How to Replace the Cord Guard on a Skilsaw

Kinked cord? You probably need a new cord guard. The power cord passes through the cord guard as it goes into the saw's handle. The cord guard gives extra support to the cord, preventing it from kinking and rubbing against the handle. The cord guard is made of rubber, which will eventually harden and crack. Once it does, the cord may kink or crack near the handle. This can lead to broken wires. Left unprotected, the cord can also rub against the handle housings, eventually rubbing through the insulation (leaving bare wires).

Let's get started.

REMOVING THE CORD GUARD   1. Remove half of the pistol grip handle.

a. Remove the four (smaller) screws securing the two halves of the pistol grip handle.

b. Remove the two (larger) screws securing the top and bottom of the pistol grip handle to the motor housing.

c. Remove the right half of the pistol grip handle.

  2. Remove the cord clamp.

a. Remove the two screws securing the cord clamp to the handle.

b. Remove the cord clamp from the saw.

  3. Remove the power cord.

a. Remove the screw securing the switch assembly to the handle.

b. Pull the switch away from the housing.

c. Note the locations of the wires that are connected to the switch (to simplify reassembly).

d. Remove the screws securing the cord wires to the switch assembly.

e. Disconnect the cord wires from the switch.

f. Remove the screw securing the ground wire to the motor housing.

g. Remove the power cord.

  4. Remove the cord guard.

a. Remove the cord guard from the power cord.

INSTALLING THE NEW CORD GUARD

  5. Install the cord guard.

a. Slide the new cord guard over the cord wires and onto the power cord.

b. Slide the cord guard (backwards or forwards) along the power cord until approximately one inch of insulation is exposed (beyond the cord guard).

REASSEMBLING THE UNIT

  6. Connect the power cord.

a. Thread the screw through the eyelet on the (green) ground wire and secure the screw (and the ground wire) to the motor housing.

b. Refer to your notes (and use a screwdriver) to reconnect the wires to the switch assembly.

  7. Reinstall the switch.

a. Install the switch into the handle.

b. Secure the switch to the handle with the screw.

  8. Reinstall the power cord.

a. Install the power cord (and the cord guard) into the handle. (The cord guard should fit snugly into the recess on the handle.)

b. Install the cord clamp.

c. Secure the cord clamp with the two screws.

  9. Reassemble the pistol grip handle.

a. Tuck the cord and switch wires into the (left half of the) pistol grip handle.

b. Install the right half of the pistol grip handle.

c. Secure the top and bottom of the handle with the two (larger) screws.

d. Secure the two halves of the pistol grip handle with the four (smaller) screws.