O-Ring MaintenanceUpdated an hour ago
O-rings are an important part of your Foil Drive system. They create the seals that help keep water out of the electronics housing and motor connection.
For instructional video, see: O-Ring Care & Maintenance
Each system has three O-rings:
- Front O-ring – seals the nose cone to the electronics housing.
- Motor O-ring – seals the removable motor plug connection.
- Motor Cable O-ring - Seals the removable cable to the stator.
The front O-ring varies in size for the Gen2 Assist Slim. All other Gen2 and Gen2.5 systems use the same front O-Ring. The motor and cable O-ring is common across all systems.
Important: All O-rings must be correctly installed and in good condition before operating your Foil Drive system.
Gen2 Assist Slim Gen2 & Gen2.5
Keep Your O-Rings Clean
An O-ring can only seal correctly when it is clean and free from sand, salt, dirt and debris.
Sand is particularly common around the O-rings when the nose cone is removed at the beach. Wind can easily carry sand and debris into the O-ring groove.
Regularly inspect both O-rings and their grooves, particularly if you frequently remove the nose cone or motor.
Removing an O-Ring for Cleaning
If an O-ring needs to be cleaned:
- Use the O-ring pick tool supplied with your Foil Drive system.
- Carefully slide the pointed end underneath the O-ring.
- Gently lift the O-ring out of its groove.
- Clean the O-ring by pulling it through a clean cloth or paper towel to remove sand, dirt and grease buildup.
- Inspect the O-ring for damage, cuts, deformation or excessive wear.
Clean the O-Ring Groove
Don't forget to clean the groove where the O-ring sits.
If you find sand or debris in the groove, use a clean cotton bud or a small piece of paper towel to carefully remove it.
The groove should be completely clean before reinstalling the O-ring.
Reinstalling the O-Ring
Before reinstalling the O-ring, apply a small amount of Foil Drive Battery Grease to the O-ring and spread it evenly around its surface.
The grease helps lubricate the O-ring and allows it to sit correctly in the housing.
- Place the O-ring gently over the groove.
- Lightly tap around the O-ring with your finger, allowing it to naturally settle into the groove.
- Avoid forcing one section of the O-ring deep into the groove, as this can cause the O-ring to pull out or become unevenly seated.
- Use the flat edge of the supplied tool to gently push any remaining sections into position.
- Check that the O-ring is sitting evenly and is not twisted or protruding from the groove.
- Install the nose cone or motor plug to fully seat the O-ring.
Do not use excessive force when seating an O-ring. It should naturally settle into the groove when correctly positioned. If it is deformed, replace the O-ring before next use.
Motor O-Ring
The motor O-ring requires the same cleaning and maintenance process.
It may require more frequent cleaning if you regularly remove and install your motor, as sand, dust and debris can easily enter the connection area.
Each time you remove the motor:
- Inspect the O-ring.
- Remove any sand or debris.
- Clean the O-ring groove.
- Reapply a small amount of Foil Drive Battery Grease if required.
- Ensure the O-ring is correctly seated before installing the motor.
Don't Leave the Nose Cone Latched for Extended Periods
Avoid leaving the nose cone fully latched onto the unit for days, weeks or months at a time.
When compressed for extended periods, the O-ring can become temporarily deformed and lose some of its ability to spring back into its original shape.
If this happens:
- Remove the nose cone.
- Remove the O-ring.
- Allow the O-ring to rest without pressure for several days.
- Reinstall it once it has returned to its normal shape.
- If the O-ring remains deformed, it will need to be replaced before next use.
Important: Air Travel
Always remove the nose cone before transporting your Foil Drive system by air.
The O-ring creates a water-resistant seal, but it also creates an enclosed air space inside the housing.
At high altitude, changes in air pressure can cause the trapped air inside the sealed housing to expand. This can place unnecessary pressure on the housing and potentially damage your system.
Never fly with the nose cone latched onto your Foil Drive unit. Always travel with the nose cone removed.
Never Glue the O-Ring in Place
Do not use glue, adhesive, sealant or other products to permanently secure the O-ring in its groove.
The O-ring is designed to compress and move within its groove to create the correct seal.
Adding adhesive or other material to the groove can create a false seat and prevent the O-ring from compressing correctly when the motor plug or nose cone is installed.
If your O-ring is not staying in position, do not glue it in place. Remove it, clean the groove and O-ring, and reinstall it correctly.
If the O-ring is damaged or no longer seating correctly, replace it with a spare.
Always Check Both O-Rings Before Riding
Before operating your Foil Drive system, always check that all O-rings are correctly installed.
Front O-ring
☐ Correct O-ring for your system is installed
☐ O-ring is clean and undamaged
☐ O-ring is correctly seated in the groove
☐ Groove is free from sand and debris
Motor O-ring
☐ O-ring is installed before fitting the motor
☐ O-ring is clean and undamaged
☐ O-ring is correctly seated
☐ Motor connection is free from sand and debris
Cable O-ring
☐ O-ring is installed before connecting to the stator
☐ O-ring is clean and undamaged
☐ O-ring is correctly seated
☐ Plug connection on cable and stator are free from sand and debris
Never operate your Foil Drive system without all O-rings correctly installed.
If an O-ring is damaged, missing or no longer seating correctly, replace it before entering the water.
Proper O-ring maintenance is your responsibility and is an important part of safely maintaining your Foil Drive system.
Replacements can be purchased directly from the Foil Drive website or your local dealer.