Fusion Staff Troubleshooting & Care Guide

Keeping your Fusion Dragon Staff in top condition means understanding how to clean it, maintain it, and troubleshoot common issues. While we have put together a full video guide, this article breaks it all down step by step so you can follow along at your own pace.

In this guide, we’ll cover:

Cleaning & Maintenance

Proper cleaning keeps your Fusion locking system working smoothly. Dirt, oil, or fuel can stop the cam bolt from gripping properly which means your staff might slip or fail to tighten.

Steps to clean your Fusion staff:

1. Use a cloth with mild soapy water to wipe the rubber bushes, cam bolt, and inside the staff ends.
2. Make sure you clean away any fuel, dust, or residue from spinning.
3. Dry all parts completely. If parts are damp, they can slip instead of locking.
4. For deep cleaning, use a tool like a chopstick or dowel with cloth to reach inside the staff ends.
5. Let everything fully air dry or use a dry towel before reassembling.

If you’re cleaning fire spokes, also check our full Fire Safety Guide for important safety info.

Removing the End Caps

You may need to remove the end caps for deep cleaning or to replace parts. They are tightly fitted, so take care when removing them.

Steps to remove end caps:

1. Try pulling them off by hand first, working your fingernail under the edge.
2. If too tight, insert a piece of dowel or similar tool from the opposite end of the staff.
3. Tap the dowel firmly against a hard surface until the end cap pops out.
4. Avoid using sharp tools that could damage the carbon fibre or cap.

Fusion Connector Not Fitting into Staff

If your Fusion connector will not fit inside the staff end, it usually means the rubber bushes are expanded in the locked position.

Steps to fix connector not fitting:

1. Turn the cam bolt anti clockwise by hand to relax the rubber bushes.
2. If too tight to turn by hand, insert the connector partially into the staff.
3. Use the handle as leverage to turn the cam bolt and release pressure.
4. Once the bushes are relaxed, insert the connector fully and tighten clockwise to lock.

Changing the Parts on a Fusion Handle

Over time, you may need to replace the washers, rubber bushes, or cam bolt on your handle. Doing this correctly ensures your locking system works as designed.

Steps to change Fusion handle parts:

1. Locate the small locking grub screw opposite the Fusion logo on the connector.
2. Use an M2 Allen key to loosen, not remove, the grub screw.
3. Unscrew the cam bolt anti clockwise and remove it completely.
4. Slide out the internal parts (nylon washers and rubber bushes).
5. Replace or clean parts as needed. You can order genuine Fusion replacement parts directly from us.
6. Reassemble in this order: nylon washer → rubber bush → nylon washer → rubber bush → cam bolt.
7. Screw the cam bolt clockwise until it touches the rubber bushes. Do not overtighten.
8. Retighten the locking grub screw so it sits flush. Do not drive it in fully as this stops the cam bolt from turning.

Understanding the Fusion Locking System

The Fusion handle uses a compression locking system, which makes it secure but also easy to remove when maintained correctly.

How the Fusion locking system works:

1. Inside the connector, a cam bolt expands rubber bushes outward as you twist it clockwise.
2. The expanded bushes grip the inside wall of the staff end, creating a tight lock.
3. Twisting anti clockwise relaxes the bushes, allowing the connector to slide out.
4. Keeping the bushes and staff ends clean ensures the lock grips firmly every time.

Nylon Washer Stuck Under Rubber Bush

Sometimes a nylon washer can slip inside a rubber bush, stopping the bushes from relaxing.

Steps to fix washer stuck under bush:

1. Loosen the locking grub screw with an M2 Allen key, just half a turn.
2. Unscrew the cam bolt anti clockwise until it comes out.
3. Remove all the internal parts, including the rubber bush with the washer stuck inside.
4. Use tweezers or a hex key to pull the washer out.
5. Reassemble in the correct order: nylon washer → rubber bush → nylon washer → rubber bush → cam bolt.
6. Screw the cam bolt back in clockwise until it meets the bushes.
7. Retighten the grub screw so it sits flush, but do not overtighten. 

If you need replacements, you can grab new Fusion spokes or other parts anytime.

Conclusion

With the right care and a little troubleshooting knowledge, your Fusion Dragon Staff will stay solid, smooth, and ready to spin. This guide covers the most common issues, but if you ever run into a problem you cannot solve here, or if your staff needs replacement parts, our team is always happy to help.

Get in touch with us for support or spare parts: Contact Threeworlds Support
Ready to explore new setups? Check out our Dragon Builder.