- 1 Large Flat Blade
Heavy Screwdriver (10" long or
- 2 medium size narrow
flat blade screw drivers about
the same in size
- Torx Driver or Torx
Bit Set (For Later Models)
- Phillips Screwdriver
(For Earlier Models)
- Narrow blade
screwdriver or Ice Pick
- Good Grade of
Silicone or other type Sealant
BE SURE YOUR KIRBY VACUUM IS
UNPLUGGED BEFORE PROCEEDING.
Remove the Kirby Brushroll nozzle so
that the fan case is exposed.
Remove the mini emtor (plastic base
of cloth bag). Just rotate it out
toward you and it will release.
Depress the button (#1) and Remove
the Kirby Handle.
Remove the Screw (#2) from the rear
cord keeper. Kirby Generation 3 and
early G4 models used phillips screws
- later models use a torx screw.
Remove the screw (phillips or torx)
from the side cord cover, remove the
cord cover and unplug the cord from
the receptacle of the Kirby Vacuum.
Remove the screw from the plastic
motor cover shroud. Remove the
shroud and set it aside along with
handle and cord.
Remove the 2 screws from the rear of
the motor cover.
Remove the 2 screws from the front
of the motor cover and remove the
Kirby Ultimate G Models Have a 2
Speed switch attached to the motor
cover. Carefully remove this switch
from the motor cover before setting
the motor cover aside.
You will not see this switch on any
Remove 5 screws from the front of
the fan case.
The Fan case on your Kirby is sealed
at the factory with silicone
sealant. Make sure you have removed
all 5 screws from the front of the
fan case in step 9 above before
proceeding. To fully remove the fan
case; using a large flat blade
screwdriver with heavy tip at the
point shown in the picture; tap the
handle of the screwdriver solidly
with a hammer. This will loosen the
sealant enough to completely remove
the fan case.
Place a narrow blade screwdriver or
ice pick through the hole in the fan
You will find the rear of the motor
shaft directly below the push button
that releases the handle. Find the
flat spot on the motor shaft and
using a 3/8 inch open end wrench
secure the motor shaft so it won't
turn. Return to the fan pulley and
using the ice pick or screwdriver,
turn the fan pulley CLOCKWISE to
remove the pulley.
Using 2 narrow flat blade screws on
either side of the fan; pry up
evenly to remove the fan.
You can purchase the original Kirby
Fan as a six piece kit
It will include; fan, pulley, metal
spacer, rubber grease seal, fiber
washer and metal washer.
Put the rubber grease seal over the
metal spacer. Place the spacer and
seal with seal toward motor on the
motor shaft first. The fiber washer
goes next, followed by fan, metal
washer and fan pulley. Turn the fan
pulley counter cockwise until it is
just snug. DO NOT overtighten.
Before reassembling the fan case;
put a narrow bead of silicone all
away around the outside of the fan
case. Reassemble and tighten all
hardware. BEFORE YOU APPLY FULL
POWER; be sure to spin the fan by
hand a few times to make sure
nothing is jammed and you have a
smooth rotation of the fan and