Introduction

Over time, O-rings will wear out and your pump will begin to develop leaks. Some indicators of worn O-rings are low pump resistance while inflating tires, abnormal hissing when pumping, or a pump plunger jam.

Lift the rubber ABS hose cover to expose the ABS hose fitting. Turn the silver ABS hose fitting counter-clockwise until it fully unthreads. Remove the ABS hose from the pump.
  • Lift the rubber ABS hose cover to expose the ABS hose fitting.

  • Turn the silver ABS hose fitting counter-clockwise until it fully unthreads.

  • Remove the ABS hose from the pump.

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Pull the ABS hose cover off the pump by pulling it straight away from the pump. Flip the pump around and unplug the rubber cover on the outlet side of the pump. Remove the outlet cover the same way as the ABS hose cover.
  • Pull the ABS hose cover off the pump by pulling it straight away from the pump.

  • Flip the pump around and unplug the rubber cover on the outlet side of the pump.

  • Remove the outlet cover the same way as the ABS hose cover.

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Pull the pump plunger up until the silver cap is exposed.
  • Pull the pump plunger up until the silver cap is exposed.

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Use channel locks or pliers to grip the silver cap and turn it counter-clockwise until it is loose. We highly recommend using something soft, like an old inner tube shown in the picture, to protect the aluminum body from chipping or scratching. Be sure that the material you use won't slide on the polished aluminum. Continue turning the silver cap counter-clockwise by hand until it fully unthreads.
  • Use channel locks or pliers to grip the silver cap and turn it counter-clockwise until it is loose.

    • We highly recommend using something soft, like an old inner tube shown in the picture, to protect the aluminum body from chipping or scratching. Be sure that the material you use won't slide on the polished aluminum.

  • Continue turning the silver cap counter-clockwise by hand until it fully unthreads.

  • Pull the pump plunger out of the pump body.

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Locate the pump outlet cap on the pump body.
  • Locate the pump outlet cap on the pump body.

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Use channel locks or pliers to grip the pump outlet cap and turn it counter-clockwise until it is loose. Use the cushioning material from removing the silver cap to prevent damaging the pump body and outlet cap. Continue turning the outlet cap counter-clockwise by hand until it fully unthreads.
  • Use channel locks or pliers to grip the pump outlet cap and turn it counter-clockwise until it is loose.

    • Use the cushioning material from removing the silver cap to prevent damaging the pump body and outlet cap.

  • Continue turning the outlet cap counter-clockwise by hand until it fully unthreads.

  • Remove the pump outlet cap.

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Use your finger to remove the bump-stop O-ring from below the pump's outlet cap threads.
  • Use your finger to remove the bump-stop O-ring from below the pump's outlet cap threads.

  • Place a new bump stop O-ring into the pump.

    • The O-ring can be inserted into the other side of the pump body. As long as it is straight, the pump plunger will push it down to it's proper place.

    • Be sure the O-ring is not in any of the pump body's threads or it may become damaged during re-assembly.

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Replace the 3 O-rings on the ABS hose. Use a small flathead screwdriver to help pry the old O-rings off and stretch the new O-rings on. Replace the 3 O-rings on the ABS hose. Use a small flathead screwdriver to help pry the old O-rings off and stretch the new O-rings on.
  • Replace the 3 O-rings on the ABS hose. Use a small flathead screwdriver to help pry the old O-rings off and stretch the new O-rings on.

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Replace the two O-rings on the pump plunger using the same method as the previous O-rings. Replace the outlet cap O-ring using the same method as the previous O-rings.
  • Replace the two O-rings on the pump plunger using the same method as the previous O-rings.

  • Replace the outlet cap O-ring using the same method as the previous O-rings.

  • Re-assemble the pump by using these instructions in reverse.

    • Remember to not allow the thin bump stop O-rings to get caught in the threads of the pump body.

    • It is a good idea to apply a small amount of Loctite to the outlet cap during re-assembly to prevent the cap from vibrating loose.

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Finish Line

iRobot

Member since: 09/24/2009

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