MAINTENANCE

A well maintained Aqua-Cycle™ can last for 20+ years

Rental operators should follow these lubrication and maintenance guidelines to keep their Aqua-Cycles™ properly maintained for customer safety, highest profits and the least amount of downtime.

For more detailed information about specific maintenance or parts, please fill out the information below or contact our office at CustomerService@aquacycles.com or call 800-970-2688 (International +1.714.970.2688).

We are available to answer any questions and help you to best maintain your Aqua-Cycles™ for even longer life and better riding experiences.

REQUEST REPLACEMENT PARTS

SAFETY

Never allow Aqua-Cycles™ to be used without…

1. Fork guard properly installed!
2. Belt guard properly installed!

This is for the protection of the users and equipment. If you have a question about safety, please contact our office.

Bearing Blocks & Maintenance (Part BBRK)

All Aqua-Cycle™ bearing blocks (black pillow blocks that hold the pedal crank and rear axle onto the frame) should be replaced every 200 hours of use. Failure to replace the bearing blocks as recommended will cause stress and irreversible damage to the pedal crank and rear axle as these parts rotate.

Worn pedal crank and rear axle bearing blocks cause stress damage to the parts.  With each rotation the damage accumulates. Eventually the pedal crank and/or rear axle will break near the center plate that holds the gear. Do not rely upon your ability to SEE when the bearing blocks are worn and need replacing. By the time you can see it, there already has been irreversible damage to both the pedal crank and rear axle.

PROTECT YOUR AQUA-CYCLEs™ AND THE SAFETY OF YOUR RIDERS BY REPLACING THE BEARING BLOCKS AS SPECIFIED ABOVE.

Weekly Maintenance

Grease all pedal crank and rear axle bearing blocks to keep your Aqua-Cycles™ running smoothly and reduce wear to the parts. Grease fittings are located on each bearing.  Some are covered by the plastic belt guard and can can be greased through the access holds in the belt guard or by temporarily removing the plastic belt guard for access. Never operate the Aqua-Cycle™ with the belt guard removed.

To grease the Aqua-Cycle™, flip it over so it is resting on the handle bar and top of the seat back. This way the wheels are free to turn and you have easy access to the grease fittings.

Use a high-quality marine grease. Force enough grease into the bearing blocks so a little comes out the sides. Rotate the pedal crank and rear axle to spread the grease around the bearing blocks before turning the Aqua-Cycle™ right side up. Wipe off any excess so it does not collect dirt or grease, or get onto the riders.

Never operate the Aqua-Cycle™ without the belt guard properly installed for the safety of your riders and protection of the Aqua-Cycle™.

See pedal crank and rear axle for alignment instructions when replacing bearing blocks.  Also, see Broken Pedal Crank or Rear Axle for more information related to bearing replacement.

A Bearing Replacement Kit is included in the SparePak (spare parts kit) ordered with your Aqua-Cycle or by ordering part BBRK.

Belt Maintenance (Part BRK27)

The belt should be tight, but not like a banjo string. There may be a small amount of variation in tightness as the pedal crank is rotated. This is normally caused by an off-center pedal crank gear or rear axle gear when mounted. Try reinstalling the gear(s) and rotate the part before reinstalling on the Aqua-Cycle™ to be sure it is properly centered.

Another cause of a loose belt is that the bearing blocks have not been replaced as specified for the model Aqua-Cycle™. It is important to replace the bearing blocks as recommended for the protection of the pedal crank and rear axle.

Clicking or Snapping Sound

This is usually an indication of very worn bearing blocks and will be corrected when both new pedal crank and rear axle bearing blocks are installed. If not, then you might try drilling new bearing mounting holes on the bearing brackets for the pedal crank or rear axle bearing blocks so the parts are moved farther from each other, causing the belt to be tighter. Do not over-tighten the belt. A belt that is too tight will cause the same damage to the pedal crank and rear axle as bearing blocks that are worn.

Sometimes a frame is damaged or torqued so the pedal crank and rear axle are out of alignment. Seldom can a repair be made to a frame damaged in this way.

Belt Guard Maintenance (Part: BGB)

The plastic belt guard fully covers the belt and gear area (drivetrain) of your Aqua-Cycle™ for the protection of your riders, keeping fingers and toes out of this area.

Never allow your Aqua-Cycle™ to be operated unless the belt guard is properly installed. Contact our office if you have any questions about the belt guard, its proper installation or other safety related issues.

Front Fork Maintenance (Part FRK)

The front fork is mounted to the frame by a ‘fork pin” which rotates inside of two fork bushings. The top and bottom of the fork pin should be periodically lubricated with WD-40 or silicone lubricant. Turn the fork while spraying so the lubricant can run down the pin and be spread from side to side. Lubricating the fork pin keeps wear to a minimum and the fork from squeaking.

Fork bushings should be checked annually and replaced when wear is noticeable. Be sure there is enough shoulder on each fork bushing to keep the aluminum fork and fork pin from rubbing against the neck, causing wear to those parts.

