How To Replace Parts
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Download Luggage Zipper Repair Instructions (large file, may take 1-3 minutes to download)
You will need a Philips screwdriver (preferably electric), and pliers.
Wheel Well & Wheels
- Open your Rollerbag and unzip the liner.
- Remove the 4 screws from around the wheel well – you will need to grip the nylon nut bolt from the inside while you unscrew from the outside.
- Pull out the well.
- Remove the bolt from within the wheel. Push the small clip out of position, and pull out the bolt.
- Replace the wheel and washers – one washer on each side.
- Replace the axle and attach the clip through the slot on the axle.
- Replace the well - while making sure to tuck in the material.
- Replace the 4 screws around the wheel well and tighten.
3 Stage Handle
- Open your Rollerbag and unzip the liner.
- Remove 5 screws on the plastic handle interior near the top of the bag. Remove this plastic piece.
- Follow the 2 black shafts of the handle to the bottom of the bag. At the base of the shafts, there is a black plastic piece.
- Where the 2 shafts enter this plastic piece, there are 2 screws, 1 in each shaft, Remove each screw. You can leave the bottom plastic piece in place. While working on the next step – leave your luggage handle locked in place.
- On the exterior plastic portion of the luggage handle, the bottom 2 corners need to be pulled out of their holes first. If needed, go to the inside of the bag and push out the plastic buttons on the back plate in order to remove the plastic piece. You may need to work with it going around the entire plastic piece little by little.
- Remove the handle assembly.
- Take the new handle and feed it through the opening.
- Feed the shafts of the handle through the bottom plastic portion, press the button on your luggage handle to extend these 2 shafts fully.
- Screw each shaft in the plastic bottom.
- Maneuver the plastic top portion so the plugs on the handle, fit into their position through the aluminum frame.
- Screw the interior top plastic piece, making sure that the screws go into the plastic buttons.
Replaceable Material Exterior
- Follow instructions to remove luggage handle.
- Remove all of the exterior screws for the top, side and bottom handles, j-hook strap, wheel wells, and the 2 protective plastic strips.
- There are 27 screws to remove. You can leave the bottom plastic portion of the luggage handle in place.
- On each side of the bottom of the bag, undo the Velcro.
- Now the material will pull off like a pillow case.
- Take the new material and replace it on all 4 corners.
- Working slowly, pull down on each corner about 1 inch at a time making sure that the bag material is centered. You may need to check to see if the inside liner is not bundled up under the outer skin. Pull from the inside.
- Make sure the material is aligned correctly with the corners of the bag and centered correctly. The holes that are pre-made may not line up exactly, which is ok. The friction with the screw when installing the parts will melt through the skin without a problem and is ok.
- Continue at this pace until you have the material fully in place. Pull on material from the bottom numerous times to ensure an accurate fit.
- Seal the Velcro on the bottom, centering the bottom rubber piece. *For install with Vortex 1 Frames, the bottom tab holes will not line up as with a Vortex 2 frame. This is ok as well. Just drill through the holes and place a screw and nylon nut to cover up. The bottom fabric handle holes are in the correct spot.
- You will need to take a sharp utility knife and cut the material for the wheel wells. Use the metal frame as a guide, and start at each corner inward at an angle towards the middle or center of the wheel well opening. Do this for each side.
- Start replacing the pieces from the bottom up. These include the handles, j-hook, small clips, 3 stage handle, protective strips. If you start with the wheel wells first, the fabric will hold correctly.
Congratulations! You now have a brand new bag!
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