First, read the complete instructions before beginning
the repair. I know this is against all natural instincts, but grit
your teeth and do it anyway.
The repair should be made while the pump is resting
on its side. This will keep the glue from dripping on the pump handle
or running down the pushrod and permanently gluing the pushrod to
What you will need to make the repair:
You will need some means of cutting the pushrod. I
recommend a hacksaw with a 24-tooth blade.
You will need a small can of PVC cement marked REGULAR
CLEAR. We use Oatey brand available in Home Depot, Lowes, or most
hardware stores, but any brand will work.
You will need some paper towels and a tissue. You
will need a thin pole or coat hanger.
Put some newspaper on your work surface and be careful
with the glue. It will permanently damage most plastic surfaces.
Now to the repair:
First remove the three screws located under the handle.
Put the screws in a safe place, as they will be used again.
Remove the handle and pushrod assembly from the pump
base assembly, and set the base assembly out of the way.
Make a pencil mark on the pushrod at a point 3/4 inches,
19 mm, from the bottom of the top assembly.
Cut the pushrod at the pencil mark. Make the cut as
square as possible. This is not critical but the squarer the better.
Remove the broken handle and set it aside.
Next, remove all the plastic chips from the cut ends
of the pushrod with a knife or similar sharp instrument. Blow out
the plastic chips from the top assembly.
Take a tissue and stuff it in the piston end of the
pushrod. Using a long thin pole or straightened coat hanger, push
the tissue until it exits the pushrod at the cut end. This will
remove all of the plastic chips from the pushrod.
Now is the time to clean the piston and piston seal,
following the instructions included with the provided grease.
For the next two steps you will need the new handle,
the top assembly, the provided coupling, and the pushrod,
Place the new handle on the pushrod and slide it to
the piston. Be sure the handle is facing in the proper direction
on the pushrod. The top of the handle should face away from the
NOTE, You must do the next two steps quickly as the
PVC Cement dries very fast. When applying the cement, the cement
thickness should be more than a thin film but not so much that it
runs or drips.
Apply a small amount of PVC Cement around the inside
of one end of the provided coupling, and, with a twisting motion,
immediately push the glued end of the coupling over the short piece
of pushrod extending from the bottom of the top assembly. The coupling
should touch the end of the top assembly.
Is the handle in the proper position on the pushrod?
The top of the handle should face away from the piston.
In a similar fashion, apply a small amount of PVC
Cement around the inside of the other end of the coupling, now attached
to the top assembly, and, with a twisting motion, immediately push
the coupling over the end of the pushrod. Push the coupling as far
on the pushrod as it will go, about 1 inch, 25.4 mm.
While the glue is drying, clean the pump tube and
be sure to remove the bits and pieces of stuff from the bottom of
the tube. Apply a small amount of the provided grease to a paper
towel or cloth and wipe the inside of the tube with the grease.
Use the grease sparingly, as a little bit goes a long way.
Put the piston in the cleaned large tube by inserting
one edge of the piston in the tube at an angle while holding the
pushrod at an angle to the large tube. Straighten the pushrod such
that the piston tips into the tube until the pushrod is in line
with the tube. This will prevent the piston seal from jamming in
Allow the glue to dry for an hour or two and your
pump repair will be complete.
If you have any questions or problems contact me via
email at email@example.com, or by telephone at +1-518-765-4585
and I will try to help.