Annual Service

Annual Service Guide
1 Dive Xtras Inc. 4433 Russell Rd, Ste 106, Mukilteo, WA, 98275 USA 425 493-9600, info@dive-xtras.com, www.dive-xtras.com
Annual Service Below is a picture of the items that are in an annual service kit. Please double check you have the items listed below:
Everything you need to perform (or replace in your spare kit) your annual service. 1 * Face seal body o-rings - (2-261) 1 * Barrel seal body o-rings - (2-263) 1 * Rear shaft seal - (010-1008) 1 * Retaining ring for rear seal - (010-1314) 1 * Dowel Pin - (010-1315) 10 * Clutch washers - (010-1309) 1 * Counter sunk prop screws - (M5-12-FHSCS)
O-Rings
Counter Sunk Prop Screw
Rear Shaft Seal
Retaining Ring Rear Shaft Seal Dowel Pin Clutch Washers
Figure 1. Annual Kit
2 Dive Xtras Inc. 4433 Russell Rd, Ste 106, Mukilteo, WA, 98275 USA 425 493 9600, info@dive-xtras.com, www.dive-xtras.com
Performing Annual Service

Step 1. Check Scooter The following steps will take you through replacing the essential items on your XScooter; however you should use this opportunity to check your whole X-Scooter. 1. Give the X-Scooter a thorough cleaning, especially where the o-rings are. 2. Check all the fasteners are tight and in place, particularly the two screws under the handle, and the M8 on the nose holding the D-Ring. Careful not to over tighten screws. 3. Check all the electrical connections (inc. fuse) are clean and corrosion fee. Clean as necessary. 4. Look for corrosion on the X-Scooter, if there is a lot, clean it up and consider your rinsing regime for the next year. 5. Check the reed switch position, and that the reed switch is secure.
Step 2. Replace O-Rings Place the tail of the X-Scooter on the work bench. Remove old barrel (2-261) and face O-rings (2-263). Discard. Select new O-Rings (see tip below). Lightly lubricate and replace. Barrel O-Ring first, followed by Face O-Ring. Do Not roll on!!!
Tip: Selecting the barrel vs. the face o-ring. Place both o-rings in your hands. Stretch out O-Rings. The barrel O-ring is slightly smaller one. The face O-ring is the larger one.
Step 3. Remove Pitch Adjustment Knob Flip X-Scooter tail over, placing it down on the motor. Using a #2 Phillips screwdriver, remove sheet metal screw from pitch adjustment knobs. Remove the pitch adjustment knob.
Step 4. Remove Outer Hub. Remove the 3 Sheet Screws from the outer hub.
Step 5. Remove Propeller Blades Lift loosened propeller system off using the pitch adjustment screw. The outer hub and three propeller blades should come off exposing the M5 propeller screw.
M5 Prop Screw
Step 6. Loosen Prop Screw Using a 3mm hex Allen key. While holding the inner hub with your left hand, (through the shroud) loosen the prop shaft M5 screw (counter clockwise). Ensure you use the correct Allen wrench and it fits tightly, If this screw becomes stripped it is very hard to remove
Step 7. Remove Old spring Stack Carefully remove M5 Screw, Washer and Bellville washers. Count how many Bellville washers there were. If there has been some corrosion these items may take a little force to remove. Discard the M5 screw and Bellville washers.
Step 8. Remove Inner Hub Remove Inner Hub
Step 9. Remove Clutch Plate Remove clutch plate. Carefully pry it up with a flat screw driver if needed. Make sure you protect your X-Scooter with foam or some other padding if you pry it off, so as not to damage your tail cone.
Step 10. Remove Old Dowel Pin Remove SS dowel pin and discard
Step 11. Remove Old Retaining Ring and Discard You should now see the Shaft seal, seal retaining ring and motor shaft. Using a retaining ring pliers remove retaining ring and discard.
Motor Shaft
Retaining Ring Rear Shaft Seal
Step 12. Remove Old Shaft Seal and Discard, Part 1 Remove top half of shaft seal (spring and washer) by grabbing as low as you can on the pump seal and pulling upwards. If the entire top half comes off then discard and move to step 12, otherwise remove the rest of the top half of pump seal, by carefully prying it up with a flat screw driver similar to step 12. Make sure you protect your X-Scooter with foam or some other padding so as not to damage your tail cone.
