive Shaft Spline

 

 

 

1.1 Assemble RH Crank Arm to Motor Drive Shaft Spline and secure with 15 mm Crank Bolt. [Tools: Rubber Mallet, 8 mm Hex, Torque Wrench set to 50 Nm]

INFORMATION: Fit the Right-Hand Crank Arm (marked RH on outside face adjacent to Pedal thread) to the Drive shaft Spline and tap it firmly into place using a small head rubber mallet without making contact with buoyancy components. The Crank Bolt must progress at least two full turns without tension before tightening. Fastening the Crank Bolt with only one thread engaged can strip the thread from the Crank Bolt in which case it must be replaced.

1.2 Fit a 15 mm ISIS Crank Bolt through the Right-Hand Crank to engage the internal thread of the Motor Drive Shaft. [Tools: 8 mm Hex, Torque Wrench]

INFORMATION:  Use the Torque Wrench set to 50 Nm and fasten to the pre-set torque level. Rotate the Crank Bolt clockwise (right-hand thread) to fasten.

 

1.3 Assemble Left-Hand Crank Arm to Motor Drive Shaft Spline and secure with 15 mm Crank Bolt. [Tools: Rubber Mallet, 8 mm Hex, Torque Wrench set to 50 Nm]

INFORMATION: Fit the Left-Hand Crank Arm (marked LH on outside face adjacent to Pedal thread) to the Drive shaft Spline and tap it firmly into place using a small head rubber mallet without making contact with buoyancy components. The Crank Bolt must progress at least two full turns without tension before tightening. Fastening the Crank Bolt with only one thread engaged can strip the thread from the Crank Bolt in which case it must be replaced.

1.4 Fit a 15 mm ISIS Crank Bolt through the Left-Hand Crank to engage the internal thread of the Motor rive Shaft. [Tools: 8 mm Hex, Torque Wrench]

INFORMATION: Use the Torque Wrench set to 50 Nm and fasten to the pre-set torque level. Rotate the Crank Bolt clockwise (right-hand thread) to fasten.

1.  Fit Front Buoyancy

TOOLS REQUIRED

ID	Description	Task
	Long Nose Pliers	Remove Buoyancy Clips

1.1 To fit the Right-Hand Front Buoyancy set, align the Buoyancy Module with the frame and Battery Tray. Apply pressure just below the front of the Battery Tray and push the Buoyancy set upwards to engage with the lip of the Battery Tray and into position.

1.2  To fit the Left-Hand Front Buoyancy, align the module with the Frame and Battery Tray. Partially engage with the lip of the Battery Tray and apply pressure to the buoyancy module near the front of the battery tray while pushing upwards. At the same time maintain sufficient separation between the Left-Hand and Right-Hand buoyancy modules so that the locating inserts and pins can align and engage. Check that both Front Buoyancy halves are captured between the Battery Latch brackets and behind the horizontal lip feature of the Battery Tray.

1.3 Ensure that all five the inserts engage with the corresponding inserts with pins.

INFORMATION: With the Front Buoyancy fitted the inserts should fit together with little or no gap to ensure that the Buoyancy Clips will fit properly.

1.4 Reach past the Motor Power Cable and slide the Stirrup (highlighted in the image) backward into the locked position.

1.5 To complete the assembly, fit all 5 Buoyancy Clips that lock the two halves together. If any one of the clips do not lock properly or do not pull the two buoyancy halves together, remove the clip using Long Nose Pliers and refit.

1.  Fit Battery Tray

TOOLS REQUIRED

ID	Description	Task
	M4 Hex Key	Fit M6 Countersink Head Screws

1.1 Push cable to the side and fit the Stirrup to the Frame. The ideal position is with a gap of 65 mm between the Rear Buoyancy and the Stirrup.

INFORMATION: The Stirrup is used as fastener for and locks the Front Buoyancy into place. Positioning the Stirrup with the 65 mm gap to the Rear Buoyancy positions the Stirrup in the ideal position for fitting the Front Buoyancy later.he Battery Tray can remain in place during this procedure.

1.2 Thread the cable with the connector through the keyhole and position the Battery Tray (with warning labels attached) to align the screw holes with the corresponding threaded holes in the Frame brackets.  

 

1.3 Position the Battery Latches with M8 Set Screws on the right-hand side of the Hydrofoiler XE-1 so that the fastener holes and edges align with the mating features on the Battery Tray. 

1.4 Fit the M6 countersink head screws through the Battery Latches and Battery Tray into the threaded brackets on the bike Frame. Fit all four screws loosely using the taper shape of the screw heads to align the Battery Latches. The Battery Tray position can now be adjusted to align with the Battery Latches before the screws are fully fastened.

1.5 With the Battery Tray aligned, fasten the screws to a torque value of 5 Nm. [Tools: 4mm Hex]