head disassembly:
1. Remove both threaded caps.
2. Pull out the rubber grommets and the plastic part behind each one. Note: It will help if you twist the gray collar with the arrows printed on it each way because this will push out the rubber and plastic pieces slightly. If necessary, slap the pump against your hand to get them out or if really necessary, use a tool to pull them out. Take note as to how the parts were oriented. Also, you will find that the rubber grommets are the same as each other but were installed backwards from each other.
3. Now the head will easily slip off because it was the plastic parts you already removed that were holding the head on. If you want, you can dig out the rubber grommet on the gray collar but this shouldn't be required.
4. During reassembly, be sure that the parts go back inside in the same orientation as they came out. The rubber grommet over the shrader plastic piece will have the big hole facing outwards whereas the rubber grommet over the presta plastic piece will have the small hole facing outwards.
body disassembly:
1. Unscrew the gray plastic tube from the gray collar. Be careful because inside the gray collar is a small rubber disc that is the one-way valve. If you lose this part, the pump won't work properly. There's an o-ring inside the gray collar also, but you should never need to replace it.
2. Unscrew the black thread ring from the black tube. This will expose the large piston o-ring if you extend the pump all the way.
3. This next part is a little trickier. Unscrew the gray piston from the gray tube. You may need pliers to be able to get a good enough grip on the piston but be careful not to damage it. You can now remove the gray tube and you will see the small piston with an o-ring.
4. It’s possible to unscrew the small piston from the small aluminum tube but it unnecessary. You already have good enough access to replace o-rings and/or give the pump a thorough cleaning.
5. Reassembly is opposite. If only using your fingers, tighten the gray piston to the gray tube as much as possible. If using a tool, be gentle. To install the one way valve rubber disc, hold the head upside down and drop the rubber disc into the center of the gray collar. Look inside and make sure that the rubber disc is centered and laying flat. Then, while still holding the head upside down, screw down the gray tube. It's important that the rubber disc stays in the center of the gray collar until the gray tube is tight.
disassembly of the switch.
1. We don't recommend you do this because reassembly is tricky and the decal will lose some adhesion…but if you insist: Remove the decal from the end of the Air Switch. You may find it necessary to use a sharp object in order to pry under the edge of the decal. Keep the decal clean.
2. Remove the black plastic bow-tie shaped spring from inside the Air Switch. Unscrew to remove the Air Switch. Inside you will find an o-ring.
reassembly:
1. Screw in the new Air Switch until it just barely begins to feel like it's making contact inside and then loosen the Air Switch about 1/8 of a turn.
2. Drop the black bow-tie shaped spring into the Air Switch.
Test to be sure that it works. Be sure to keep the bow-tie spring from falling out during this test. If you did everything correctly, then the Air Switch should click into two positions, one of which will cause the pump to pump a lot of air, the other to pump a little air. If not, start over with step 1 of Reassembly. Then, re-apply the decal.
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