This guide explains how to correctly install a Foil Drive V2 Motor onto a Carbon Integrated Mast, including preparing the motor puck, applying dielectric grease, securing the motor, setting the motor cable length and completing the installation.

Once installed correctly, the motor can remain fitted to the mast between sessions. Regular inspection and maintenance are recommended, but the motor does not need to be removed after every use.

Before You Begin

You will need:

• Carbon Integrated Mast with motor puck and cable
• Foil Drive V2 Motor — Standard or High Power
• Red motor puck O-ring
• Dielectric grease
• 4 x M4 motor-to-puck screws
• Mast split bolt and barrel nut
• Base plate mounting hardware supplied with your mast
• 3 x M4 motor plug bolts supplied with your Foil Drive system
• Appropriate tools for your mast hardware

Important: We recommend completing the installation with the rotor and propeller removed from the stator. This makes installation easier and helps keep your tools straight when tightening the motor plug bolts.

Installation Overview

1. Free the Motor Puck and Cable

If you need additional cable length to position the motor puck, remove the small screws securing the mast base plate cover.

Gently remove the cable from its channel to provide enough movement for the motor puck and cable to hang freely.

Take care with these small screws. The hardware can vary between mast brands, so always use the correct tool and avoid damaging or stripping the screw heads.

2. Check the Red O-Ring

Before installing the motor, check that the red O-ring is fitted to the motor puck.

The O-ring should normally arrive pre-installed, but always confirm that it is present and correctly seated before fitting the motor.

This O-ring helps seal the connection between the motor and the motor puck.

Do not install the motor without the red O-ring.

3. Apply Dielectric Grease

Apply dielectric grease to the cavity surrounding the electrical plug.

This is slightly different from applying grease to other Foil Drive electrical connections.

You do not need to completely cover or pack the electrical pins with grease. Instead, apply grease around the outside of the plug so that when the motor and puck are brought together, the O-ring seats into the greased area and creates a well-protected interface.

Correct application

• Apply grease into the cavity surrounding the plug.
• Ensure there is sufficient grease for the O-ring to seat into.
• Avoid unnecessarily coating or packing the individual electrical pins.

4. Attach the Motor Stator to the Puck

For easier installation, remove the rotor and propeller and work with the stator only.

Position the stator onto the motor puck, making sure:

• The red O-ring remains correctly seated.
• The electrical connections are correctly aligned.
• The motor sits squarely against the puck.

Insert the four M4 motor-to-puck screws.

Start each screw by hand before tightening any of them fully. This helps ensure all four holes are correctly aligned.

Once all four screws have engaged their threads, progressively tighten them.

Do not overtighten. Firm finger tension is sufficient; excessive torque is unnecessary and may damage the hardware or threads.

5. Insert the Motor Puck into the Mast

Before inserting the puck, identify the flat section of the motor puck.

The flat section must face toward the mast base plate.

Carefully fold the cable between the locating sections of the puck so that it sits neatly inside the mast and cannot become pinched during installation.

Slide the puck into position.

Important

The puck should fit naturally into the mast.

Do not force it.

If it does not feel right, remove it and check:

• Puck orientation
• Cable positioning
• Alignment within the mast

6. Install the Split Bolt and Barrel Nut

Align the holes through the mast and motor puck.

It can be helpful to temporarily use the longer bolt to align the holes before installing the barrel nut.

Once aligned:

1. Remove the alignment bolt.
2. Insert the barrel nut first.
3. Insert the bolt from the opposite side.
4. Engage the thread.
5. Tighten using the appropriate tools.

Tighten only until the motor is securely clamped.

Do not apply excessive torque.

Once installed, check that the motor is:

• Rock solid
• Unable to rotate
• Unable to tilt forwards or backwards

If there is movement, check the split bolt before using the system.

7. Set the Motor Cable Length

Correct cable length is important to prevent unnecessary tension on the motor connection.

Initially, reinstall the mast base plate cover screws loosely enough that the cable can still slide through the mast.

Connect the motor cable to your Foil Drive unit.

Then:

1. Position the mast onto the Foil Drive unit.
2. Slide the mast forward into its installed position.
3. Align the mast mounting holes.
4. Temporarily engage the mast-to-unit mounting bolts.
5. Check that the motor cable connection sits naturally without pulling on the plug.

The Foil Drive unit should sit flat against the mast base plate without the cable pulling or lifting the unit.

If there is tension, feed a little more cable through the mast until the connection sits naturally.

Some mast cables may have a reference marking to help identify the correct cable position.

8. Secure the Cable Position

Once you are happy with the cable length, carefully remove the mast from the Foil Drive unit without allowing the cable position to change.

Tighten the mast base plate cover screws.

This secures the cable at the correct length so that future installation is simple and repeatable.

The cable should now remain at the correct position each time you attach your Foil Drive unit.

9. Attach the Mast to the Foil Drive Unit

Reconnect the motor cable and position the mast onto your Foil Drive unit.

Install the supplied base plate mounting bolts according to the hardware supplied with your mast.

These bolts allow the mast and Foil Drive unit to remain attached as one assembly if desired.

10. Secure the Motor Cable Connection

Install the three M4 motor plug bolts supplied with your Foil Drive system.

Keeping the rotor removed during this step provides better access and makes it easier to keep your tool straight.

This is important because inserting or tightening these bolts at an angle can damage or strip the threads in the Foil Drive unit.

Start each bolt carefully and tighten using firm finger tension.

Do not overtighten.

11. Reinstall the Rotor

Once the motor, mast and cable are fully secured, reinstall the rotor.

The rotor contains strong magnets and can pull quickly toward the stator.

Control the rotor with your hand and allow it to move onto the stator slowly. Do not allow it to snap into position.

Complete any remaining propeller installation required for your setup.

Final Checks Before Riding

Before riding, confirm:

• The red motor puck O-ring is installed.
• Dielectric grease has been applied around the motor plug cavity.
• All four motor-to-puck screws are secure.
• The motor puck is correctly oriented.
• The cable is not pinched.
• There is no tension on the motor cable when the unit is installed.
• The split bolt and barrel nut are secure.
• The motor is rigid and cannot rotate or tilt.
• The motor plug bolts are correctly installed.
• The rotor and propeller are correctly installed.

If the motor can move on the mast, do not use the system until the mounting hardware has been checked and secured.

Frequently Asked Questions

1. Does the Mast Need to Be Watertight?

No. The mast cover and cable channel are not designed to create a sealed, watertight compartment.

Small amounts of water may enter and drain from this area during normal use. The components housed within this section are designed for this environment.

The mast cover primarily protects and neatly contains the internal cable.

2. Ongoing Maintenance

You do not need to remove the motor after every session. Ensure the rotor is removed, cleaned and stored separately to your stator between sessions.

As part of periodic maintenance, we recommend inspecting the motor installation approximately every 1-2 months, depending on how frequently and in what conditions you ride.

Before every session:

• Check that the motor remains rigid on the mast.
• Check the split bolt and other mounting hardware for movement.
• Rinse accessible areas with fresh water.
• Inspect the motor plug and O-ring.

Periodically:

• Remove and inspect the motor connection.
• Reapply dielectric grease around the plug cavity when required.
• Check the cable and mounting hardware for signs of wear or damage.

Bolts can loosen gradually through repeated use, so checking the motor for movement should also form part of your normal pre-ride inspection.

Once correctly installed and maintained, your integrated mast and motor can remain assembled and ready for your next session.