How to replace the power switch on a Kirby G4
This repair requires extensive disassembly. First remove the handle, bag assembly, and switch "scuff" plate. To remove the switch plate, remove the screw at the bottom, and the upper screw that secures the cord. Insert a screwdriver into the rectangular slot in the plastic and pop it off. The cord must also be removed. One screw holds the cord cover to the lower motor shell. Remove the screw and push with a flat screwdriver on the back of the cover to unlatch it. Next remove the upper motor shell ( 4 screws ). The next piece to come off is the switch button. Pry upward on it's attaching lugs to free it, pull it upward far enough to disconnect it from the switch rod. The power drive assembly is next to go. Three screws on the bottom of the motor unit hold it in. DO NOT remove the center screw beneath the shift lever. The drive pedal must be in DRIVE for removal. The transmission drops down to get it out ( you may have to wiggle and pull on it to free it). Next the headlight frame assembly must be removed. You will see 2 screws at the rear, and 2 long screws in front which also secure the fan housing. After removing the screws, the headlight frame can be removed. Be careful to note the proper location of all wires! The right carbon brush assembly must be removed to allow the switch to slide back for removal. It is held in place by 1 screw and a tab on it's holder. Two screws hold the switch itself in place. One is on a tab on top of the switch, and the other is on the right bottom of the lower motor shell. The lower screw also serves as a motor mount screw. The switch can now be removed by inserting a small screwdriver along it's front edge and prying it backwards. It is wise to clear dust and lint from the motor contacts prior to re-assembly. Be sure the terminals on the field coil have not gotten bent before putting the new switch in place. Snap the new switch in place and replace the screws. It is easiest to replace the wires in this order:
1- Holding the headlight assembly off to the right, install the lower headlight wire.
2- Next connect the wire from the left carbon brush to the upper switch terminal.
3- Connect the upper headlight wire.
4- Gently replace the right carbon brush assembly, secure it with it's screw ( do not overtighten ) , and connect it's wire to the lower switch terminal.
After the switch is in, install the headlight frame screws, transmission and belt, and switch button in reverse order. Be sure the shift arm on the left side of the drive unit engages the slot or pin on the handle pivot assembly. The cover and trim pieces can now be re-installed.
Feb 16, 2011 |
Kirby G4 Bagged Upright Vacuum