ERS7 Lower gear guide

If your AIBO is suffering from a clicking or grinding noise from one of the legs, it could be caused by dirt in the servo. Firstly, you should be aware that when handling sensitive electronic equipment you should take static prevention measures.

I hope you’ve been honest with yourself about your skills.
There is no warranty here. Use this guides at your own risk!

You will need Philips PH0 screwdriver, a small brush and a tooth pick.

Remove and safely store your AIBO’s battery and memory stick before attempting to remove any covers. The last thing you need is for your AIBO to wake up during its operation!

Do not attempt to reactivate your AIBO until all limbs and covers are reconnected and reassembled.

Remove the two screws from the lower leg casing.


There is a small catch on the underside of the paw that holds the two halves together. Be careful not to break it. If you slide a guitar pick or fingernail between the two halves, you can pop this clip without leaving any marks.


Remove the four screws that hold the gearbox together.


Be carefully when removing locket. There is a flexi wound up under the main knee gear, so you should just move it far enough to free the gears and no more, also be sure not to pinch it, or get it tangled. Put something under to keep parts in place.



To make things easier, you might remove the axles.


Brush or pick out any debris in the gear teeth. Then blow them off with some canned air.
It goes easier, if add a few drops of dish soap to warm water and brush them clean.


Reassembly is a reversal of this procedure.

For getting back the leg on to the main gear once you’re done cleaning, follow this steps.
The axle with the shape edge has to fit into the pot. When putting together, move slightly in both direction. You will notice when it’s fits. Press softly both parts together while moving.



Potentiometer cleaning if needed.

If your AIBO is suffering from tremors, shaking or juddering limbs it could be down to a dirty potentiometer in the limb or body. Potentiometers are there to sense the position of the specific joints in the AIBO. Over time and use they can become corroded and dirty causing the position of the limb to be misinterpreted by the AIBO itself.

You will need Philips PH0 and PH1 screwdrivers. A small, sharp knife and a can of switch cleaning spray with a “tube” attachment. I have had best results using “Kontakt 61”


The potentiometer (silver coloured casing) is located at the knee joint and is covered by a flexi circuit. The flexi is plugged into a small grey connector and can be released by sliding the 2 black lugs on the connector. Carefully pull the flexi out of the connector once these lugs have been released.


Use a sharp knife to carefully pry open the corner of the potentiometer cover. The cover can then be removed exposing the inside.


Inside the potentiometer is a black circular disc on which is mounted spring contacts. Carefully remove this by using a blunt object in the cut out area shown.


Spray the switch cleaner over the potentiometer surface. At this point, a soft, lint free cloth may be used to wipe the potentiometer surface.


Carefully replace the black disc and silver cover.

When the disc and cover are in place and the potentiometer is safely back together, gently move the joint back and forth to work the cleaner across the contact surface.

Reassembly is a reversal of this procedure. Carefully reconnect the flexi.


With all the limbs and connectors safely reconnected and the covers back on your AIBO, you can now replace the memory stick and battery and test your AIBO.

If everything has gone according to plan, your AIBO’s limbs will move smoothly without any clicking/ratchet sounds. If they don’t, you may need to give the affected limb another treatment. If another treatment doesn’t work, there may be a different problem with that particular limb. At this point it is better to seek further advice than attempt to resolve the problem yourself by other means.


Thanks to:
Frootloop & Rambozo