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Verify collection bag or chute correctly depresses safety switch plunger.
Disconnect safety switch from magneto primary wire at bullet connector.
Test switch continuity from bullet connector to ground using multimeter.
Adjust safety switch tab by bending downwards if continuity breaks with slight pressure.
Replace safety switch if it fails to break ground path when plunger is pressed.
Verify switch completes ground path from magneto when plunger is up.
Troubleshoot switch grounding failure by checking switch or ground connection.
Remove safety switch from frame using a 5/16" wrench or driver.
Test switch independently for continuity with plunger in the up position.
Verify switch shows no continuity when the plunger is pressed.
Troubleshoot switch grounding issue by inspecting wiring or ground connection.
Perform operational test to check drive system speed range.
Remove belt cover using a 3/8" wrench for inspection.
Inspect variable speed pulley for full movement across speed range.
Observe variable speed sheave travel on input shaft for proper movement.
Ensure drive belt is routed correctly on pulleys.
Monitor idler pulleys and mounting bracket for free movement.
Check spring attachment for idler pulleys if they do not react properly.
Remove rear wheels to access and inspect final drive gears.
Inspect the condition of the teeth on the rear wheel.
Verify correct installation of drive gears, noting R/L markings.
Remove retaining ring and gear to check dowel pin seating.
Disconnect the high tension lead from the spark plug before proceeding.
Remove collection bag or blower chute from the unit.
Detach and remove the vacuum hose if it is connected.
Remove three self-tapping screws securing the belt cover with a 3/8" socket.
Insert 3/8" breaker bar into tensioner arm square hole to release belt tension.
Pull breaker bar rearward to slip drive belt off variable pulley.
Support rear of unit and remove rear hub caps.
Remove rear wheels, shoulder bolts, and washers using specified wrenches.
Remove retaining ring holding drive gear and dowel pin on axle.
Remove the dust cover.
Remove E-clip and flat washer from the axle.
Remove three self-tapping screws from transmission brace using a 3/8" socket.
Remove two Phillips screws securing transmission to the brace.
Detach barbed fitting securing variable speed cable to transmission bracket.
Disconnect Z-fitting from transmission using needle nose pliers.
Remove spring from the transmission actuating arm.
Push hexagonal drive axle bushings out from both sides of the frame.
Pivot transmission rearward and slide it to the right to remove.
Slide transmission to the left once the left side is free.
Install new transmission by following removal steps in reverse order.
Disconnect the high tension lead from the spark plug.
Remove transmission as per the Transmission Removal section.
Tilt and support unit front for access to wheel and nozzle hardware.
Remove the hub caps.
Remove front wheels using a 1/2" wrench.
Remove height adjusters and cross bar using 15/16" and 9/16" wrenches.
Remove three screws from black plastic nozzle to lower housing with 1/4" wrench.
Remove four Phillips head screws securing nozzle front to the frame.
Tilt black plastic nozzle toward engine for removal.
Remove all fasteners connecting lower housing to upper housing.
Block impeller and remove bolt, washers securing it to crankshaft using 9/16" socket.
Use lubricated impeller removal tool threaded into crankshaft to slide off impeller assembly.
Inspect impeller, hub, blade, and flails for damage; replace if necessary.
Remove drive belt by pulling it through the crankshaft hole.
Install new drive belt through the crankshaft hole.
Disconnect the high tension lead from the spark plug.
Remove three bolts securing the chipper chute to the upper housing.
Remove black plastic nozzle as detailed in Impeller Removal section.
Remove flat head cap screw holding chipper blade to impeller using 3/16" Allen wrench.
Use 1/2" socket, universal, and extension to reach nuts on flat head cap screws.
General