Correct installation of the Motor Plug and securing bolts is important to prevent cross-threading, stripped threads and damage to the threaded inserts in your Foil Drive system.

The M4 securing bolts are small and require care when installing. The bolts should always be started by hand and threaded straight into the unit.

Click here to watch the video on how to correctly install the motor plug and bolts

Before you start

Before installing the Motor Plug:

• Make sure the Motor Plug and securing bolt threads are clean and free from sand, salt or debris.
• If the rotor and propeller are obstructing access to the bolts, remove the rotor first.
• Have your 2.5 mm Allen key/driver ready.
• Make sure the Motor Plug is sitting flat and level against the sealing surface.

1. Remove the rotor

The propeller can make it difficult to keep the Allen key straight when installing the securing bolts.

If the rotor or propeller is obstructing access:

1. Remove the rotor.
2. This gives you clear access to all four securing bolts.
3. Keep the Allen key straight and perpendicular to the Motor Plug when installing the bolts.

Removing the rotor makes installation significantly easier and reduces the risk of cross-threading.

2. Check the threads

Before installing the bolts, make sure there is no sand, grit, salt or other debris in the threaded holes.

Never force a bolt into a dirty or obstructed thread.

If the system has been used in sand or salt water, clean the threads before installing the bolts.

Cleaning a dirty thread

If you suspect there is debris inside a threaded hole:

1. Use a cotton swab (Q-tip) to gently clean inside the thread.
2. A cotton swab can be slightly dampened to help pick up debris.
3. Carefully work it into the thread and remove it.
4. Check that the thread is clear before installing the bolt.

Do not force a bolt into a thread containing sand or grit. Doing so can damage the thread.

3. Install the Motor Plug

Position the Motor Plug so that it is flat and level against the sealing surface.

Do not begin threading the bolts while the Motor Plug is sitting at an angle.

An angled bolt can cross-thread the hole and damage the threads.

4. Start the securing bolts by hand

This is the most important step.

Insert each M4 securing bolt and start the thread using only your fingers.

The bolt should thread in smoothly with minimal resistance.

The bolt must go in straight

The Allen key should be positioned straight and perpendicular to the Motor Plug.

Do not attempt to thread the bolt in at an angle.

If you feel significant resistance while starting the bolt:

Stop. Do not apply more force.

Remove the bolt, check that the Motor Plug is sitting flat, and inspect the threads for debris or damage.

You should not need to use significant force to start the bolt.

5. Tighten the bolts

Once all bolts have been started correctly:

1. Tighten the bolts gradually.
2. Work between the bolts so the Motor Plug is pulled down evenly.
3. Tighten securely, but do not over-tighten.

The Motor Plug should be held firmly and evenly against the sealing surface.

If a bolt will not thread in

Do not force it.

If a bolt becomes difficult to thread:

1. Remove the bolt.
2. Check that it is not damaged.
3. Check the threaded hole for sand, salt or other debris.
4. Make sure the Motor Plug is sitting flat.
5. Try cleaning the thread with a cotton swab.
6. Re-start the bolt carefully by hand.

If the bolt still will not thread smoothly, contact Foil Drive Support before applying additional force.

If the thread has been damaged

If a securing bolt has been cross-threaded or the thread has been stripped, do not continue forcing the bolt into the damaged thread.

Some damaged threads can be repaired using a Helicoil/thread insert repair, which replaces the damaged thread with a new threaded insert.

A qualified technician or machine shop can assess the damage and determine whether a thread repair is appropriate.

Before repairing the thread

A bolt that will not thread may not necessarily have a damaged thread.

Debris such as sand or salt can prevent the bolt from engaging correctly. Always check and clean the thread before assuming it requires a repair.

A suitable bottoming tap can also be used by a suitably experienced technician to gently clean an existing thread. It should not be used to cut a new thread or enlarge the hole.

Saltwater maintenance

Foil Drive systems are commonly used in salt water, so regular cleaning and maintenance of the securing bolts and threads is important.

Stainless steel bolts installed into aluminium components can experience dissimilar-metal corrosion if left assembled for extended periods, particularly in a saltwater environment.

To reduce the risk of corrosion and seized bolts:

• Rinse the system with fresh water after saltwater use.
• Remove and clean the securing bolts periodically.
• Inspect the threads for corrosion, salt or debris.
• Lubricate the bolts as recommended.
• Do not leave the system assembled and unrinsed for months at a time.

Regular maintenance helps prevent bolts from seizing and makes future removal much easier.

Remember

Straight → Finger-tight → Check → Tighten

If the bolt does not start easily by hand, stop and investigate rather than forcing it.

Incorrect installation, particularly starting a bolt at an angle, can strip the thread and damage the unit.