Ion 39350 ION G2 8 inch Series 036545 2020

This guide covers the maintenance and common repairs for the Ion G2 8-inch Electric Ice Auger (Model 39350). Since this is a high-torque electric tool with incredibly sharp components, please prioritize safety above all else.

Safety Precautions

Warning: Always remove the battery before performing any maintenance, blade changes, or clear-outs. The blades are razor-sharp; use protective gloves and keep the blade guard on whenever possible.

Required Tools

• 10mm wrench or socket

• Hex key set (metric)

• Phillips head screwdriver

• Light machine oil or lithium grease

• Clean rag

Troubleshooting Guide

Core Repair Procedures

1. Blade Replacement

The G2 utilizes a high-strength composite bottom head. If the auger is "skating" on the ice rather than pulling itself down, the blades are likely dull.

• Removal: Use a 10mm wrench to remove the two bolts holding each blade to the bottom head.

• Inspection: Check the composite head for cracks. If the head is warped, the blades will not sit at the correct shaving angle.

• Installation: Align the new blades. Hand-thread the bolts first to avoid cross-threading into the composite head, then tighten firmly. Do not over-tighten, as you can crack the mounting points.

2. Shear Bolt Inspection

If the motor spins but the drill assembly remains stationary, the shear bolt has likely broken. This is a safety feature designed to protect the motor if the auger hits a hard object or freezes in the hole.

• Location: The bolt is located where the powerhead output shaft meets the auger flighting (the spiral drill).

• Replacement: Align the holes of the shaft and the flighting. Push a new 1/4-20 x 1-1/2" grade 8 bolt (or the official Ion replacement part) through and secure it with a nylon locking nut.

3. Handle and Trigger Assembly

If the trigger feels "mushy" or fails to engage, the issue is usually a loose connection or a physical obstruction inside the handle.

• Access: Remove the Phillips head screws on the handle casing.

• Repair: Check the wiring leads to the trigger switch. If a wire has vibrated loose, re-seat it. Ensure the spring-back mechanism on the safety-lock and trigger is free of ice or debris.

• Note: The G2 uses a digital controller. If the wiring is intact but the motor won't engage, the control board may need professional replacement.

4. Gearbox Maintenance

The G2 features a planetary gear system. While generally "sealed for life," extreme use may require attention.

• Checking: If you notice grease leaking from the output shaft, the seal has failed.

• Lubrication: If the gearbox sounds dry or "whiny," you can remove the powerhead cover to access the grease ports. Use a high-quality synthetic cold-weather grease that won't stiffen in sub-zero temperatures.

Battery and Storage Care

The Ion Gen 2 batteries are the most expensive component of the system.

• Off-Season Storage: Do not store the battery on the charger or completely empty. Charge it to approximately 50-70% (2 or 3 lights) and store it in a cool, dry place.

• Temperature: Lithium-ion batteries lose performance in extreme cold. Keep the battery in a side pocket of your bibs or a heated bag until you are ready to drill.

• Terminals: Keep the copper contacts on the battery and the powerhead clean. Use a Q-tip with a tiny amount of rubbing alcohol to remove any oxidation or dirt.

Maintenance Schedule

• Every Trip: Check that the blade bolts are tight and the blade guard is secure.

• Monthly: Check the shear bolt for bends or wear. Wipe down the flighting with a light coat of oil to prevent surface rust.

• End of Season: Remove blades, grease the threads of the bolts, and store the battery at partial charge.