Step 13. Remove Old Shaft Seal and Discard, Part 2 Once you can see the white ceramic seal (lower half of the shaft seal), then carefully pry the lower half of the pump seal up. Slowly work the left and right side of the seal up. It may separate leaving the rubber boot in the well. Remove both the white ceramic seal and rubber boot and discard. Make sure you protect your X-Scooter with foam or some other padding so as not to damage your tail cone.
Step 14. Clean the area Clean area and prop shaft. Use clean cloth or Scotch Bright to clean surface stains on prop shaft.
Step 15. Install New shaft Seal, Part 1 Install lower half of the new shaft seal. Make sure the white ceramic seal is up. Dont get grease or dirt on white ceramic section.
Step 15. Install New shaft Seal, Part 2 Lube prop shaft with a small amount of 0il. Install top half of new shaft seal. Push all the way down firmly
Step 16. Install New Retaining Ring Install new retaining ring using retaining ring pliers. Do not over expand retaining ring. Slide down prop shaft until it fits into grove below SS Dowel hole in prop shaft.
Step 17. Install New Dowel Pin Insert new SS Dowel pin
Step 18. Install Clutch Plate Install lower clutch plate, lining up SS Dowel with grove in the bottom of the clutch plate.
Step 19. Install Inner Hub Install Inner hub
Step 20. Build new spring stack Build the spring stack from new Bellville spring washers on a hex wrench or screw driver. Bellville washers are like a small plate. They are slightly beveled. When the bevels faces each other they make a spring pair.
Single Spring
Spring Pair
To build your stack, put one Bellville washer on Hex wrench facing outward. Then put one spring pair on (two Bellville washers facing each other) at a time, until you have put on the same number of springs as you took off the X-Scooter.
Once all the Bellville washers are on the Hex wrench or screw driver, slide wrench end into prop shaft, allowing the Bellville washers to slide down onto prop shaft. The first Bellville washer should face down towards the inner hub,
Step 21. Install new screw Once Bellville washers are in place, Put the new M5 screw through the inset washer and then apply a small amount of medium strength Lock tight to the M5 prop screw.
Step 22. Compress springs Slowly tighten down prop screw ensuring the spring washers stay aligned. Use your fingers to press in washers that may extrude. Tip: Tighten down until washers begin to compress. Then remove shaft from propeller yoke. Put yoke in place. Insert the hex wrench through top of yoke. Continue to tighten down.
Step 23. Tighten Screw Hold the inner hub firmly with left hand while firmly tightening down the prop screw. Make sure the spring washers are compress tightly. (You may have to remove the yoke to see the spring washers if you used the tip)
Step 24. Install Yoke Screw shaft into the yoke until almost the bottom. Place yoke and shaft into place.
Step 25. Install Prop Blades Attach propeller blades individually. (They attach to the nubs on the yoke.)
Step 26. Install Outer Hub Put outer hub in place, pressing down, causing the propeller blades to rotate into place.
Step 27. Install Outer Hub Cont. Screw in 3 sheet metal screw. Secure firmly but do not over tighten. They are tightening into plastic stanchions.
Step 28. Install Pitch Adjustment Knob Put variable pitch knob in place. Tighten down sheet metal screw. The tighter the screw the harder it is to adjust.
Step 28. Final Testing The annual service is now complete. 1. You should verify that the prop pitch adjustment works and you can adjust it over the full range 2. Run the prop for a few seconds and check that it spins ok without significant wobble or hitting the shroud. 3. Lightly lubricate your new O-rings 4. Water tight test the X-Scooter as per the quick starts guide. (Remember you have swapped all the seals on the X-Scooter and may have made a mistake. 5. Go diving.
Contact Dive Xtras (info@dive-xtras.com) or your local X-men if you have encountered issues with any of this process.

Annual Service

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Annual Service Guide

Counter Sunk Prop Screw

Rear Shaft Seal

Retaining Ring Rear Shaft Seal Dowel Pin Clutch Washers

Figure 1. Annual Kit

Performing Annual Service

Step 8. Remove Inner Hub Remove Inner Hub

Retaining Ring Rear Shaft Seal

Step 19. Install Inner Hub Install Inner hub

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