How to Replace a Broken Brake Lever on the RS800 CVT Transaxle of a Riding Mower

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This #diy #repair video shows you how to replace a broken brake lever on a common RS800 CVT #transmission found in many riding mowers and lawn tractors. You'll find this transaxle in riding lawn mower brands such as Craftsman, MTD, Husqvarna, Troy-Bilt, Toro and John Deer.
For this repair, you'll need the General Transmissions Driven Pulley Removal Tool www.searspartsdirect.com/prod... .
You'll also need the brake lever kit www.searspartsdirect.com/prod...
You can order that tool online or call 1-800-437-1673 to speak with a parts specialist to order the tool.
If you need to have a Sears Technician repair your riding mower, schedule service online at www.searshomeservices.com/rep...
Transcript:
The next failure we're going to look at is a loss of brake. In this case we did find that the brake lever itself is broken. The brake lever, you'll notice, has 2 holes on the end. Ours does not have that. So, we're going to disassemble the unit. We have to go under the case to replace the brake lever. So, we're going to start by removing the drive unit with a T-25. This is also a good time to check the function of the CVT. You want to make sure that you have springs and that it does move freely. Once the drive unit is out, we'll set it aside. The next step is with a T-20, we're going to remove these 3 screws on the driven unit. Remove the cap. To remove the next piece, we've got to press down to release the spring pressure and pull out the pin. Remove the base. The next step is that we've got to remove this nut. This is held in place with 65 ft-lbs. You will need the tool from General Transmissions to remove this nut. Retain the pin. There's also a washer. Remove the cover. The next step is to remove the unit -- be careful, there are 8 roller bearings and a spring. Again, with the T-25 wrench, we're going to remove the cover bolts. The 2 top cover bolts also have washers. Then the cover just lifts off. Here is the brake lever that we're going to be replacing -- you can see that it is broken and the spring is not attached. With the T-25, we're going to remove the 2 screws. With a flat screwdriver we're going to pry gently on the bottom side of the brake lever. It lifts off. When replacing the brake lever, make sure that the O-ring is in place. It simply slides down and taps into place. This time we're going to reinstall the spring. It goes in the 2nd hole and over this post. This is also a good time to make sure that you're centered -- this spring is centered here and that your orientation of the CVT is in the right location. We're simply going to put the cover back on, the driven unit back on and the drive unit back on. The 2 top bolts have washers. Our next step is the spring, the cover with the ball bearings and the cover. At this time, we're going to reuse the pin and the tool from General Transmissions. We're going to torque the nut to 65 ft-lbs. Install the riser plate, spring and cover. At this point we have to depress the spring. Install the pin and the cover. The 3 T-20 screws go in next. Torque to 1.5 ft-lbs. of pressure. Next, we install the belt and the drive kit, making sure we have the belt keeper to the outside and speed screw to the outside. Then we're going to reinstall the T-25 bolts using blue Loctite and 2.5 ft-lbs. of torque. At this time we reattach the spring to the brake pedal.