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
Hi! On the Chi I’m trying to save the yellow circular component has totally burned to dust. Does anyone know the product code for it? I’v ezoomed into the picture posted here and can roughly make out ’5?A7?’ etc. Obviously not enough
Is there any help for me out there? THANKS!!!!!
Hey, first off thanks for putting this site together… it has been a great help so far. My girlfriend’s chi stopped working overnight last night. I have taken it apart and do not see any charring on the circuit board.
I believe that the problem is either in the power chord swivel connector male plug or in the swivel connector female piece. I have minimal experience in this area and went to radio shack for advice. I was wondering if it is possible to just remove the swivel connector and crimp the wires from the power cord (black and white) directly to the wires coming from the swivel receptor (red and white).
The person at Radio Shack warned me that if the swivel piece contained any other parts (such as capacitors) that this could fry the whole iron. Is this indeed something that I should be concerned about? Thanks so much!
Nice site, and great pics/how to.
Brett: I don’t think that directly connecting the wires to the cord will impose any problems electrically, but unless you stop the end piece from rotating, you will create stress that will tear your wires apart, especially if your girl rotates the Chi a lot when doing her hair. You would need some sort of strain relief so that the cord doesn’t just pull out and tweak the wires.
My husband is an electrician and took it apart. He said that the problem with mine is in the plates….Where can I get plate replacements??
THx Joe. My wifes third CHI stopped working. Used your tutorial to discover a broken wire from one of the plates and dirty contacts in the rotating power cord. All is well now !
Boycott this company, even though they make the best iron, little needs to be said about their tech support/customer service. They haven’t the foggiest clue about what it means to all of us! Paperweight!
Thanks Joe.. my chi iron quit this morning while I was getting ready for work. I contacted SalonArt and they weren’t very friendly. It worries me to ship it off, don’t know that I’ll get it back. Sooooo.. I’m going to show my husband your page and hope he’ll try to fix it. Maybe you’ll insprie him!! =)
i just got my chi yesterday and last night the LED light would not come on but it still heats up fine, wat would the problem be and howdo i fix it
Thanks for the “take-apart” photos! It really helped a lot. My husband is trying to fix mine. Did anyone of you have problem with the cord connections inside? Mine is just not making contact all the time, its arching (means the electricity is making a little bit of spark internally, not visible). My CHI still works and I’ve had it for 5 years now..this problem just started 2 months ago although it is still working, I just have to turn the swivel cord and make sure it doesn’t move when the red power light comes on..otherwise it shuts off. My husband is an electrician and I insist on him trying to figure out what is wrong or if its fixable..anything to save me $199.99! He is fixing it as I write on here
Any advice would be helpful:)
By the way, he switch is fine and the ceramic still heats up super fast!
Will you fix mine? I have two that go on and off when the cord shifts or the plates are pushed down.
Thanks for the help! The switch on my daughter’s Chi got stuck in the OFF position. Following your advice, I got it open and shorted the switch. I just took long-nose pliers and bent the ‘middle’ and ‘on’ contacts together and soldered them. Works great!
Awesomeness! great step by step and really good high quality images to help through the process. Thanks for taking the time to share the tutorial!
If I send mine to you can you fix it for $40?
Hello Joe….Wow women can really use a guy like you around the house…lol! Well here i s my situation…I don’t have a guy around the house to fix my CHI. So have you considered doing this one the side and helping out some single moms with their CHI problems? Heck I’d be willing to throw a few dollars your way along with shipping expense rather than buying a new one! Besides…I don’t like my hair curly all the time
Joe,
Great site. I have a fake CHI that my wife has had for about 1 1/2 years. It will turn on and heat up fine. but after about five minutes of being on it cuts off and will NOT come back on till it cools off. Just wanted to confirm if you think this sounds like thermal fuse?
Thanks,Ray
@Kate Glad to hear this helped you. I did clean the cord connection for our Chi when i had it apart, although it was not giving us any specific trouble. That is definitely a weak spot in the design. If you can, a good wire-brushing would probably help your situation a bit.
@Heather I dont know that it would be worth your money to ship me your Chi. I am not a pro electrician / electronics guy. I think you would have better luck bringing the Chi into your local electronics repair shop and seeing if they can take a look at it. I would love to have $40, but I dont know that I would be the best use of your money. (If anyone has some recommended repair shops, let me know. maybe we can get a list together to recommend to folks)
@Linda Thanks for the complement. (as for the fixing, see Heathers reply above)
@Ray Yes, it sounds like the thermal fuse to me… although be careful because it is possible that the unit is really overheating and the fuse is just doing its job.
Joe,
when i had apart and fuse was out in open where it could cool and not under plate it would not cut out like when it was assembled. Thanks for the fast replies. Ray
New Thermal fuse installed from Radioshack. It is a bit lower rating 228 degrees C instead of 240 like original one but it has now been on for about 30 mins and has not yet shut off. Thanks for your help. Ray
I forgot to say it was fixed for 1.80 for part suppose to be a
SEFUSE
SF240E
240°C
10A
250V
Radioshack only had 228° so I got that and took me abouot an hour to take apart and put back together. Easy to do GREAT fix for saving Expensive irons.
Hi,
I bought two chi one for my daughter and one for me. After 5 months of usage ever time I plug it in it seems to shut down. If I move the cord back and foreword it comes back on. It keeps going on and off every time. What do you think it is?Should I do the same thing you did?thx
THANK YOU SO MUCH! this helped a lot i was able to fix it in about 5 minutes the hardest parts were screwing the parts back together lol