Attempting to repair a Chi Flatiron
The Chi Flat Iron is an expensive device. When my Wife’s Chi broke, a little web research showed that problems with the power cord seem like a pretty consistent complaint. However, i could not find any good tutorials on how to fix the cord problem.. or even how to take the Chi apart. In the end, my problem was not related to the cord. I took photos as I dissembled the Chi in the hopes that some other poor husband who takes this on can have an inside look at the Chi before deciding to ‘dig in’
Using a knife or small flatblade screwdriver, remove the hinge cover on both sides of the Chi.
WIth the covers removed you will see the two screw heads that go through the hinge. using two screwdrivers carefully remove the screws. Use caution when removing and finally separating the two sides of the Chi, there is a spring in the hinge that may leap out at you.
You may find the process of removing the screws easier if you can gently clamp the Chi to a table or workbensh so it does not get away from you.
Here is the chi with the sides seaprated. I put the screw back in the hinge to avoid losing it.
The Chi with the cord removed. From what I read, this is a big point of failure with the Chi. While I had the cord out, I used a small wire brush to clean the contacts seen in the photo here.
The rotating cord
The backside of the circutboard, note the charring
the fried switch.
I removed the fried switch and then soldered a small piece of wire across where the switch was located, closing the circuit that was originally interrupted by the switch. So, now the Chi is on at all times when it is plugged in. Which is not a problem because my wife always keeps it unplugged anyway.
UPDATE 2009.12.31: Over 6 months later and the CHi is still going strong! :)
Also, I found an article by Nicholas Colyer dealing with troubleshooting and replacing the thermal fuse on a knockoff Chi, I read the article and it looks like the same information could be applied to an actual Chi. Check him out: http://thehackerdiary.blogspot.com/2009/07/repairing-flat-iron-thermal-fuse-fun.html
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Thanks for the photos, I needed to get ours apart and fix the heater wire that broke off with 10 cents of solder to save $129.89 + tax!!
Brad,
I could not find any take-apart photos for the Chi which is why i photographed my experience int eh first place. I am glad to hear my efforts have come full circle 
Sweet deal dude. I am glad these helped you.
-Joe
Joe,
How did you initially take it apart? I don’t want to break anything more…
So, did you end up being able to fix it??
@James I need to take it apart again to get photos of the first few steps. I did not have the idea to start photographing last time until I already had it apart. There is a screw that goes through the pivot-point on the chi. You remove the two plastic plugs that are over the hinge area and you will see the screw. it was pretty tough to get loose. I actually ended up using a clamp on the Chi to hold it still while i was trying to get the screws loose the first time.
@Michelle, Yes. it has been rock solid since the fix. The Wife just unplugs it when she is done (she always did anyways). No more problems.
So..
I just disassembled mine (honestly without any electrician knowledge). How do I figure out what is wrong with it? Or how to fix it?
Thanks!
joe did you find any schematics or info on the resistors on the circuit board? my g/f’s friend dropped her chi and now it does not work…. I have taken it apart… no charing… I am getting power past the swivel point… but im not sure how to find out much after that… I see that one iron has a purple power wire and the other has a red…any input is appreciated
@Cory: Sorry dude, I am not skilled enough to be able to perform component level troubleshooting. I cant help you there. And i have not seen any schematics. If you come across any I would love to see them (and share them on the site here.)
Good luck.
A little extra correspondence that took place via email that may be helpful to other readers:
Joe: Hi Michelle, thanks for reading my blog. i wanted to let you know I
replied to your comment (my system does not do auto notifications.)
thanks again!@!
Michelle: were you able to fix it after all?
Joe: yes, it has been working solid since the fix bypassing the switch fixed the problem. The Wife just has to unplug it when she is done with it (she did all the time anyway)
Michell: I don’t think I can fix this on my own. I checked in with Salon Art, I guess they are the repair shop for Chi and they are going to charge me $30 to fix it, and $11.46 for shipping and handling. Unbelievable. Glad you got your wifes working though!
Joe: That is not a terrible price considering the chi is worth around $200 (right?). Also it took me about 2 hours to fix our chi…. if i was making $15/hr as a tech to fix the iron, you would break even paying the $30 to get it fixed at the shop.
Good luck!
Michell: This is true, thanks!
Joe: Oh by the way, if you dont mind I would like to paste our correspondence here into the comments of the blog post. I will obscure your full name and email of course. Is that cool?
Michell: Of course, you have been helpful.
Joe: Hi Nicole. I got your comment on my chi article. Congrats on the successful take-apart
What are your symptoms? How is your chi malfunctioning?
