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Big Game Prowler Install Page 2

INSTRUCTIONS

The LPW Kayak Power System is designed around a MinnKota Endura 30-34# thrust trolling motor because of easy availability, reasonable price, durability, reliability and power. This motor is readily available at Wal-Marts, K-Marts and also used at garage sales nationwide. IMPORTANT: More is not better...hull designs don't allow for faster speeds and you will just waste battery power with a larger motor.

INSTALLING MOTOR ON RUDDER/MOTOR MOUNT ASSEMBLY

STEP 1. Remove switch housing, handle and everything off the top of the motor. You should have 4 wires you've disconnected from the switch--black, red, yellow and white. DO NOT TUG OR PULL ON THESE WIRES.

STEP 2. Clamp motor shaft in a suitable vise or wood clamp. TAKE CARE NOT TO COMPRESS TOO HARD--THE SHAFT IS CARBON FIBER--YOU COULD BREAK IT.

STEP 3. Measure to cut length down in length. From center point of motor to cut point of shaft will be 18-20" length depending on your motor selection. Before making the final cut on the motor shaft, temporarily install the motor in plastic clamp and verify that it can go from the down position to the full up position without the prop hitting the tip of the rudder. If you have chosen to use a speed sleeve, slip the sleeve over the shaft and check the relationship of how it fits on the motor and that the bottom mount block will touch the top of the speed sleeve. Then make sure you have at least 1" of shaft (carbon fiber) above the top nylon mount block. (Mounting the motor we would like to keep the prop tip one inch below bottom of rudder.) Take a piece of masking tape and wrap around shaft squarely at edge of cut line.

STEP 4. Take a hacksaw blade and slowly cut just barely through the inside surface so as not to cut wiring inside shaft. Rotate motor shaft and start a new cut, always cutting on the top so that gravity holds wiring away from cut.

STEP 5. Once the cut is complete clean inside of hole. Tip up and tap to drain away any saw filings. (Use a Q-tip, do NOT use compressed air.) Holding motor upright (shaft down) take a small file and deburr the inside of the hole. This is important--you'll see why later.

STEP 6. You now have a short shaft with four wires protruding..white, yellow, black and red. Cut the female spade terminals off the red and black wires close to the terminal itself. Cut the white wire off about 6" above the carbon tube then cut the yellow one off about 8" from top of tube.

Slide the 5/8" heater hose over the wiring. Put a small amount of RTV (or bathtub caulking) all around the inside of the motor shaft and on the hose up about 3-½". Push and twist the heater hose down the shaft for at least 4 inches then wipe away excess silicone. This makes a watertight seal. Organize the hose so the natural curve of the hose points upward. Then wipe away excess silicone and set unit aside to cure for 1 hour. Using a good electrical tape wrap the joint about 1" each side of center. Solder the two pin connector to the red and black wires and apply the heat shrink. Insert the 3/8 diameter breather tube so the end comes out at the tip of the electrical connector. Put some silicone sealer in the hose and wrap the wires and hose with electrical tape all the way to the 2 pin connector.

STEP 7. Fold the rudder assembly open--find the 4 countersunk hoes in the motor mount. Install the 4 ½-20 2-½ inch long screws. Make sure that the heads are below the surface of the aluminum part. This is important due to the fact that these parts pass by each other. If the head is too high it will restrict movement or scratch the finish. Install the motor mount blocks over the ½-20 screws on the opposite side. Install washers and finger tighten nuts in position.

NOTE: The shaft on the MinnKota is 1.125" in diameter. If your shaft is smaller you will have to shim it with cut pieces of plastic milk jugs and/or wrap the area in several layers with a good electrical tape.

STEP 8. The shaft should stick up above the top of the motor mount bracket approximately 1" Firm the bolts but don't tighten them as you will need to make alignment adjustments as compared to the rudder. If you have finished the motor mount on the rear of the kayak proceed to Step 9.

STEP 9. Take the 2 D-shackles and install the steering cables on the steering yoke. Finger tighten or use your Leatherman tool. Looking straight down on top of the motor, align the motor case parallel to the rudder. Tighten the ¼-20 clamp bolts making the amount of exposed thread equal to each other. Tighten to 10 ft lbs torque. Don't over tighten as it will crush the nylon mounts.

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