Integrated Carbon Masts provide a clean, streamlined Foil Drive setup by integrating the motor and cable into the mast. This guide covers the general installation process, cable adjustment, motor installation and ongoing maintenance for compatible Integrated Carbon Masts.

Always follow the specific instructions supplied with your mast, as hardware, motor positions and cable requirements may vary between manufacturers.

For instructional video, see: Carbon Mast Installation Guide

Before You Start

Both the V2 Standard or High-Power Motor are compatible with Carbon Integrated Masts.

Some integrated masts are designed to accommodate different Foil Drive systems, such as Gen2, Gen2.5 or Fusion. The cable length and connection position varies for the Fusion, and lengthen the cable on the mast is necessary for use with this system.

Check your mast and Foil Drive system compatibility before beginning installation.

Fusion Systems - Extending the Motor Cable

Integrated Carbon Masts have a motor cable that can be adjusted inside the mast to accommodate different Foil Drive Electronics Boxes.

If you are using a carbon integrated mast on a Fusion, follow these steps below:

To adjust the cable:

1. Remove the mast base plate or access cover to expose the motor cable.
2. Carefully pull the cable out of its internal channel so the motor puck and cable can move freely.
3. Connect the mast to the Electronics Box to determine the correct cable length.
4. Position the cable so there is no unnecessary tension when the mast is seated against the Electronics Box.
5. Ensure the cable sits neatly within its channel without being pinched.
6. Once the correct position is confirmed, secure the cable and reinstall the base plate or access cover.

The cable should have enough length to connect naturally without pulling, bending sharply or placing tension on the connector.

Once correctly set, the cable should remain at this length and should not require adjustment every time the mast is installed.

Remove the Motor Puck Split Bolt

Before installing the motor, remove the split bolt and barrel nut securing the motor puck in the mast pod.

A T30 driver is required.

If the bolt spins while you're trying to remove it, use a second T30 driver on the opposite side to hold the other end while loosening the bolt.

Once removed, carefully remove the barrel nut and motor puck.

Removing a Tight Puck

If the puck is difficult to remove, gently shimmy it from side to side.

A T30 driver can also be inserted slightly into the available hole and used to provide very gentle leverage to help release the puck.

Do not force the puck out or pry aggressively against the mast or pod.

Prepare the Motor and O-Ring

Before installing the motor, check that the red O-ring is correctly seated on the motor puck.

The O-ring creates the seal between the motor and puck connection.

Always confirm the O-ring is correctly installed and undamaged before assembly.

Apply Dielectric Grease

For Integrated Carbon Mast motor connections, dielectric grease should be applied differently from a standard exposed connector.

Do not cover the electrical pins with grease.

Instead:

1. Apply dielectric grease into the cavity surrounding the motor plug.
2. Work the grease around the outside of the plug.
3. Ensure the cavity is well coated without filling the electrical contact area with excessive grease.

When the motor is installed, the O-ring compresses into this greased area to help seal the connection.

More grease is not better. Avoid excessive grease on the electrical contacts.

Install the Motor

For easier installation, remove the rotor and propeller assembly before fitting the motor.

This provides better access to the motor mounting hardware and makes it easier to keep tools straight when tightening the bolts.

Install the Motor:

1. Confirm the red O-ring is correctly seated on the puck.
2. Align the motor with the puck.
3. Install the supplied M4 mounting bolts.
4. Start all bolts by hand before tightening any of them.
5. Once all bolts are correctly engaged, tighten them gradually and evenly.
6. Use finger tension only — do not overtighten.

Starting all bolts before tightening helps keep the motor correctly aligned and prevents the mounting holes from becoming difficult to engage.

Do not use excessive force when tightening the motor mounting bolts.

Install the Motor Puck into the Mast

Before inserting the puck, identify the correct orientation.

The flat section of the puck must align with the corresponding flat section inside the mast pod.

If the puck does not slide into position naturally:

Stop and check the orientation. Do not force it.

Position the Cable

Before pushing the puck fully into the mast:

1. Fold the motor cable neatly into the available cable channel.
2. Ensure the cable is not trapped beneath the puck.
3. Make sure there are no sharp bends or pinch points.
4. Carefully push the puck into position.

The cable should sit neatly within the mast and move freely enough to prevent tension when the Electronics Box is connected.

Install the Split Bolt and Barrel Nut

The split bolt and barrel nut secure the motor puck inside the mast.

A useful installation technique is to pre-align the holes with the bolt first, then remove it and install the barrel nut.

1. Insert the split bolt through the mounting holes to align the components.
2. Remove the bolt.
3. Install the barrel nut into position.
4. Reinsert the split bolt and engage the thread.
5. Tighten the bolt using appropriate tools on both sides if required.

Once installed, the motor should be:

• Rock solid
• Unable to rotate
• Unable to tilt backwards or forwards
• Securely seated within the mast

Do not reef on the split bolt. Tighten it firmly without excessive force.

Reinstall the Mast Access Cover

Once the motor and puck are installed, reinstall the mast access cover or base plate.

Initially, leave the cover slightly loose so you can check the cable position against the Electronics Box.

Check the Cable Length

Connect the motor cable to the Electronics Box and carefully position the mast.

Check that:

• The connector reaches without tension
• The mast sits flat against the Electronics Box
• The cable is not being pulled tight
• The cable is not pinched
• The mounting holes align correctly

f the mast is being pulled or lifted by the cable, adjust the cable length before finalising the installation.

The mast should sit flush against the Electronics Box with no unnecessary tension on the cable.

Once the correct cable position has been confirmed, remove the mast and securely tighten the access cover.

Install the Mast-to-Box Hardware

Install the supplied mast-to-Electronics Box mounting bolts.

These bolts secure the mast to the Electronics Box and, depending on the system, may allow the mast and Electronics Box to remain assembled as a single unit between sessions.

Tighten the bolts securely according to the instructions supplied with your specific mast and Foil Drive system.

Install the Motor Plug Bolts

Install the supplied motor plug bolts into the motor cable connection.

For best results:

1. Ensure the motor plug is correctly seated.
2. Start each bolt by hand.
3. Keep the tool straight and aligned with the bolt.
4. Tighten carefully and evenly.
5. Use finger tension only unless your specific system specifies a torque setting.

Do not tighten the bolts while the tool is angled.

Keeping the tool straight helps prevent damage to the bolt head and reduces the risk of cross-threading or damaging the threaded insert.

Reinstall the Rotor and Propeller

Once the motor is fully secured, reinstall the rotor and propeller assembly according to your Foil Drive system instructions.

When installing the rotor, control it carefully as it seats into position to prevent it from snapping or slapping into place.

Before entering the water, confirm the propeller rotates freely and that there is no interference with the motor or mast.

Final Installation Check

Before using your Integrated Carbon Mast, check:

• Motor puck is correctly seated
• Red O-ring is correctly installed
• Motor mounting bolts are secure
• Split bolt is secure
• Motor does not move or rotate
• Motor cable is correctly positioned
• Cable has no unnecessary tension
• Motor plug is fully seated
• Motor plug bolts are secure
• Mast-to-Box bolts are secure
• Rotor and propeller are correctly installed
• Propeller rotates freely

The motor must be completely rigid. If the motor moves, tilts or rotates, stop using the system and inspect the installation.

Important

Integrated Carbon Masts are designed to make your Foil Drive setup cleaner and more streamlined, but correct installation is essential.

Never force components into position. Never overtighten the mounting hardware, and always make sure the motor is completely rigid before riding.

For system-specific installation, cleaning and safety requirements, always refer to the Foil Drive User Manual and the instructions supplied with your Integrated Carbon Mast.