Nicole: it just won’t power up. And the “reset” button has done nothing. So some type of electrical problem I suppose? Any ideas?
Joe: That is what happened to my wifes Chi. he switch was acting flaky for
a while then the unit finally stopped working. Does the power switch
on the Chi move OK? or is it grindy and/or too loose seeming? your
switch may have fried like ours did. If that is the case you may be
able to get the switch replaced or bypassed like I did… but If you
are not an experienced solderer I would recommend seeking help from an
electrician. good luck! Let me know how it works out or If i can help any more.
Thanks for the photos and comments. I had a failed switch, too, but instead of removing the switch I just soldered the 2nd and 3rd switch pins together on the bottom of the board and that just shorted the switch. It was much easier and faster than removing the switch and soldering in a wire.
Hi, I brought my chi to Peru with me this summer and plugged it in thinking the voltage was right but appartantly it wasn’, the chi turned on and then turned off and hasn’t worked since, I’m guessing I fried something inside, can I fix it or do I need a new part?
so joe, my chi iron wire that connects to the chi tore. do u know how to fix it?
Joy: I am guessing you fried it. There is a chance that you just fried the cord/breaker portion of your Chi cord. (can you press the test/reset buttons on it still?)
Rose: If the cord is frayed, someone experienced with electrical repairs will be able to solder and re insulate your cord no problem. If you need to replace the cord entirely, that wont be that difficult ether, you will need to locate a dealer who sells a compatible replacement cord and then just follow the first few steps that I used above to dissemble the chi to be able to attach the new cord to the chi.
Good luck!!
Ok Joe, what do you know about “thermal fuses”. I think this is what could be wrong with my ridiculously priced CHI. The reset button on the cord still works and so I don’t think it is the cord. I was just using it and all of a sudden, no more heat. I have had it for a little over a year, which sucks cause of the 1 year warranty. I am not worried about taking it apart, just taking it apart in vain, and not being able to put it back together.
Melissa,
I just found an article by Nicholas Colyer dealing with troubleshooting and replacing the thermal fuse on a knockoff Chi, I read the article and it looks like the same information could be applied to an actual Chi. Check him out: http://thehackerdiary.blogspot.com/2009/07/repairing-flat-iron-thermal-fuse-fun.html As far as the take- apart goes, it is not that bad if you are a little technically inclined. If the chi is dead what is the worst thing that can happen?… break it more? (Just dont hurt yourself messing with electricity please!)
Thanks for the help. This will be the fourth time I have worked on my wife’s chi. The other times were because the plates came off. I used epoxy to glue them back on. It holds up to the high heat. It does smell for a couple of months but then goes away. This time it seemed to have a short in the cord. Your pictures were very helpful in getting it apart. Thanks.
Just added a link back to you. Thanks a million!
how do you get the spring back in?
For me, the spring was not all that tight of a fit. I just held it in place while I reconnected the two sides.
hey joe,
Glad you are there. I am having a hard time getting it back in. Does the end pieces go in the led side?
Sounds like you were able to get it back in but I am not having much luck
Hi Monica, honestly it has been many months since I had the Chi apart. I am looking back at the photos above, (3rd one) and it looks like most of the hardware goes on the non-LED side, then after you line up the two sides, you insert the screw that locks the sides together. (if you get it back together successfully and can report back what you did i would love to have it here for other readers. (My wife will kill me if i take hers again unnecessarily)
thanks but that was not help
I will keep trying thanks
if your chi’s not working and the power cord is fine, look underneath the ceramic plate on the same side as the switch. there is a thermal fuse under there that goes out quite a bit, you have to get them online but they only cost 1 dollar. i have repaired over 20 of the chi’s and 90% of the time it is this fuse. hope that helps somebody
My CHI won’t work. I thought it was the ground fault plug. When I push the yellow button it clicks. I don’t think it clicks on the red button, but the light did flash. Do you think it’s the cord or the fuse. Thanks, Jean
Thank You! This is the exact problem that my wife’s Chi is experiencing and, until now, did not know how to disassemble it. Thanks again.
Hi, my chi does not get hot enough to straighten my hair.. will the fuse issue fix the heat, or do you know how to turn up the heat? The cord is fine. thanks,Candace
Hi: Just found your web site. My chi problem I believe is definately in the cord - next to the actual plug. If I move the cord just right - my chi will heat and I can use it if I’m cautious not to move the cord. My question - can I replace the plug on my chi as I think the wire must be loose or cracked and that is why if I can make an exact connection, she works fine.
thanks
Gail