When the Zephyr is cutting, it circulates cooling water to the blade in order to keep the diamonds cool. Over time, this water will become more and more contaminated with glass dust or fine particles of whatever material you are cutting. This finely ground glass powder is very abrasive, and eventually wears away the parts that it comes in contact with. You can extend the life of the saw components by taking a few simple steps.
UNPLUG SAW FIRST!!!!!
1. Keep the saw clean.
After use, it is advisable to clean the saw by emptying the base and the hand held portion of the saw. You can then rinse these parts with fresh water. This will reduce the amount of abrasive that travels through the mechanism. Because of the abrasive nature of the material that collects in the saw, it is advisable to rinse the saw in the yard rather than in your sink. If that is not practical, you can use a paper towel to wipe as much material out as you can before rinsing.
2. Inspect for wheel wear.
The area where you are likely to see the most wear is in the plastic inserts inside the three gold wheels. In the photograph below you can see a comparison of a new wheel and a well worn wheel. Note that the wear has enlarged the channel in the wheel to the point where the blade has little lateral support. This will make the blade seem sloppy while cutting and could even result in blade breakage. The plastic insert for these wheels is inexpensive and easy to replace, so keeping your saw in top operating condition is painless. To replace the rubber insert, use the wrench that came with your saw to unscrew the two metal halves of the wheel. The wheel unscrews by turning the rim counter-clockwise.
The purple wheels should also be inspected for wear because the black drive belt carries the cooling water to these as well.
Complete New Wheel on Right
New Plastic Insert in Center
Badly Worn Plastic Insert on Left