Check the welds on the fork and fork legs, especially at the lower cross brace point, to be sure there are no cracks developing.

Be sure that the nuts and bolts are secure, holding the fork pin in place.

Check the frame neck assembly and gussets to be sure that the welds are holding securely.

A fork guard should be on all Aqua-Cycles™. The fork guard encloses the turning area of the fork to protect fingers and hands from getting into the fork turning area of the Aqua-Cycle™.

Never allow your Aqua-Cycle™ to be moved or operated unless the fork guard is properly installed. Contact our office if you have any questions about the fork guard, its proper installation or other safety related issues.

Fork Guard (Part FGK)

A fork guard kit is available for all Aqua-Cycle™ models. It encloses the turning area of the fork to protect fingers and hands from getting into the fork turning area of the Aqua-Cycle™.

Never allow your Aqua-Cycle™ to be moved or operated unless the fork guard is properly installed. Contact our office if you have any questions about the fork guard, its proper installation or other safety related issues.

Front Wheel & Maintenance (Part FWK)

Inspect the front wheel for cracks along the center seam. Check that the wheel plugs are properly installed.

Check that the wheel is centered between the fork legs without potential of the wheel rubbing on one or the other leg. If off-center, possibly the wheel has “slid” on the center tube so more tube is sticking out one side than the other. If so, remove the wheel, saw off the excess tube on one side and reassemble the wheel onto the fork. If spacing is needed between the wheel and fork leg, add stainless steel washers between the fork leg and the hex nut.

The wheels are made of polyethylene plastic. This makes them impervious to most kinds of damage. However, it also makes them hard to repair if damage exists. To patch or seal a crack in the front wheel, use clear GE Silicone II Caulking.

Carefully clean off all sand, oil, dirt, moisture and salt before applying the caulking. Sometimes it is necessary to carefully cut or trim away some of the material in the crack or hole to be repaired.  Only apply caulking to a dry and clean surface. Force caulking well into the crack or hole so it adheres not only to the outside surface, but also to the inner surface of the area being patched or repaired.

Once the repair is finished, let the caulking cure for 72 hours before putting the Aqua-Cycle™ into service.

Front Wheel Axle (Part FWAK)

The front wheel axle is a stainless steel rod that goes through the middle of the front wheel and attaches on each side to a fork leg. Two bushings are inserted into the front wheel center aluminum tube. The axle slides through the bushings. Hex nuts are tightened (carefully) against those bushings before the axle with wheel are attached to the fork legs. Mount the front wheel with axle installed onto the fork legs. Install the lock nuts onto the axle that extends through the fork legs.

Be sure the bushings have not been forced into the center aluminum tube, damaging it. Be sure the outer lock nuts are tight, holding the folk legs firmly against the inner hex huts.

Pedal Crank & Maintenance (Part PCRK)

“My pedal crank broke. Why?” CLICK HERE for more information.

Lubricate the bearing blocks weekly as described on this page under BEARING BLOCKS & MAINTENANCE.

The rest of the pedal crank maintenance is relatively simple as long as the bearing blocks are replaced as recommended and the pedal crank has been properly installed.

Check that a locking collar is installed on each end of the pedal crank and on the outer side of the bearing blocks.  They will keep the pedal crank from sliding sideways, which causes belt alignment problems with the rear axle gear. If misaligned, the belt can be severely damaged.

If the belt guard has been removed, reinstall the belt guard before use.

Never allow the Aqua-Cycle™ to be operated without the belt guard properly installed, for the safety of your riders and protection of the Aqua-Cycle™.  Contact our office if you have any questions about the belt guard, its proper installation or other safety related issues.

Pedals & Maintenance (Part PRK)

Pedals are held onto the pedal crank by stainless steel screws. Periodically check to be sure the pedal screws are tight.

Aqua-Cycle™ pedals are larger than regular pedals to be more comfortable for bare feet, but because of their larger size they need to be checked from time to time.

A Pedal Replacement Kit is included in the SparePak (spare parts kit) ordered with your Aqua-Cycle or by ordering part PRK.

Rear Axle Maintenance (Part RARK)

“My rear axle broke. Why?” CLICK HERE for more information.

Lubricate the bearing blocks weekly as described on this page under BEARING BLOCKS & MAINTENANCE.

The rest of the rear axle maintenance is relatively simple as long as the bearing blocks are replaced as recommended for this specific model Aqua-Cycle™.

Check that the axle collars are tight against the inside edge of the side axle bearing blocks.  This will keep the axle in alignment with the pedal crank gear and not allow it to slide sideways. If misaligned, the belt can be severely damaged.

If the belt guard has been removed, reinstall it before use.

Never allow the Aqua-Cycle™ to be operated without the belt guard properly installed for the safety of your riders and protection of the Aqua-Cycle™.  Contact our office if you have any questions about the belt guard, its proper installation or other safety related issues.

Rear Wheel & Maintenance (Part RWK)

The wheels are made of polyethylene plastic. This makes them impervious to most kinds of damage. However, it also makes them hard to repair if damage exists.

