Instructions for making plunger fork tool.

Drawing for the trigger assembly

499 Parts Drawing / Ordering Information

Tools you will need to disassemble a model 499

Remove shot tube from barrel shroud

Remove forearm screw

Remove forearm

Remove top stock screw

Remove stock screws

Remove stock

Remove lever nut

Remove lever screw

Remove lever assembly

Remove trigger screws and nuts

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

Remove safety from trigger and barrel shroud

Remove trigger assembly from barrel shroud

Using plunger fork insert into the barrel to compress plunger spring

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

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

release

Remove the anchor pin

Using a flat screw driver remove the plunger assembly

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

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

Remove the abutment

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

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

Put abutment seal on the abutment plug

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

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

easier

Insert abutment with threaded side first into the barrel shroud

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

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.

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

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

place

To change plunger head remove the plunger pin

Remove plunger pin

Take off plunger head

Take off steel plunger washer

Remove plunger spring from plunger casing

Replace plunger spring on casing

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

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

Compress the plunger spring so you can insert the plunger pin

Rebuilding trigger instructions are for trigger pull to the left

Remove safety from trigger casing

Remove trigger pin

Remove pawl

Remove pawl spring

Remove trigger and trigger spring

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

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

Old and new trigger with trigger springs

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

left hand

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

Line up trigger in trigger case so pin will go through

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

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

Line up pawl hole with trigger and trigger case

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

casing

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

Pin should go all way through to the other side

Top view of assembled trigger

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

When installing safety the pawl spring is under the safety

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

Push safety all the way into trigger assembly

See leg opening in correct position

Trigger is completely rebuilt and ready to insert into your gun

Installing plunger back into your gun

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

plunger assembly into the barrel

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

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

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

Compress plunger fork all the way forward and install anchor pin with the curve of the pin toward

the back of the gun

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

Installing trigger into barrel. Remove safety from trigger assembly

Slide trigger assembly into barrel

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

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

Tighten screw a couple of threads to hold in place

Insert the back trigger screw into the barrel and trigger assembly

Tighten screw a couple threads to hold in place

Insert safety into safety hole

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

safety

Push safety into place

Safety should fit flat against barrel shroud

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

Insert lever into barrel shroud and line up the screw hole

Insert lever screw

Tighten lever screw

Put nut on lever screw and tighten

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.

Insert stock into barrel shroud

Line up screw holes with the barrel shroud

Screw in side stock screws on both sides of stock

Put nuts on trigger screws and tighten

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

Replace forearm screws and tighten

Screw top stock screw in place

Insert shot tube in barrel shroud

Tighten shot tube into the abutment

Shot tube should be tight against the barrel shroud

Parts of the trigger assembly

Trigger with post, trigger spring with small amount of grease

Trigger spring installed on the trigger

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

the sear

Trigger in trigger casing with pin hole lined up

Inserting pawl into the trigger assembly

Line up pawl in trigger casing, insert post on pawl under the tip on the sear, wide side of pawl is

closest to you

Pawl inserted in place

Line up pawl with the pin hole

Holding the trigger in place to insert the pawl spring

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

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

Close up of pawl spring in correct position

Inserting safety into trigger assembly

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

Tuck pawl spring under the safety

Push safety into the trigger assembly

Safety is installed into the trigger assembly

View of trigger assembly from the front