2. Instructions for making plunger fork tool.

3. Drawing for the trigger assembly

4. 499 Parts Drawing / Ordering Information

5. Tools you will need to disassemble a model 499

6. Remove shot tube from barrel shroud

7. Remove forearm screw

8. Remove forearm

9. Remove top stock screw

10. Remove stock screws

11. Remove stock

12. Remove lever nut

13. Remove lever screw

14. Remove lever assembly

15. Remove trigger screws and nuts

16. Using a flat screw driver compress leg on safety so the safety can be removed

17. Remove safety from trigger and barrel shroud

18. Remove trigger assembly from barrel shroud

19. Using plunger fork insert into the barrel to compress plunger spring

20. Line up plunger fork on sides of the plunger casing so you can compress the plunger spring forward

21. Holding plunger fork handle against the table push down on the barrel shroud so anchor pin will release

22. Remove the anchor pin

23. Using a flat screw driver remove the plunger assembly

24. Using a steel rod 5/8” – ¾” in diameter put into the front of the barrel shroud to remove abutment

25. Tap rod with mallet until the abutment is loosened and will come out the back of the barrel shroud

26. Remove the abutment

27. You can test the magnet on the abutment before installing in the barrel by putting a bb on it to see if it will stay in place

28. I do this so you do not have to tear the gun apart again if the magnet is bad

29. Put abutment seal on the abutment plug

30. Seal goes on with flat side against plug and open end to the outside

31. Insert abutment with seal into the barrel, put a small amount of grease on seal to help slide in easier

32. Insert abutment with threaded side first into the barrel shroud

33. Using your rod push abutment all the way into the barrel shroud until it stops

34. Using a pointed punch re-stake the abutment into the barrel shroud. Be sure the abutment is all the way forward in the barrel shroud.

35. Before staking screw in shot tube and be sure the tube is right against the muzzle of the barrel.

36. Stake in place with a pointed punch or nail, make sure dimple is deep enough to hold abutment in place

37. To change plunger head remove the plunger pin

38. Remove plunger pin

39. Take off plunger head

40. Take off steel plunger washer

41. Remove plunger spring from plunger casing

42. Replace plunger spring on casing

43. Steel washer can go over the plunger head to make it easier to get back together

44. Insert plunger head with steel washer in plunger casing and line up the holes for the plunger pin

45. Compress the plunger spring so you can insert the plunger pin

46. Rebuilding trigger instructions are for trigger pull to the left

47. Remove safety from trigger casing

48. Remove trigger pin

49. Remove pawl

50. Remove pawl spring

51. Remove trigger and trigger spring

52. New style post trigger is on left and I am holding the old style trigger with cut out for spring

53. Put trigger spring on post or in cut out. Use a small amount of grease on tip next to trigger

54. Old and new trigger with trigger springs

55. End of trigger spring must tuck into the notch inside the trigger sear right above thumb nail on left hand

56. Insert trigger with spring into trigger casing lining up the trigger spring into the sear notch

57. Line up trigger in trigger case so pin will go through

58. Insert pawl into the trigger casing the post on the pawl will tuck under the pointed end of sear

59. Wide side of pawl will be on the top side of the trigger casing

60. Line up pawl hole with trigger and trigger case

61. Tuck pawl spring under the pawl the short leg of spring is to the right and flat against the trigger casing

62. Holding the trigger, pawl and pawl spring together insert the trigger pin

63. Pin should go all way through to the other side

64. Top view of assembled trigger

65. Safety goes into trigger assembly with the leg opening up toward the top of the trigger assembly

66. When installing safety the pawl spring is under the safety

67. Push safety into assembly be sure the pawl spring is under the safety and the open leg is up

68. Push safety all the way into trigger assembly

69. See leg opening in correct position

70. Trigger is completely rebuilt and ready to insert into your gun

71. Installing plunger back into your gun

72. Use a small amount of grease on the plunger head and inside the back of the plunger casing. Insert plunger assembly into the barrel

73. The back on the plunger casing has a flat top and one with legs. The flat top goes to the top of the barrel shroud

74. Using your plunger fork align forks on both sides of the plunger casing and push forward

75. Plunger fork will compress plunger spring so anchor pin can be inserted

76. Compress plunger fork all the way forward and install anchor pin with the curve of the pin toward the back of the gun

77. Drop anchor pin into barrel shroud be sure the anchor pin is behind the plunger spring

78. Installing trigger into barrel. Remove safety from trigger assembly

79. Slide trigger assembly into barrel

80. Line up trigger with the trigger screw holes in the barrel shroud

81. Insert the front trigger screw into the barrel and trigger assembly it is easier to do by holding your trigger in place from the inside

82. Tighten screw a couple of threads to hold in place

83. Insert the back trigger screw into the barrel and trigger assembly

84. Tighten screw a couple threads to hold in place

85. Insert safety into safety hole

86. With the leg opening to the top of the barrel insert into barrel make sure the pawl spring is under the safety

87. Push safety into place

88. Safety should fit flat against barrel shroud

89. Be sure the leg is open inside the barrel shroud using a flat screw driver to spread it apart

90. Insert lever into barrel shroud and line up the screw hole

91. Insert lever screw

92. Tighten lever screw

93. Put nut on lever screw and tighten

94. You can test your gun to be sure it is working by cocking the lever and pulling the trigger. If trigger does not catch push safety forward and pull trigger.

95. Insert stock into barrel shroud

96. Line up screw holes with the barrel shroud

97. Screw in side stock screws on both sides of stock

98. Put nuts on trigger screws and tighten

99. Replace forearm, push into barrel shroud so holes will line up for the screws

100. Replace forearm screws and tighten

101. Screw top stock screw in place

102. Insert shot tube in barrel shroud

103. Tighten shot tube into the abutment

104. Shot tube should be tight against the barrel shroud

105. Parts of the trigger assembly

106. Trigger with post, trigger spring with small amount of grease

107. Trigger spring installed on the trigger

108. Inserting the trigger and trigger spring in the trigger casing, be sure to line up trigger spring in notch on the sear

109. Trigger in trigger casing with pin hole lined up

110. Inserting pawl into the trigger assembly

111. Line up pawl in trigger casing, insert post on pawl under the tip on the sear, wide side of pawl is closest to you

112. Pawl inserted in place

113. Line up pawl with the pin hole

114. Holding the trigger in place to insert the pawl spring

115. Tuck pawl spring under the pawl, short leg of spring is against the trigger, long leg is toward the left side of the trigger assembly

116. Pawl spring is in the correct position ready to insert the trigger pin

117. Close up of pawl spring in correct position

118. Inserting safety into trigger assembly

119. Safety is installed into the trigger assembly with the leg opening to the top of the trigger

120. Tuck pawl spring under the safety

121. Push safety into the trigger assembly

122. Safety is installed into the trigger assembly

123. View of trigger assembly from the front