2107

I have one of those gold D4V2.

You’re in luck: you got the flush retaining ring so the light should be repairable. The flush retaining ring is removable. Unlike the raised retaining ring which I found impossible to budge.

  • Get a small Victorinox mini pocket knife, open the nail file.
  • The tip of the file should be a flat screwdriver with rounded edges.
  • Coming in from the side, insert it under the retaining ring just above where the rubber switchboot sat. Once it is wedged in, use it as a lever to lift up the retaining ring. The retaining ring is press-fit and should lever right up.

Next step is to desolder all the wires to the aux board and the star. Only attempt this if you have soldering skills and a fine tip for your soldering iron available. The wires to the aux LEDs are tiny. Before desoldering, take a picture so you can make sure to get every wire back to the right bondpad when reassembling.

After desoldering, remove the aux board and the star. Then insert a toothpick or other tool into the wire whole and push the driver out of the head. Once it is partially out you should be able to access to tiny wires which go to contacts on the underside of the red switch. Assuming those bondpads didn’t rip off the switch, soldering the switch wires back on. Reverse the process to reassemble.

Notes:

  • Since the rubber switch boot is destroyed you will need to obtain or make a replacement.
  • Also, if the switch retaining ring eroded the head coming out, you might find it may not stay in place. If you experience this try adding some super-glue gel between the retaining ring and head.
  • Due to the numerous small wires involved I wouldn’t recommend attempting this repair unless you’re an experienced modder. If not, you might want to contact Emisar about having them repair it.
  • It can be difficult threading the 4 aux board wires plus the 2 LED wires through the hole in the head and the star. If you have difficulty, solder some long narrow gauge guide wires onto the ends of the wires and then pull the guide wires through. Then desolder the guide wires.