Here at Great Vacs we sometimes get asked how you replace a Kirby fan. Usually a fan breaks or cracks because you picked up something metal or hard when you were vacuuming. So this will tell you how to replace it. Tools needed are a flat head screw driver, 9mm end wrench and a long nail or vice grips, phillips head screwdriver for models G3 and G4; and a star bit screw driver for models G5 and up.

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The main steps to replacing the fan is taking the vacuum apart to be able to get to the fan. The following steps are how to take it apart.CLICK ON ANY OF THE THUMBNAILS TO SEE FULL SIZED PICTURE!

	WARNING: NEVER ATTEMPT TO PERFORM ANY TYPE OF MAINTENANCE OR WORK ON THE VACUUM IN ANY WAY WHILE VACUUM IS CONNECTED TO A POWER SOURCE. DOING SO MAY RESULT IN ELECTRIC SHOCK. Remove the Powerhead To do this you will select your carpet height adjuster to its highest settings. Then spin the belt lifter so the two red arrows are pointed at each other. Then disconnect the head and take it off. Side note - when you are done and putting your head back on don't forget to realign the arrows to green on green.
	Remove the bag and handle Right where the handle goes into the actual vacuum it snaps out. To unsnap the handle their is a button on the back of the handle right at the base where it goes into the vacuum. To take off the bag put your hand under the boot mini emptor (plastic part at bottom of bag) and pull away from the vacuum and it snaps off. That is how you take off the handle and bag.
	Remove the trim around the Pivot handle The next step is to remove the trim around the pivot handle (where the handle snaps in). The first thing you want to do is to undo the screw at the bottom of the trim. The screw is located right above the transmission switch. Then you want to remove the screw that holds the cord under the trim. When that is off you want to unsnap the trim buy grabbing the bottom of it and lift up and at the same time push toward the front of the vacuum. The trim then comes off.
	Remove the Metal Body With the powerhead and rear trim removed the 4 screws that remove the Metal body are now visible. First we remove the 2 on the rear of the metal that were covered up by the trim. Once those are removed we move to the front of the vacuum and remove the two remaining screws that are holding on the front of the trim. With the 4 screws removed now you simply lift the Metal body off of the vacuum.
	Remove the Front Fan Cover Plate With a star bit or a phillips screw driver (head type depends on model) remove the 5 screws on the front plate and pull off the front plate. To get it off you might have to pry it off with a flat head screw driver.

	Remove the old fan O.K. first you put your nail through the pulley or clamp your vice grips on the pulley to secure it from moving. Next we attach the 9 mm end wrench on the motor shaft so the shaft will not spin (see picture). Then you are going to turn your nail or vice grips backwards (reverse threaded) and the pulley will un-thread. Then you are going to pull off the fan. If the fan will not come off get 2 flat head screwdrivers and put pressure on both sides of the fan and pry it off. With the fan off I usually clean behind the fan and then put on the new fan.
	Putting the new fan on The best way to do this is look at the order the old fan came off and then reverse it. However I will also explain how to do it in detail as well. With the fan their should be 4 pieces. A metal coupler, a rubber gasket, a plastic washer, and a metal washer. What you do is put the rubber gasket on over the metal coupler. Then you slide those on the shaft with the flat side facing the fan side. Then you put the plastic washer on (this is correct if you look at the picture I mixed up the order of washers but the metal washer goes between the fan and the metal belt pulley), then you put the new fan on, then the metal washer on and then you screw the pulley back on. Then reattach your tools and tighten everything until it is good and snug.
	Put everything back together Now you simply put everything back together. Do it in the reverse order than you took it apart. The only thing you need to do differently is when you put the front plate that covers the fan you will need some gasket sealer on it and then put the 5 screws back in. You do this so no air leaks around the fan casing and you have good suction. After you tighten the screws you will see some excess gasket sealer squeeze out. Take a rag and wipe the gasket sealer off while it is wet. Then simply put the vacuum back together and test your work.

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