Copyright © 2010-2012 Aquatic Adventures International, Inc Phone:800.970.2688
A well maintained Aqua-Cycle will last for many years.
Rental operators should follow these lubrication and maintenance guidelines every week to keep their Aqua-Cycles properly maintained for customer safety, highest profits and the least amount of down time.
SAFETY - Never allow Aqua-Cycles to be used without the fork guard and belt guard properly installed for the protection of the users and equipment. If you have a question about safety please call our office. Click on a link for more information.
BEARINGS & Maintenance
All Aqua-Cycle bearings (black pillow blocks that hold the pedal crank and rear axle onto the frame) should be replaced every 200 hours of use for AC4 and AC5 models and every 100 hours of use for an AC3 model. Not replacing the bearings frequently enough will cause stress to the pedal crank and rear axle as these parts rotate. With worn bearings each rotation of the pedal crank and rear axle causes stress to the parts which 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 bearings are worn and need replacing. By the time you can see it there already has been irreversable damage done to the pedal crank and rear axle.
PROTECT YOUR AQUA-CYCLE AND THE SAFETY OF YOUR RIDERS BY REPLACING THE BEARINGS AS SPECIFIED ABOVE.
WEEKLY - Grease all pedal crank and rear axle bearings to keep your Aqua-Cycle running smoothly and reduce wear to the parts. Grease fittings are on each bearing, however some are covered by the plastic belt guard. These fittings 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 gives you easy access to the grease fittings.
Use a high-quality marine grease. Force enough grease into the bearings so a little comes out the sides. Rotate the pedal crank and rear axle to spread the grease around the bearings 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 bearings.
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All Aqua-Cycle bearings (black pillow blocks that hold the pedal crank and rear axle onto the frame) should be replaced every 200 hours of use for AC4 and AC5 models and every 100 hours of use for an AC3 model. Not replacing the bearings frequently enough will cause stress to the pedal crank and rear axle as these parts rotate. With worn bearings each rotation of the pedal crank and rear axle causes stress to the parts which 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 bearings are worn and need replacing. By the time you can see it there already has been irreversable damage done to the pedal crank and rear axle.
PROTECT YOUR AQUA-CYCLE AND THE SAFETY OF YOUR RIDERS BY REPLACING THE BEARINGS AS SPECIFIED ABOVE.
WEEKLY - Grease all pedal crank and rear axle bearings to keep your Aqua-Cycle running smoothly and reduce wear to the parts. Grease fittings are on each bearing, however some are covered by the plastic belt guard. These fittings 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 gives you easy access to the grease fittings.
Use a high-quality marine grease. Force enough grease into the bearings so a little comes out the sides. Rotate the pedal crank and rear axle to spread the grease around the bearings 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 bearings.
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BELT & BELT TENSIONER Maintenance
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 the pedal crank gear or rear axle gear not being centered 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 bearings have not been replaced as specified, every 100 hours of use for AC3 model and every 200 hours of use for AC4 & AC5 models. It is important to replace the bearings as recommended for the protection of your pedal crank and rear axle.
CLICKING or SNAPPING SOUND - This is usually a case of very worn bearings and will be corrected with new bearings . If not, then you might try drilling new mounting holes on the bearing brackets for the pedal crank or rear axle so that part is moved farther from the other, causing the belt to be tigher. 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 bearings 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.
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BELT TENSIONER - We have a tensioner for AC3 model and one for AC4 & AC5 models that will help keep the belt tight as the pedal crank is rotated. A tensioner is not the best fix, but can help reduce the problem of a belt snapping or jumping on the gear.
Watch for loose strands of fiber extending out the sides of the belt. Keep any fiber strings trimmed so they do not get caught in the gears or bearings.
Never operate the Aqua-Cycle without the Belt Guard properly installed for the safety of your riders and protection of the Aqua-Cycle.
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BELT GUARD Maintenance
The plastic belt guard fully covers the belt and gear area (drive train) of your Aqua-Cycle for the protection of your riders, to help keep fingers and toes out of this area.
Never allow your Aqua-Cycle to be operated unless the belt guard is properly installed. Please call our office if you have any questions about the belt guard or other safety related issues.
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FRONT FORK Maintenance
A Fork Guard is available for all Aqua-Cycle models. It covers the turning area of the fork to protect fingers and hands from getting into the turning area of the Aqua-Cycle.
The top and bottom of the fork pin should be 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 squeeking.
Fork Bushings should be checked annually and replaced when wear is noticeable. Be sure there is enough shoulder on the fork bushings to keep the fork from rubbing against the neck, causing wear to that aluminum part.
Check the welds on the fork, especially at the lower 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 neck assembly and gussets to be sure that the welds are holding securely.
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FORK GUARD Maintenance
A fork guard is available for all Aqua-Cycle models. It encloses the turning area of the fork to protect fingers and hands from getting into the turning area of the Aqua-Cycle.
Order yours today and never allow your Aqua-Cycles to be used without a fork guard properly installed.
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FRONT WHEEL & Maintenance
Inspect the front wheel for cracks along the center seam. Check that the drain plugs are properly inserted.
Check that the wheel is centered between the fork legs without risk of rubbing on one 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 betwen 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. If you need to patch or seal a crack in the front wheel, use GE Silicone II caulking. Be sure to carefully clean off all sand, oil, dirt, moisture or salt before applying the caulking. Once the repair is done, let it dry and cure for 72 hours before putting the Aqua-Cycle into the water.
