Ryobi Circular Saw Broken, and Fixed!

[Redbaran]

So I'm only posting this because I couldn't find anyone on the internet that had the same problem, so unless you have this saw, or want to laugh at me for buying a cheap saw, you can probably just skip this thread all together. If you're searching the internet 5 years from now and have the same problem and this posts helps, feel free to drop a "thanks" reply to this thread.

The circular saw I have is a "Ryobi 14 Amp 7-1/4 in. Circular Saw with Laser, Model # CSB142LZK". I bought it about 2 years ago and used to build an outdoor pergola and it worked great. I only used it once since then and I had to knock it a couple times for it to start working, but then it worked fine the rest of that day. This week when I went to use it had been about a year since the last time that it worked.

So the issue that I had was that my saw just wouldn't start. The lights were on (the power light, the LED work light and the laser), but pressing the trigger did nothing. After ordering a new Makita circular saw, I figured I had nothing to lose by taking this one apart.

Using a multimeter, I found that with the switch pressed, I didn't have continuity across the negative or across the positive terminals on the switch, when the switch was depressed. Taking apart the switch I found that the contacts were slightly corroded as shown in the attached image, but not terrible IMHO (though honestly, I haven't see many). When I pressed the contacts against the mating contacts to complete the circuit, I got continuity on the negative, but not the positive. This makes me think I had two problems, dirty contacts (causing the positive circuit to never complete) and a switch that didn't work (also causing the negative to not work). Cleaning all eight contacts allowed me to get continuity on both when I pressed them together manually.

The real problem, and the reason I guess I'm posting this is to talk about putting this darn switch back together. The manual says this is a "pre-travel safety switch", which means that the switch doesn't engage until you've pressed the switch some. The way this is accomplished is there are two plates: the plate that is attached to the trigger that slides up when the trigger is pushed, and a parallel plate that has the contacts on it. There is a spring, that is LOOSE for heavens sake that sits between the two plates and it held in place by the combination of pressure and two nubs on each plate. When the trigger side plate slides up, the nub and that end of the spring slides over the top of the contact plate and it's nub, which causes the spring to snap the contact plate down and complete the circuit. The nubs aren't very big, so I think the spring must have slid off of the nubs and that's why I wasn't getting continuity on either leg.

Getting this put back together is a major pain in the butt. Next time you hear about some poor Chinese worker committing suicide, it's probably the guy that has to assemble these switches. Hopefully there is some easier way to put this back together, but what I did is the following:

1. Take the entire switch out of the saw
   
   
2. Place the half with the terminals on it's back. There is a spine to this piece, so I put it in the miter slot of my table saw so that it laid flat resting on the edges instead of the protruding narrow spine.
   
   
3. Place the plate with the contacts into the terminal half of the house.
   
   
4. Carefully balance the spring in a vertical position on top of the nub on the contact plate. Cussing may help this process.
   
   
5. Partially press the trigger so that the nub on the switch side plate lines up with the top of the spring which should be directly over the nub on the back of the contact plate.
   
   
6. Lower the trigger half onto the terminal half so that you compress the spring between the two nubs.
   

Once the switch is back together, you should hear it make a snapping noise when you press the trigger and the contact plate snaps down. I tested for continuity at this point to make sure the switch was working before I put it back in.

I can't imagine that this "safety" feature adds enough safety to make it worth such a simple thing being the weakest link in the whole process. I suppose we should thank the lawyers. I'm glad I bought a new circular saw so that I'll have a reliable tool, and fixing this allows me to sell it and at least recoup some money.

Anyways, good luck if you have the same problem. A new switch is about $20 with shipping if you find you have the same problem and don't want to screw with it. When looking for parts, I had to search for "CSB142LZ".

[davestanton]

Ryobi is not my favourite brand but I am glad you found a fix. Now you have a spare or an ebay item.

[Hybrid-woodworker]

I don't own this saw but do appreciate the description of the problem. There are probably lots of switches out there that have similar configurations and this post should help explain some of them. I also have one or two Ryobi tools but have not been overly impressed with the build quality.

BRuce

[TRBaker]

The only Ryobi tool that I've ever been impressed with is the 20" chainsaw that I bought. It started on the first pull and worked like a charm. It only cost around $100.00. I would have bought a better saw if I used a chainsaw very often, but I only use one every blue moon.

[Danjapan]

Thanks for posting this. You helped me fix my saw. I bought this model refurbished and used it once to make sure it worked. I then shipped it to Japan and tried to use it again. The lights and laser would come on but the motor wouldn't. I found your post on the first page of my google search.

