How do you take apart a generation 4 kirby?

As a seller of Kirby vacuum parts and supplies, I know a lot about common repairs and have much experience. If you have any questions or need a part, PLEASE ASK! There are NOT enough help forums on the net for this subject! With this instruction guide, I will hopefully enable you to do your own Kirby fan / impeller repair and I hope to save you LOTS OF MONEY!!
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This is a common repair that I have many inquiries about. I will do the best I can to make this repair easier for you. HOPE THIS HELPS!!

TOOLS NEEDED:

G3 & G4 models>> Medium sized phillips screwdriver

G5, Gsix, Ultimate G models>> #15 Torx (star) screwdriver and a #20 Torx

Other tools needed for ALL G series fan repairs>> medium flathead screwdriver, standard pliers, #9 wrench

DIRECTIONS: (be sure that as you remove the screws, that you remember where they came from...lol) When I started, I arranged mine on a magnetic bowl so that I didn't lose track of where they went.


1) Remove the handle, cloth bag assembly and power nozzle from the machine

2) Turn the main unit around so that you are looking at the on/off switch and remove the screw that is right underneath the neutral/drive button (not underneath the machine, but on the rear near the bottom)

3) Remove the smaller screw that holds the cord to the machine (located to the right, between where the handle plugs into the unit and the on/off switch) This requires the smaller Torx driver.

4) Insert the tip of the flathead screwdriver into the small open slot in the center of the "scuff plate" (the plastic trim piece) and pry gently upward to remove the plastic piece. Remove the two rear screws that are now visible that hold the aluminum shell on. (above the N/D button)

5) Turn the machine around so that you are looking at the fan case (front). Remove the top two screws, put the hood down and lift off the aluminum top shell.

6) Raise the hood again and remove ALL FIVE screws from the front of the fan case. Now you can remove the front aluminum piece that covers the fan. There is a little gap between the fan case and the main body of the Kirby....right above the hole where the the bag attaches to. It is helpful to use the flathead screwdriver in this gap to pry the front off, as it will probably have some sealant holding it on. Don't be afraid...it's ok to break the seal. It is up to you whether you want to reseal it when reassembling. It doesn't really need it, but you can if you'd like.

OK....I'll try to explain this part as well as I can...lol

7) Look from the side (where the cloth bag was) into the "guts" of the Kirby, right underneath where the handle plugs in. Take hold of the fan shaft in front and turn it slowly. KEEP LOOKING CLOSELY INTO THE SIDE WHILE TURNING! You will see that near the back end of the shaft is a small flat spot. Use the #9 wrench to grab the flat spot. (if you put it up against where the flat spot is and turn the shaft slowly, it should slide right on.) Hold the wrench still while unscrewing the front shaft. This will prevent the shaft from turning and allow you to unscrew the front of the shaft with the pliers. IMPORTANT>>>The front shaft loosens by turning it to the RIGHT and tightens when turning it LEFT...it is threaded so that it doesn't unscrew itself when the Kirby is running. After you get the shaft off, simply pull the fan and hardware off and put the new assembly on. Pay close attention to the spacers' position and how they look to avoid mistakes when reassembling. Put the new drive shaft on by turning it to the LEFT. It is not necessary (actually could be detrimental) to tighten the shaft too much, so just take it to finger tight and then give a half turn with the pliers. It will tighten up automatically when the machine is running.

8) Now, reverse all directions given so far and put the Kirby back together, starting with the aluminum fan case.

I hope this was helpful, as it is my first attemt to write a repair manual. If it helps anyone, or if anyone has problems understanding these instructions, please contact me via eBay messaging. I'll be glad to help!


HAPPY VACUUMING!!!!

eBay ID... b0sslady2001 (Marci)
June 2007