Difficulty
Moderate
Steps
7
Time Required
10 - 35 minutes
Sections
1
- Flex
- 7 steps
Flags
3
Grammar Police
Embrace your inner English teacher and help improve this guide’s grammar!
Markup Mishap
This guide needs better markups. Help out by correcting or making some markup annotations.
Member-Contributed Guide
An awesome member of our community made this guide. It is not managed by iFixit staff.
BackMakita HS7601J
Full Screen
Options
History
Save to Favorites
Download PDF
Edit
Translate
Get Shareable Link
Embed This Guide
Notify Me of Changes
Stop Notifications
Introduction
What you need
Step 1
Removing cover
- Remove the five screws shown on photo, for this a philips or slotted screwdriver will do.
Remove the five screws shown on photo, for this a philips or slotted screwdriver will do.
1024
Step 2
Removing cable grip
- Remove the two black screws that hold the red cable grip in place.
Remove the two black screws that hold the red cable grip in place.
Step 3
Removing old cable
- Using a philips screwdriver, unscrew the screw on the live terminal (the brown wire), there should be a little brass piece below the screw (do not lose this piece).
- Using a 3.5mm screwdriver, loosen the terminal screw on the white connector and remove the neutral wire (the blue wire).
Using a philips screwdriver, unscrew the screw on the live terminal (the brown wire), there should be a little brass piece below the screw (do not lose this piece).
Using a 3.5mm screwdriver, loosen the terminal screw on the white connector and remove the neutral wire (the blue wire).
Step 4
Preparing to bare cable
- For this step you will need to source a replacement flex for the saw, the saw does not require an earth so a two core flex will be acceptable. The diameter of the wire can be 1mm-1.5mm. The length of the flex can be whatever you want it to be but I suggest a similar length to what it was originally.
- If you can’t get a replacement flex with a moulded plug top, you will need to source a new plug top as well. The replacement flex I had to hand had a moulded plug top so I won’t be showing how to wire one here.
- For this step you will also need a crimp that has a similar size of hole to the one that was originally on the cable. You will also need a crimping tool to crimp the wire and a pair of side cutters and a sharp knife to bare the cable and prepare it for termination.
For this step you will need to source a replacement flex for the saw, the saw does not require an earth so a two core flex will be acceptable. The diameter of the wire can be 1mm-1.5mm. The length of the flex can be whatever you want it to be but I suggest a similar length to what it was originally.
If you can’t get a replacement flex with a moulded plug top, you will need to source a new plug top as well. The replacement flex I had to hand had a moulded plug top so I won’t be showing how to wire one here.
For this step you will also need a crimp that has a similar size of hole to the one that was originally on the cable. You will also need a crimping tool to crimp the wire and a pair of side cutters and a sharp knife to bare the cable and prepare it for termination.
Step 5
Baring cables
- Bare the flex back around three to four inches, for this you can use a sharp knife to very lightly slice around the flex being very careful not to cut the cores inside. If you score it well you will be able to manipulate the cable by bending it back and fourth and it will snap the insulation along the line that you have cut with the knife.
- Please be very careful not to cut yourself or others while doing this. If you have cut into or damaged the inner cores in anyway cut it off and start again. When you have removed the outer insulation you will have two cores (a brown and a blue). Bare both the cores back around 8mm and be careful not to damage the strands of the wire.
- you should now look at the crimp you are going to use and decide whether or not there is space for the wire to be doubled over, doing this will insure the cable has a tight and secure connection.
- place the crimp onto the end of the bared cable (the brown wire), and make sure the copper is showing just ever so slightly through the top of the crimp, also make sure there is no copper showing out of the back of the crimp, then using the crimping tool, crimp the wire then lightly pull in the crimp to make sure it’s secure and doesn’t come off.
Bare the flex back around three to four inches, for this you can use a sharp knife to very lightly slice around the flex being very careful not to cut the cores inside. If you score it well you will be able to manipulate the cable by bending it back and fourth and it will snap the insulation along the line that you have cut with the knife.
Please be very careful not to cut yourself or others while doing this. If you have cut into or damaged the inner cores in anyway cut it off and start again. When you have removed the outer insulation you will have two cores (a brown and a blue). Bare both the cores back around 8mm and be careful not to damage the strands of the wire.
you should now look at the crimp you are going to use and decide whether or not there is space for the wire to be doubled over, doing this will insure the cable has a tight and secure connection.
place the crimp onto the end of the bared cable (the brown wire), and make sure the copper is showing just ever so slightly through the top of the crimp, also make sure there is no copper showing out of the back of the crimp, then using the crimping tool, crimp the wire then lightly pull in the crimp to make sure it’s secure and doesn’t come off.
Step 6
Termination cable
- Before you do anything else with the cable, reattach the flex protector (the rubber sheath that protects the flex from bending. For terminating the brown wire, place the crimp on the wire over the screw hole, place the brass piece on the screw and place the screw roughly in the hole and use a philips screwdriver to tighten it.
- Make sure the screw is not loose and is fairly tight as you don’t want this coming loose again. For the blue wire, loosen off the screw in the white connector using a 3.5mm screwdriver all the way and slide the blue cable in till there is no copper showing and make sure no strands are showing as well then tighten.
Before you do anything else with the cable, reattach the flex protector (the rubber sheath that protects the flex from bending. For terminating the brown wire, place the crimp on the wire over the screw hole, place the brass piece on the screw and place the screw roughly in the hole and use a philips screwdriver to tighten it.
Make sure the screw is not loose and is fairly tight as you don’t want this coming loose again. For the blue wire, loosen off the screw in the white connector using a 3.5mm screwdriver all the way and slide the blue cable in till there is no copper showing and make sure no strands are showing as well then tighten.
Step 7
- Piece the components back into the handle and make sure the wires are neat and tidy, do not let any of the wires spill out of the case as it will be difficult to put the cover on. Once you have placed everything in properly, place the cover on and place all five remaining screws in their holes and tighten them using a philips screwdriver.
- Now you have successfully replaced the flex, now you should plug it in and test it. Also make sure that there is a 13 Amp fuse in the new plug top.
Piece the components back into the handle and make sure the wires are neat and tidy, do not let any of the wires spill out of the case as it will be difficult to put the cover on. Once you have placed everything in properly, place the cover on and place all five remaining screws in their holes and tighten them using a philips screwdriver.
Now you have successfully replaced the flex, now you should plug it in and test it. Also make sure that there is a 13 Amp fuse in the new plug top.
Cancel: I did not complete this guide.
One other person completed this guide.
Author
with 1 other contributor
Dylan
Member since: 07/16/2021
145 Reputation
1 Guide authored
Badges:
2