I took out the switch and disconnected the wires. But before opening the switch I exercised the trigger a few times. It then started making a nice clicking sound which it wasn't doing before. I plugged it in and sure enough it's working. Awesome !

[lensman]

@RedBaran - Thanks for this. I have discovered same problem (don't know about the cause yet) as you stated. I bought this saw in the summer of 2012 to build a deck. Worked perfect. Put it away in the storage bag that came with it and left in garage through two Canadian winters and summers until we come to today.... And now the damn thing doesn't work. As noted above the light and laser still work fine.... just no power to damn blade. I don't know if I have the technical ability to repair it as you did but at least this will give me a start...

[markjb57]

For me, I had the same experience as danjapan. I took out the switch but didn't take it apart. The action of testing the switch with the multimeter (putting the leads into the screw holes) seemed to "reset" the click mechanism, and the click was back.  When the switch clicked closed, the circuit was successfully closed on each side.

 

Thanks for info, as without it I probably wouldn't have tried.

[Air Al]

So I'm only posting this because I couldn't find anyone on the internet that had the same problem, so unless you have this saw, or want to laugh at me for buying a cheap saw, you can probably just skip this thread all together. If you're searching the internet 5 years from now and have the same problem and this posts helps, feel free to drop a "thanks" reply to this thread.

...

 

Redbaran,

 

I signed up here expressly to thank you for your post.  I had a similar problem with my Ryobi CS1151 corded circular saw.  Loved the thing but it suddenly didn't work after a period of no use. I suspect that I had abused it, possibly setting it down too roughly after the last use, which might have dislodged the spring.  That theory seems logical since it did not fail during use.  It does seem that use could also dislodge the spring.  If it fails again I will drive to a Ryobi plant and throw it through the front window, with RMA #CRAPPYSWITCHDESIGN sharpied onto it.

 

Your description was extremely helpful in fixing mine.  One thing that might be different with my model is that the spring has two small concave cupped disks covering each hold in the spring's ends. These tiny disks also were just loose in the trigger contacts box. I had to carefully place those onto the spring's ends THEN balance it the way you described.  I added one little trick to help balance the spring, I put small dab of silicone grease on the contacts plate which held the spring and tiny disks in place on the peg just long enough for me to luckily line up and snap the thing back together with the trigger peg aligned. It was absurdly tedious and difficult, almost impossible seemingly, and I was equally absurdly lucky that it worked in one attempt.

 

What a ridiculous design. I will treat this saw with tender loving care from now on to hopefully avoid jostling this precariously positioned switch spring.

 

Thanks again for your detailed and thoughtful solution.

 

Peace,

Al

[54Bear]

Glad I found this!

 

Similar problems - blue model Ryobi that refused to spin up after being idle for some months.

 

I suspect I was luckier than most as I didn't even get to pick up a screwdriver.  In the act of putting it back onto the workbench, my finger slipped off the trigger (it was unplugged), the trigger sprang back and made a click sound.  That seemed to restore the click mechanism thingie so the saw works again.

 

Just depress the trigger fully then slide finger off the trigger so it springs back.

 

Of course, it MAY have been the mean look I gave it, or the extensive (but highly creative) string of obsceneties aimed at the designers...

 

Yours Aye,

~Bear™

[JP Ouch]

Hi all, just wanted to throw my experience in here as we'll in case it saves someone a few minutes. Bought my saw reconditioned & didn't even plug it in until long after 30 days, so never knew it was inoperable when it arrived & had no recourse for return. Oops.

I tried what 54Bear said about not taking it apart & just flicking the switch, didn't work. However, that method did work the rest of the week after taking the saw apart & taking the switch out (but not taking it apart). First time I pressed the trigger while it was out of the casing, it clicked. After putting it back together, about half the time I'd need to flick the trigger to get the click back, but it never stopped working entirely.

[JP Ouch]

Update: the trigger stopped working again after the saw sat unused for a few months.  No amount of trigger-flicking or "gentle tapping" on the handle would bring back the click.  However, what did work was putting sideways pressure on the trigger while pulling it - so instead of just pulling the trigger, push it to the left as you pull.  Glad I didn't have to take it apart again!

[Doctorj]

Great help...I have the same saw and it wouldn't work in the middle of rehabbing my pool house...had to finish with a battery saw (yuck!). Saw your post about the switch and the "pull trigger with pressure to the left" worked on the second try! Moral: China has exported this same technology to its satellite, North Korea. Probably explains why their missiles don't work very often. Clever way to keep a rowdy subordinate nation under control! Thanks so much for the help.  Doctorj  

[Air Al]

Thanks JP Ouch.  Mine failed again.  I'll try the push to the left option.  I'd love to replace the switch, but there probably isn't an improved part.

