Replace the Main Brush Clutch

To replace Junior’s main brush clutch you’ll need a Phillips head screwdriver, the flat head screwdriver included in his box, and a new clutch piece.

Before starting any repair on Junior, turn his side power switch OFF and remove his dustbin.

Then, flip Junior over onto a flat surface and remove his side and main brushes using the flat head screwdriver.

Keep all removed screws and parts safely aside, as they may be needed for later re-assembly. Use a Phillips head screwdriver to remove the 7 screws on Junior’s underside that hold him together.

There are 5 screws along the edges of Junior: One screw on each side of the front wheel.

One screw to the right of the main brush motor. And one screw on each side of the dustbin. The final two screws are in Junior’s brush compartment.

Junior’s cover is no longer secured, so hold the top and bottom together as you carefully flip him back onto his wheels.

Grip Junior’s cover from the back and lift up to expose the mainboard.

Slide the power inlet down and tuck it somewhere safe to avoid compressing its wires.

To detach Junior’s cover completely, disconnect 4 circuit plugs:
Two at the lower edge of the mainboard, near the wheels.
And two more at the top edge, near the bumper.

Junior’s cover is now completely detached and can be set aside for the rest of the repair.

The main brush clutch, where the pin sits, is found beside the power switch. Use one hand to push the clutch up from underneath Junior, then uninstall its screw and remove its cushion. Keep both aside for later reassembly.

Lift Junior up, and two pieces will fall out: the clutch and the spring on top of it.

Place your new parts underneath Junior. Hold the spring on top of the clutch piece while putting them back in their space. Make sure the semi-circular gap faces the main brush motor, not the outside of Junior.

Push the clutch piece up from underneath Junior so you see the screw post protruding through his interior. Hold the clutch there as you replace the small cushion and reinstall the screw.
When finished, you’re ready to close the cover.
Reattach all 4 circuit plugs connecting Junior’s cover to the mainboard.

There are two that connect to the top edge of the mainboard. And two more that connect to the bottom edge.

Remember to slide the power inlet back into its space on Junior’s cover. Align the cover’s edges precisely. Then, flip Junior over onto a flat surface.

Ensure that no wires are compressed in the main brush compartment or visible at the edges of the bumper. If so, take a step back and lift the cover to tuck the wires into the appropriate spaces inside Junior.

Once the wires are all safely tucked away and Junior’s cover is aligned properly, reinstall all 7 screws previously removed from Junior’s underside.

Install the main brush and dustbin before your next use and Junior is completely re-assembled.

Turn the side power switch back on and congratulations! You’ve just replaced Junior’s Main Brush Clutch. Happy cleaning!

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