For models:
- K-180: Aspen LE, Tamarack LE, Aberdeen LE, Alpine LE.
- K-250: Ashwood LE, W Classic LE, Cambridge LE, Cascade LE.
The burn tubes, the baffle plate, the bypass plate, and the right side heat shield must be removed prior to removing and replacing the bypass hinge. The catalytic and catalytic flame guard can be removed for ease of access. Note that a new gasket will be required for the catalytic when reassembling the stove.
- Tube and baffle plate removal video or instruction sheet
- Bypass plate removal instructions
- Right side heat shield removal instructions
Step by Step Instructions
Remove the nut holding the bypass pull bar to the bypass arm and the two nuts that hold the bypass hinge in place using a 7/16 wrench or socket. The two nuts holding the bypass assembly in place are connected to carriage bolts that are inserted from the inside of the stove. You may have to reach into the stove to hold the carriage bolts against the inside wall of the stove. These carriage bolts cannot be seen easily and may have to be found by "feel".
Remove the bypass hinge assembly from the right-hand side of the stove. The hinge will slide a few inches to the right before dropping out of the hole on the left. Once it's free on the left-hand side, the bypass hinge will require some back and forth motion to "weave" it out of the stove to the right.
Insert the new bypass hinge assembly into the right-hand side of the stove. "Weave" it into place until the mounting plate is contacting the side of the stove. If the original carriage bolts remained in place, line the mounting plate up with the bolts as it slides on. You will need to guide the left end of the bypass assembly into place through the left-hand side of the stove. The hole in the left side of the stove cannot be seen easily. The left end may need to be aligned by "feel" from the inside of the stove.
If the carriage bolts remained in place, simply re-install the original nuts or install the new nuts that came with the new bypass assembly. If necessary, install the new carriage bolts that came with the new bypass assembly. Tighten the two nuts holding the bypass assembly in place and tighten.
Reinstall the bypass pull bar to the bypass arm. Tighten the nut up to the pull bar, but do not over-tighten. This pivot point must remain loose. Tighten the nut a small amount at a time until there is very little side-to-side movement in the bar while leaving the joint to easily pivot.
