This tutorial shows how to replace the propeller drive shaft and drive gear assemblies on your XE-1.
1. Remove propeller assembly
TOOLS REQUIRED
| ID | Description | Task |
| 17 mm Open Wrench | Loosen M10 Nylock Nut |
1.1 While holding the Propeller to stop it from rotating, loosen and remove the Nose Cone by rotating it anti-clockwise. [Tools: By Hand Only].
1.2 Loosen and remove the stainless steel M10 nylock nut with washer.
1.3 Remove the Propeller with Hex Block by pulling it forward off the end of the Propeller Drive Shaft.
1.4 With the Propeller removed, it is recommended to store the nut and washer on the end of the Drive Shaft, improving safety by creating a blunt end. Tighten by hand only to engage the nylon locking seal and prevent the nut from being lost.
2. Remove Chain Guard
TOOLS REQUIRED
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ID |
Description |
Task |
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2.5 mm Hex Drive / Allen Key |
Loosen 8 Gauge Machine Screws |
2.1 Remove the five 8-Gauge Machine Screws that is used to attach the Chain Guard to the RH Rear Buoyancy. [Tools: 2.5 mm Hex Drive]
2.2 Remove the transparent acrylic Chain Guard over the RH Crank and Pedal.
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INFORMATION: Do not use solvents to clean the Chain Guard. Use warm soapy water (dishwashing liquid soap) instead. |
3. Remove Rear RH Buoyancy (Cranks Fitted)
TOOLS REQUIRED
|
ID |
Description |
Task |
|
Long Nose Pliers |
Remove Buoyancy Clips |
3.1 Remove all seven Buoyancy Clips. [Tools: Long Nose Pliers]
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INFORMATION: Make a mental note of the positions where the Buoyancy Clips are removed. It is good practice to remove the white short Buoyancy Clip in front of the Seat Tube last. |
3.2 With the crank approximately in the 6 O’clock position, remove the Rear RH Buoyancy module over the Crank and Pedal.
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INFORMATION: The transparent Chain Guard must be removed before executing this step. It is possible to remove the RH Rear Buoyancy with the Chain Guard fitted and the RH Crank in the 5 O’clock position but this practice is not recommended as it could lead to component damage. |
4. Remove Chain.
TOOLS REQUIRED
| ID | Description | Task |
|
M5 Hex Key |
Loosen M6 Cap Screws |
4.1 Loosen the two M6 Cap screws securing the Chain Tensioner Bracket with Pulley (jockey wheel).
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INFORMATION: For the purpose of removing the Chain, only loosen the screws by one or two turns sufficient to release Chain tension. |
4.2 Push the Chain Tensioner Assembly upwards clear from the Chain.
4.3 Remove the Chain.
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INFORMATION: The Chain is easily removed by derailing it from the Chainring by slowly rotating the Chainring gear while pushing the Chain to the side |
5. Remove Chain Tensioner Bracket with Pulley
TOOLS REQUIRED
| ID | Description | Task |
| M5 Hex Key |
Loosen M6 Cap Screws |
5.1 Loosen and remove 35 mm Aluminium Cap Screws with large 18 mm Washers [M5 Hex]
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INFORMATION: Note that Tef-Gel lubricant rather than Loctite thread locker is used on the screws in this location to allow for the screws to be loosened and fastened regularly when adjusting Chain tension. 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. |
5.2 Remove Chain Tensioner Bracket with Pulley Assembly
6. Remove Drive Gear Assembly
TOOLS REQUIRED
| ID | Description | Task |
| M4 Hex Key | Remove M6 Countersink Head Screw |
6.1 Remove M6 Torque Plate Screw with countersink head and thread length 35 mm. [Tools: M4 Hex].
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INFORMATION: Given that the aluminium screw with countersink head is driven with a M4 Hex, it is more likely for the screw head to get damaged than the rest of the M6 cap screws with M5 socket. Note that the screw can be removed in this scenario by drilling through the head of the screw with a 6 mm drill bit. This allows the bracket to be removed and the screw to be extracted using locking pliers (vice grips). |
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CAUTION: Do not use a shorter length screw (<35 mm) in this location. |
6.2 Remove the Drive Gear Assembly (includes Torque Plate and Sprocket) by pulling it off the Top Gearbox Input Shaft with spline.
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INFORMATION: Following removal of the Drive Gear Assembly inspect the components.
