My Harbor Freight 40V Lynxx pole saw started grinding and vibrating badly, making it unusable. I checked the chain drive tension and sprocket which seemed okay, I opted not to go further until I did some research.
I found Slowpoke Slim's "Had to fix my Harbor Freight pole saw today" post on TractorByNet.com which laid out the problem - the two Philips head screws (Owners' Manual parts diagram #24) that hold the support plate (#22) to the motor had backed out. Several other people had the same problem.
Disassembly: Remove the drive cover (#54) by removing the two hex bolts (using provided Allen wrench or T30 bit). Remove the e-washer, "Pressing Plate" (washer), and sprocket (#56 &57). Remove all the T20 torx bolts on both side to separate the clam shell. Leave the Phillips head screw that secures the chain tensioner in place. Make note of the orientation of the support plate, motor, and motor terminals. Remove the two torx bolts that hold the pressing plate (#8) that secures the cable. Lift the motor out while separating the pinion gear from the ring gear.
Repair: I removed the two screws that secure the support plate to motor. I cleaned them then added two dabs of Loctite, then reinstalled them.
Assembly: Reinsert the pinion gear, and set the support plate into the slots in the clam-shell. Reinstall the cable lock, align the ring gear and bushing and hopefully the clam shell halves will realign and close. Reinstall all of the bolts, sprocket, washer, and e-ring. Reinstall the drive cover. Test, saw, ...
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