How can I replacement my belt for my Kenmore model 116?

The following steps explain the procedure for changing the drive belt on a Kenmore Model 116.39164 vacuum Cleaner.

Tools required. #2 Phillips head screwdriver, Small flat head screwdriver

1. Unplug Vacuum cleaner.

2. Remove light lens. This is done by laying the vacuum cleaner on its back with the handle laying flat on the bench or floor. Gently pry the light lens out with a small screwdriver.

3. With the light lens removed, four screws are visible. Two hold the motor cover on. Don’t remove these; remove the two beneath the ends of the light lens. These two screws are visible with the light lens in place, but unreachable with the screwdriver.

4. With these two screws removed, gently pry or lift the cover from the back and tip forward to remove.

5. Remove the Base Frame Support. This is a short metal rod about 1 inch long and 3/8” diameter with groves cut around both ends. It can be just lifted out of its mounting slots.

6. On the belt end of the brush roller, using a small screwdriver, pry up the ends of the metal piece at the ends of the roller. These are called the brush supports. This will allow the end of the brush roller to be lifted out of its mounted position. (Note: If the belt is not broken its tension will be fairly high and may cause the brush roller to snap out of its mounting position.)

7. Lifting the freed end of the brush roller will allow the roller to be removed from its mounted position. Remove the brush roller and check it for strings, hair straight pins and needles etc. When removing the roller, be careful not to drop any washers that may be on the end of the roller shaft.

8. Looking at the motor shaft you will see just a narrow crack at the end of the shaft; not enough room to just push the belt onto the shaft. To install the belt, with your fingers pinch the belt together about one inch from the end. The belt will be in the shape of an “8” with one loop very large compared to the other. Lay the small pinched end with the edges up on top of the motor shaft; then while slightly pushing the belt toward the end of the shaft slowly rotate the belt clockwise so the right hand edge of the belt will slide through the narrow opening over the end of the shaft. You may need a small sharp pointed tool such as a skinny nail, ice pick, etc to help one edge of the belt over the shaft end. The belt will slide over the end of the shaft with little effort.

9. Stick the roller through the belt and into the groove on the roller. Stick the roller onto the left brush roller. Using some force stretching the belt push the drive belt end of the roller into its mounting location. This will take some effort because the new belt has not been stretched at this point. The metal brush supports will snap into place.

10. Replace the Base frame support.

11. Replace the top cover front edge first insuring the three mounting guides fit into their proper slots. Press down on the front corners making sure they snap into place.

12. Replace the mounting screws. Do not over tighten these screws. They go into plastic and are easy to strip. They just need to be snug. Replace the light lens. Make sure the roller will turn by hand before the motor is turned on. If for some reason the roller will not turn. Fix this problem or the belt will burn into with friction from the drive motor shaft.

Walter Huckeba
July 2007