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THE REPLACEMENT DRIVE GEAR ASSEMBLY CAN NOW BE FITTED
7. Fit Drive Gear Assembly
TOOLS REQUIRED
| ID | Description | Task |
|
Tef-Gel |
Assemble Drive Gear Assembly to Top Gearbox Input Shaft |
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M4 Hex Key |
Fit M6 Torque Plate Countersink Head Screw |
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Loctite 243 Thread Locking Compound |
Fit M6 Torque Plate Countersink Head Screw |
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Torque Wrench |
Fasten M6 Torque Plate Countersink Head Screw |
7.1 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.
7.2 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]
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INFORMATION: The M6 Torque Plate Screw has a countersink head and thread length 35mm. Do not exchange for a shorter length screw. |
REMOVAL OF THE STRUT COWL IS REQUIRED TO GAIN ACCESS TO THE PROPELLER DRIVE SHAFT
8. Removing the Strut Cowl
TOOLS REQUIRED
| ID | Description | Task |
| M3 Hex Key | Loosen M4 Cap Screws |
8.1 Remove the seven M4 cap screws from the RH side of the Strut Cowl [Tools: M3 Hex].
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INFORMATION : The seven M4 Nylock Nuts positioned in the hex shaped pockets on the LH Strut Cowl can fall out. Secure the nuts or remove and store them safely. |
8.2 Unlock the Strut Collar by rotating anti-clockwise through 70 degrees. Remove the Collar by sliding it forward over the Propeller Drive Shaft.
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CAUTION: Do not use pliers to remove the Strut Cowl Collar as it may cause damage to the component. The Collar is easily rotated by hand and can be removed with little force. |
8.3 With the screws and Strut Cowl Collar Removed, the two Strut Cowl halves (LH & RH) is held to each other only by being clipped together at the bottom trailing edge of the Strut Cowl. Unclip the RH Strut Cowl by pushing the Cowling Halves apart at the bottom of the trailing edge.
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INFORMATION : The LH Strut Cowl is transparent in the image below to show the mating boss clip feature on the RH Strut Cowl. |
8.4 Remove the RH Strut Cowl and support the LH Strut Cowl as it is only held from falling by the Cooling Hose being routed through behind the Lower LH Motor Mount Bracket. Keep LH Strut Cowl in place.
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INFORMATION : Removal of the Strut Cowl provides access to the Top and Bottom Gearbox, Vertical Drive Shaft, Bayonet (Frame to Foil attachment) and Propeller Drive Shaft Assembly. |
9. Remove Propeller Drive Shaft Assembly
TOOLS REQUIRED
|
ID |
Description |
Task |
|
40 mm Open Wrench |
Loosen Propeller Drive Shaft Hub |
9.1 To remove the Propeller Drive Shaft Assembly, loosen the Propeller Hub by rotating it clockwise. Pull the Propeller Drive Shaft forward to disengage it from the Gearbox Output Shaft. [Tools: 40 mm Open Wrench]
9.2.2 TO REPLACE THE PROPELLER DRIVE SHAFT, SIMPLY PULL IT OUT FROM THE HUB ASSEMBLY AND INSERT INTO THE NEW HUB ASSEMBLY
10. Fit Propeller Drive Shaft Assembly
TOOLS REQUIRED
|
ID |
Description |
Task |
|
40 mm Open Wrench |
Fasten Propeller Drive Shaft Hub |
10.1 Apply Tef-Gel (or equivalent) to the internal spline of the Propeller Drive Shaft. Align the Propeller Drive Shaft with Gearbox Output Shaft Spline and push the Propeller Drive Shaft onto the Gearbox Input Shaft. [Tools: By Hand Only]
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INFORMATION: The LH (left hand) thread of the Propeller Hub ensures that it is self-tightening while the Propeller is driven. With the fine thread extra caution must be taken not to cross thread with that of the Frame. To find the beginning of the thread, slowly rotate the Hub clockwise until you can feel it step off the first thread. Now rotate anti-clockwise to fasten. No torque value is specified but strong hand tight will be sufficient as the minimum torque required. |
10.2 Apply Tef-Gel to the thread of the Propeller Hub. Fasten the Propeller Hub screwing it into the frame by rotating anti-clockwise as this is a LH thread. [Tools: 40mm Open Wrench]
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INFORMATION: The LH thread of the Propeller Hub ensures that it is self-tightening while the Propeller is driven. With the fine thread extra caution must be taken not to cross thread with that of the Frame. To find the beginning of the thread, slowly rotate the Hub clockwise until you can feel it step off the first thread. Now rotate anti-clockwise to fasten. No torque value is specified but strong hand tight will be sufficient as the minimum torque required. |
11. Fit Strut Cowl
TOOLS REQUIRED
|
ID |
Description |
Task |
|
Hex Key 3 mm |
M4 Cap Screws |
11.1 Position the RH Strut Cowl to align with the LH Strut Cowl. Gently push the bottom of the trailing edges of the two cowl halves together until you hear a clicking sound as the trailing edges interlock.
