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Here is a step by step walk through with pictures on how to replace the neutral / drive pedal on any Kirby Generation vacuum (G3, G4, G5, G6, Ultimate G, Ultimate G Diamond Edition, Sentria and Sentria II) Kirby Neutral Drive Pedal Replacement Guide
The pedal assembly must be replaced,( part # 558401S), as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it of. Four screws hold the motor cover in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw and washer to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items
I have never touched a Kirby vacuum before and my wife had the same issue. The neutral/drive pedal just fell out so I figured I would give it a shot to see if I could fix it and quickly figured out the 3 screws in the bottom plate for the drive unit wasn't the answer.
I was able to figure things out out after I found a parts list with diagrams at the follow web site and address:
Vac Parts Warehouse.com http://www.vacpartswarehouse.com/category-s/2821.htm
The two parts involved are: 13. Bracket Cam Assembly Neutral Drive Pedal 557689A 16. Kirby Pedal Cam For Neutral Drive G6 558499A
Here's how to get to a point that you can get these two parts in/out of the machine.
- Remove bag and fill tube from handle and main unit - Remove floor nozzle assembly - Remove the handle via the two screws at the handle fork plate (these have loctite on them so needed a socket wrench with torex bits to get them out). - Remove the plastic rear scuff plate vie the screw with the power cord anchor and screw by the Pedal Cam For Neutral Drive. Note release plastic tab in slot in the center and lift from the back and then over the base where the handle attaches.
I did not do this as I removed the the power drive assembly so I could figure out how to put the dive assembly back together. The pressed on arm that drives the cam assembly had pulled of the pedal shaft so this also made it easier to fish out the parts and experiment on positioning the arm in the right spot . I found the arm and a spring washer inside. Note – continue disassembly below if bracket cam assembly will not come out as it is easier to work with once the drive assembly is removed.
Remove the screw on the bottom plate that attaches the Bracket Cam Assembly and slide the Pedal Cam. Then the plastic back panel and the cam assembly should slide out if you lift up on it. Note that the screw is the only one with a star lock washer on it. Also note that this entire assembly is the only way that the parts are sold and it includes plastic back plate and metal cam assembly as. I when down the path to repair the existing assembly so I needed to take the power drive out The part was 16. Kirby Pedal Cam For Neutral Drive G6 558499A at Vac Parts Warehouse.com. The one listed on the website said it was for a G6 even though the parts listing is for a G5 so I don't know....
To continue to disassemble and take the power drive assembly out: - Remove the 4 screws from the Cover Shell assembly - the metal top part. You do not need to remove the hinged Headlight Cap that is attached to it. - Remove the 4 screw from the bracket assembly that has the handle attachment and forward/reverse switch. It attached by two wires. I only disconnect one and swung it to the side. - Snap off the the on/off switch and disconnect from the Actuating Rod Foot Pedal to Power Switch. - Remove the 3 screw from the bottom plate of the power drive assembly. - Remove the drive belt. - The power drive assembly will now drop out the bottom.
I just put the spring washer and arm back on the shaft and reassembled. I'll see how long that lasts before before buying the new part. Update: this fix did not last long. Use red Loctite or super glue to attach cam to shaft so it doesn’t pull out if you want to avoid buying the new assembly. Note that the cam must be aligned so that when the neutral side is pushed the cam will stop in the detent to hold it in place. Must be reassembled in the drive position as that is the default for the drive assembly.
I know the lever you're describing, but it's very hard to tell someone how to put it back on. There's nothing wrong with your transmission, by the way, this is a part that's meant to be moveable, and it just happened to slip off in your case. You may call us at 1-866-509-1952, and we can do our best to help you.