[Klappco]

Did you have the lifetime warranty?

[Friend]

Thank you for this post! It was very helpful to fix my saw as well!!

I did almost the same thing as Danjapan and markjb57.  The lights and laser would come on but the motor wouldn't start.

I took out the switch and disconnected just first wire (white colour) . I did not disconnect all the wires and just tried the trigger few times and  it started making a nice clicking sound which it wasn't doing before. Looks like once you disconnect the wires from the switch(I just disconnected one white wire), -- it resets  the click mechanism.

Everything works perfect! It was really easy and fast fix!!

Thanks again and Good luck!!

[Gene Miller]

thanks, a friend gave me the saw, like yours, said it would not turn on. I found your web page, opened the switch cover, but before I took it apart I squirted some wd40 on the switch and pulled it a few times. It started clicking, put it back together and plugged in and it ran.  Your help and help of WD40 I have a good saw. If it stops again I know how to fix.

[Novicewoodworker]

Thanks to Redbaran and then Danjapan I was able to sort out my saw that was not spinning (laser and light had power). I hadn't used the saw for over a year so it sounded like the same problem. I didn't even have to take the thing apart, just "exercised" the trigger while the saw was put together. While repeatedly depressing the trigger I applied pressure in different directions until it started clicking. I plugged it in and it fired right up, has been working fine ever since. Thanks everyone!

 

[Chris W]

Thank you Redbaran! And to all the others that have replied over the years!
I've had this saw for years but have not used it for many. Had the same "no-click" trigger issue.
After reading through the replies, and finding out that the switch is discontinued (gee I wonder why), I was set to start taking the saw apart to fix it as RB described.
I tried pulling the trigger a few times, with pressure to the left and right, to no avail.
On whim, I grabbed a light rubber mallet and whacked the trigger housing/handle a few times.
Sonufabi#$% if it didn't do the trick.
The snap returned to the trigger. Plugged it and fired right up.
FYI: Parts Warehouse and Repair Clinic each list a trigger under my model (CSB142LZ), though not the original part number that e-Replacement Parts shows in their diagrams as discontinued.
(Each site lists a different part number, presumably both substitutes.)

[Coop]

Hell of a deal! 

[Stinkerton]

Thanks to Redbaran and all other contributors:

I also have this saw and it has seen occasional use since buying it around 2012. I also had the lights/laser, but no spinning blade issue and had it ready to go to Goodwill, but thought, I'll see if I can get it to work one last time. I disassembled the clam shell, tested continuity, and had decided the motor must be seized.... Then I found this post and after "flicking" trigger and applying lateral pressure to it, she started right up with gusto. Much obliged!

[Coop]

On 5/19/2022 at 3:57 PM, Stinkerton said:

Thanks to Redbaran and all other contributors:

I also have this saw and it has seen occasional use since buying it around 2012. I also had the lights/laser, but no spinning blade issue and had it ready to go to Goodwill, but thought, I'll see if I can get it to work one last time. I disassembled the clam shell, tested continuity, and had decided the motor must be seized.... Then I found this post and after "flicking" trigger and applying lateral pressure to it, she started right up with gusto. Much obliged!

I’ve gotta ask. So you did give Goodwill a working saw as opposed to a non working one, right?

[Fortunateone]

Thanks! I picked one of these up from goodwill for about 10$ bag included. Wasn't working but the trigger flick worked for me! Appreciate the post even a decade later!

[Frank]

After reading all the comments and solutions, I got my hammer and just

tapped around the trigger.  Voila!  You saved this saw from trash heap.  Thanks guys!!!

[Cheap at the Beach]

So how about a thank you 10 years later?!?!  Identical issue but I'm at the beach with year round humidity so tools take a beating thanks to the combination of dust, sand, salt air, and humidity.  Thanks for posting!! 

[jqsjqs]

On 9/13/2015 at 12:38 PM, JP Ouch said:

Update: the trigger stopped working again after the saw sat unused for a few months.  No amount of trigger-flicking or "gentle tapping" on the handle would bring back the click.  However, what did work was putting sideways pressure on the trigger while pulling it - so instead of just pulling the trigger, push it to the left as you pull.  Glad I didn't have to take it apart again!

This 100% worked for me. 
 

This happened to me about 5-6 years ago and I remember reading this article and taking apart it apart to get at the trigger. That fixed it that time. Happened again today after a long time not using it. Was about to trash it when I vaguely recalled something about the trigger and a fix I read, so here I am again. This time, though, just pushing the trigger to the left and pulling it a couple of times, the trigger started clicking again and it started right up.

Thank you!!