11.3 With the two internal molded locking boss features of the Prop Collar facing the Strut Cowl and aligned in the 11 & 5 o’clock position, push the Prop Collar into place while holding the two Strut Cowl halves together.
11.4 Rotate the Prop Collar clockwise (by hand only) through approximately 70 degrees until the lock stop is reached.
11.5 With the M4 Nylock Nuts held in the nut pockets of the LH Strut Cowl, fix the two Strut Cowl halves in place by fitting and fastening the seven M4X20 stainless steel cap screws to a torque value of 2.5 to 3 Nm. [Tools: M3 Hex Drive].
12. Fit Chain Tensioner Bracket with Pulley
TOOLS & JIGS REQUIRED
| ID | Description | Task |
|
M5 Hex Key |
Fasten M6 Cap Screw |
12.1 Position the Bracket with Pulley with screw holes aligned.
12.2 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.
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INFORMATION:
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13. Work Instruction - Fit Chain.
TOOLS REQUIRED
| ID | Description | Task |
|
M5 Hex Key |
Loosen M6 Cap Screws |
13.1 Prepare to fit the chain by setting up the chain tensioner assembly by loosening the pivot point screw (highlighted red) and chain tension locking screw (highlighted green) so that the Chain Tensioner Assembly can be moved freely up and down.
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INFORMATION: The Chain Tensioner Assembly with Pulley (Jockey wheel) pivots around one screw serving as an axis (highlighted in red). The adjustment range is constrained by the slot and once adjusted the assembly is secured by firstly fastening the chain tension locking screw (highlighted in green) and finally the pivot screw. Do not use Loctite thread locker to the threads of the Chain Tensioner screws but use a lubricant like Tef-Gel (or equivalent) lubricant. |
13.2 With the Chain Tensioner Assembly raised, fit the chain over the 16T Drive Gear Sprocket and 42T Chainring.
13.3 Apply light pressure (about 1 kg of force) to the top of the Chain Tensioner Bracket and fasten the chain tension locking screw positioned in the slot at the same time.
13.4 Check Chain tension by moving the Chain up and down just above the Chain Tensioner Assembly in the centre of the span between Chainring and Drive Gear Sprocket. 8-10 mm of play is ideal.
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INFORMATION: If Chain tension is too low, it is more likely that the Chain will fall off during use. With the Chain Tension too high the Pulley (jockey wheel) M5 Bolt may fail and the Jockey Wheel (pulley) to break off and drive to be lost. It is normal to observe slight variation in Chain tension as the Chainring gear is rotated. Rotate the Chainring gear through 360 degrees and ensure that the Chain is not excessively tight (< 8 mm of play) at any point |
14. Fit rear right hand buoyancy with cranks on
TOOLS REQUIRED
|
ID |
Description |
Task |
|
Long Nose Pliers |
Remove Buoyancy Clips |
14.1 With the Crank approximately in the 6 O’clock position, position the Rear RH Buoyancy Module by sliding it over the top of the RH Pedal and Crank.
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INFORMATION: If the RH Cranks are fitted, the Chain Guard must be removed before fitting the Rear RH Buoyancy to the bike. |
14.2 Align the Rear RH Buoyancy with the Frame and LH Buoyancy so that the Insert Locating Pins align with the mating inserts on the RH Buoyancy module.
14.3 Fit all seven Buoyancy Clips to secure both LH and RH Buoyancy halves to the hydrofoiler. [Tools: Long Nose Pliers].
15. Fit Chain Guard
TOOLS REQUIRED
|
ID |
Description |
Task |
|
2.5 mm Hex Drive / Allen Key |
Loosen 8 Gauge Machine Screws |
15.1 Fit the transparent acrylic Chain Guard over the RH Pedal and Crank and onto the RH Rear Buoyancy.
15.2 Align the Chain Guard with the recess on the RH Rear Buoyancy with screw holes aligned. Fit five 8-Gauge Machine Screws and fasten lightly. [Tools: 2.5 mm Hex Drive]
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INFORMATION: If the machine screws are over tightened, they will slip in the insert without causing serious damage. To maximize the life of the Buoyancy Inserts, avoid over tightening and subsequent wear of the inserts. |