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FRONT WHEEL AXLE - The axle is a stainless steel rod that goes through the middle of the front wheel and connects to the fork legs. There are two bushings inserted into the aluminum tube located in the center of the front wheel. The axle slides through those bushings and hex nuts are tightend (carefully) against those bushings before the fork legs are attached. Mount the wheel and axle onto the fork legs. Install the lock nuts on 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.
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PEDAL CRANK & Maintenance
Lubricate the bearings weekly as described on this page under BEARINGS.
The rest of the pedal crank maintenance is relatively simple as long as the bearings are replaced on schedule. For AC3 Aqua-Cycles the bearings should be replaced every 100 hours of use and for AC4 & AC5 models every 200 hours of use.
My pedal crank broke. Why? Click here.
Check that there is one locking collar at each end of the pedal crank. These keep the pedal crank from sliding sideways, a cause of alignment problems with the rear axle gear.
Never operate the Aqua-Cycle without the Belt Guard properly installed for the safety of your riders and protection of the Aqua-Cycle.
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PEDALS & Maintenance
Pedals are held onto the pedal crank by stainless steel screws. Periodically check to be sure the pedal screws are tight.
These large Aqua-Cycle pedals are more comfortable than the typical paddle boat pedals, but because of their larger size they need to be checked from time to time.
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REAR AXLE Maintenance
Lubricate the bearings weekly as described on this page under BEARINGS.
The rest of the rear axle maintenance is relatively simple as long as the bearings are replaced on schedule. For AC3 Aqua-Cycles the bearings should be replaced every 100 hours of use and for AC4 & AC5 models every 200 hours of use.
My Rear Axle broke. Why? Click here.
Check that the axle collars are tight against the inside edge of the side axle bearings to keep the axle in alignment with the pedal crank gear. If misaligned, the belt can be severely damaged.
Never operate the Aqua-Cycle without the Belt Guard properly installed for the safety of your riders and protection of the Aqua-Cycle.
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REAR WHEEL & Maintenance
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 you are getting water in the wheels, 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 the bolt mounting holds.
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 tooth paste. Don't spread it around. When the hub is inserted into the wheel the caulking will spread out to cover the surfaces. After the wheel is reinstalled on the Aqua-Cycle, let the caulking dry and 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 tighening the bolts when assembling the Aqua-Cycle. Overtightening squeezes the plastic together and crushes the wheel center area. The nuts should be snug, but not tight.
If a crack develops along the outside center seam of the wheel, use GE Silicone II caulking, forcing it into the crack and letting it cure before putting the Aqua-Cycle into service. Be sure to carefully clean away any dirt, salt, oil, moisture or sand from the crack before applying the caulking.
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SEAT & STRAPS Maintenance
Check the seat straps to be sure they are tight and that they do not show signs of weathering or cracking. Most often it is desirable to have the seat in the forward most position on the frame so riders can more easily reach the pedals.
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BROKEN PEDAL CRANK OR REAR AXLE - Why?
99% of broken pedal cranks and rear axles fall into one of two categories:
1) It can be a result of people trying to pedal the Aqua-Cycle while on land (on the beach or just barely in the water) rather than when it is free-floating in the water, or when it is setting on a sand-bar and the people attempt to pedal off of the sand bar.
Even if a rider pedals while being pushed into the water, irreversable damage can occur to the pedal crank, rear axle, frame and belt. Fatigue of the parts occurs and it accumulates until the part(s) 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) Another and more common cause is if the Aqua-Cycle has been used more than 200 hours for AC4 and AC5 models (100 hours for AC3 model) and the bearings have not been replaced. Some rental locations can accumulate 200 hours in just 25 days if used an average of 8 hours per day. Most locations accumulate 200 hours of use in just 2 months of rentals. OIthers do it in 3-4 months.
In the Assembly Instructions and on a red CAUTION plate mounted on the Aqua-Cycle, we make clear that there is a need to replace the bearings every 200 hours (or 100 hours for AC3) of use. How often that limit is reached is based upon your usage. Only you can determine how often the bearings should be changed.
The bearing replacement kit is much less than a replacement pedal crank or rear axle.
Keep in perspective that if you are charging $15 per hour, 200 hours of rental is $3,000 income . You can easily afford to replace the bearings as needed to keep the Aqua-Cycles profitable and in good working condition.
Here is a more detailed explanation of what causes these parts to break:
The bearings keep the pedal crank and rear axle in a straight line from side to side as well as up and down. If there is too much wear, 1/16th of an inch or more, the pedal crank and rear axle bow ever so slightly toward each other as the Aqua-Cycle is pedaled. In addition, an up and down bow will happen in the same situation. As the pedal crank and axle rotate in those bowed positions, reverse stress occurs and the metal begins to fatigue - just like twisting a paperclip around and around until it breaks. The stress accumulates in the center where the gear plate is welded to the bar. Eventually enough fatigue accumulates to break the metal.
The limit in bearing wear, when there is enough wear to permit a significant bow, occurs around 200 hours of use for AC4 & AC5 models (100 hours for AC3 models). From that point on the metal is damaged by the reverse stress and unnecessary fatigue accumulates. Replacing the bearings later (250, 300, 400, etc. hours) will not "heal" the damage that has begun to accumulate. Eventually a pedal crank and rear axle that is damaged by excessive bearing wear will break. If you replace the worn out bearings at some extended point the life of the damaged part(s), its life will be extended a while longer.
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