If water is getting into a rear wheel, most often it is coming in through small, almost invisible cracks in the center mounting area of the wheel. Remove the wheel from the rear axle, remove the wheel hubs and inspect the inner parts of the wheel. Look for hairline cracks or damage around or inside the bolt mounting holes.

If damage is found or suspected, clean off all sand, salt, dirt, moisture and oil, and remove any loose plastic. Scuff and scar the common surfaces of the wheel and hub that touch when assembled. Put clear GE Silicone II caulking around each bolt hole, over the small cracks and into the center axle hole.

Apply the caulking like toothpaste. Don’t spread it around. When the hub is inserted into the rear wheel, and the wheel is re-installed onto the axle, the caulking will spread around to cover the surfaces. After the wheel is re-installed on the Aqua-Cycle™, let the caulking cure for at least 72 hours before putting it into the water.

Cracks in the center mounting area of the wheel are usually a result of over tightening the bolts when assembling the Aqua-Cycle™. Over-tightening squeezes the plastic together and crushes the wheel center area. The nuts on the bolts should be snug, but not tight.

If a crack is found along the outside center seam of the rear wheel, clean off all sand, salt, dirt, moisture and oil, and remove any loose plastic. Use clear GE Silicone II caulking, forcing it into the crack. Let it cure for 72 hours before putting the Aqua-Cycle™ back into the water.

Seat Straps & Maintenance (Part SRK)

Check the seat straps to be sure they are tight and that they do not show signs of weathering or cracking. Typically seat straps are replaced annually.

Four Seat Straps are included in the SparePak (spare parts kit) ordered with your Aqua-Cycle or by ordering part SSP.

Broken Pedal Crank or Rear Axle – Why?

99% of broken pedal cranks and rear axles fall into one of two categories:

1. Cycling on Land or while Barely Floating

A broken pedal crank or rear axle may be a cumulative result of people trying to pedal the Aqua-Cycle™ while on land (on the shore or just barely floating) rather than when it is free-floating in the water, or when it is setting on something like a sandbar and the people attempt to pedal off of the sand bar.

Even if a rider pedals while being pushed into the water, irreversible and accumulating damage is done to the pedal crank, rear axle, frame and belt. Fatigue and reverse stress damage will accumulate in the parts until they finally break.

The Aqua-Cycle™ is not designed as a land vehicle. It is specifically a water vehicle and should be treated as such.

2. Bearing Blocks Maintenance

Another and more common cause of a broken pedal crank or rear axle is if the Aqua-Cycle™ bearing blocks have not been consistently replaced as recommended. Some rental locations can accumulate great amounts of wear in less than a month due to high volume of rentals. Other locations have far less Aqua-Cycle™ rentals and the recommended bearing replacement more closely matches a season period.

In the Assembly Instructions that came with the Aqua-Cycle™ and on the red CAUTION plate mounted on the Aqua-Cycle™, we define how often the bearing blocks should be replaced. If you are in doubt, replace all bearing blocks every 200 hours of use. How often that limit is reached is based upon your usage. Only you can determine how often the bearing blocks should be changed because it is based upon actual usage. If not replaced as necessary, fatigue and reverse stress damage will accumulate in the pedal crank, rear axle, frame and belt which will eventually cause the parts to break and require expensive replacement.

The bearing replacement kit is much less expensive than a replacing a pedal crank or rear axle, and less costly than the lost revenue from an out-of-service piece of rental equipment.

For example: if you only charge $15 per hour (the average is $40 per hour) 200 hours of rental at $15 is a whopping $3,000 income. Why skimp and damage the Aqua-Cycle™ parts by not replacing the bearing blocks as recommended to keep your the Aqua-Cycles™ in good working condition and profitable?

What Causes Pedal Crank and Rear Axles to Break?

The bearing blocks keep the pedal crank and rear axle in a straight line horizontally and vertically. If the bearing blocks are too worn, as little as a 1/32nd of an inch or more all around, the pedal crank and rear axle will bow ever so slightly toward each other with each rotation or when the Aqua-Cycle™ is pedaled. In addition, a vertical bow will happen at the same time. As the pedal crank and axle rotate in those bowed positions, reverse stress damage occurs and the metal begins to fatigue – just like when you twist a paperclip around and around until it breaks. The damage accumulates most where the gear plate is welded to the rod. Eventually enough damage accumulates to break the metal.

The longest bearing blocks should go without replacement, meaning when there is enough wear to permit a significant bow, is at or before 200 hours of use.

Replacing the bearing blocks later (such as at 250, 300, 400, etc. hours of use) will not “heal” the damage that has begun to accumulate. Eventually a damaged pedal crank and rear axle will break. If you replace the worn out bearing blocks at some extended point, its life will be extended a while longer, but never ‘healed”.

If you have any questions about how often bearing blocks should be replaced, whether all or just some could be replaced or about what the recommended bearing blocks replacement point is for your model Aqua-Cycle™, contact our office. We, along with you, want your Aqua-Cycles™ to have a very long and profitable lifetime.