How-to Install Polaris 280 Tune-Up/Rebuild Kit
Tools needed:
Phillips Head Screw Driver
Flat Head Screw Driver
Needle Nose Pliers or Adjustable Pliers
Step 1
Remove the filter bag, head float, and sweep hose adjustment screw
Prepare by removing the filter bag, head float and sweep hose adjustment screw. Next remove the sweep tail clip and sweep tail. Remove the top by removing the single screw on top of the cover. Pull the top cover off by pulling it over the throat of the cleaner. Leave the small screw in the top cover for easy access when returning it.
Step 2
Remove the 3 screws that hold the turbine cover on. It works well to get it out of the way by bending the tube up and and hooking the cover on the throat. Next remove the drive shaft cover plate.
Step 3
Remove all the wheels by unscrewing the 2 screws that go through the axle plate and into the frame of each wheel. Notice that the single side wheel and the front wheel have a sand plate on the inside of them. The rear wheel does not have the axle plate.
The A49 Tune-up kit and A48 Rebuild kit comes with the wheels and axles pre-assembled. If your tearing down each wheel/axle assembly, here are some notes on assembling the wheels: Each wheel takes 2 bearings so the cleaner uses 8 total c60 wheel bearings. When installing the bearings in the wheels, make sure the blue part of the bearing is facing out on both the inside and outside of the wheel. The front 2 wheels use the C66 axle with plate guard while the rear wheel does not have plate guard.
Step 4
Remove the drive shaft. Take out the 2 screw that go through each turbine bearing on either side of the drive shaft. Notice that the drive shaft bearings C80 have the “Polaris” logo facing outward.
Step 5
Remove the base by unscrewing the 2 screws on the bottom. Then remove the swing axle spring by taking out the smaller screw that goes into the bottom. Notice how the screw does not go all the way through the base, its only about ¾ the way in. Next remove the swing axle by unscrewing the screw from inside of the bottom.
Step 6
Installing the swing axle. First use the smallest screw to attached the spring to the swing axle. Then put the largest screw through the base and put the lock washer on the screw to the outside of the base. Now you can put the swing axle in place and thread the “T” nut on to the screw. When tightening down the screw from inside the base, make the “T” nut parallel to the keeper bracket. Last, you can screw in the long small screw through the spring and into the base. Only screw it into the base about ¾ of the way in. You can now re-install the idler wheel and replace the bottom on the frame with the 2 screws.
Step 7
Install the new drive shaft. Install the 2 blue turbine bearings on the shaft with the “polaris” logo thats stamped into the plastic on the outside. Next drop the axle down into the frame and reinstall the 2 screws into each turbine bearing. Next reinstall the turbine cover and drive shaft shield.
Step 8
Replace the wheels. Install each wheel with the 2 screws that go through the axle plate and axle into the frame. Leave the axle screws loose on the single side wheel and the double side front wheel so that it can be adjusted. Go ahead and tighten down the rear double side wheel, if it needs to be adjusted we will do it after adjusting the other two.
Adjusting the wheels. Start with the single side wheel. Hold the cleaner facing up and tap the bottom of the unit this will settle the wheel into the drive shaft gear so that the drive shaft engages the wheel gear approximately ¾ of the way. You do not want the drive shaft fully engaged with the wheel gears or it will cause excess wear and be to tight. After you have the wheel engaging the drive shaft properly tighten down the 2 axle screws to secure the single side wheel to the frame.
Next, do the same thing on the front double side wheel. Turn the cleaner around then hold the cleaner up and tap the bottom. This will settle the wheel into the drive shaft gear so that the drive shaft engages the wheel gear approximately ¾ of the way. You do not want the drive shaft fully engaged with the wheel gears or it will cause excess wear and be to tight. Then tighten down the 2 axle screws to secure the wheel to the frame. After the 2 front wheels have been installed and adjusted properly. Pick up the unit and spin the rear wheel, all three wheels should spin in unison. You shouldn’t struggle to spin the rear wheels. There should be sufficient tension on all the wheels. If you are struggling to turn the rear wheel then loosen the 2 screws on the axles and slide the wheel back a bit then re-tighten the axle and spin the wheels again. If the rear wheel does not engage the the idler wheel and spins on its own then loosen the 2 screws on the axles and slide the wheel forward a bit then re-tighten the axle and spin the wheels again. Some notes about wheel adjustment. If you spin the it should rotate a few times on its own. If it doesn’t then the rear wheel is too tight. All the wheels should move no matter which wheel you turn.
Replace the top cover and screw in the small screw into the housing. Attach the new hose float and tail sweep. Lastly, re-install the sweep hose adjustment screw. On this one the manufacturer position is to screw all the way in and rotate it two full turns outward. Depending on your water pressure, this screw may need to be opened more.
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