TweetFollow Us on Twitter

"Yoyo" Power Supply Repair

Volume Number: 20 (2004)
Issue Number: 5
Column Tag: Programming

"Yoyo" Power Supply Repair

by the MacTech Magazine Editorial Staff

How one goes about writing for the magazine

Problem

Apple's award-winning industrial design is world-renowned. One of the most eye-catching devices introduced with the original iBook was the so-called "Yo-yo" power adapter. Sleek and compact, it unfortunately came with a flaw; the vulnerability of the cable near where it connects to the computer. After repeated flexing (from 6 months to over a year) the braided ground portion becomes frayed and detaches inside the clear insulation. This leads to intermittent connections, then complete failure. We have experienced four of these failures, on my wife's iBook/300 and my Pismo/400. The first one was replaced under AppleCare, but the rest would require replacement at $65 each. (Used ones on eBay might be found for $35-$50).

After several months of being out-of-work (common these days for a high-tech software professional in Silicon Valley) and sharing our one functional unit between the two laptops, I finally took a look at the two broken ones we had left and decided to do a little surgery. What could go wrong? The result, after about 1.5-2 hours of careful work, is a functioning power adaptor. It's not pretty, but it should function for a while. I'd like to share the repair process.

Required Tools

Soldering iron and solder (electronic/rosin core); several pliers (slip-joint and needle-nose); an X-acto hobby knife with pointed blade; RTV silicon sealant; electrical tape and shrink-fit tubing; very steady hands and a keen eye doing close-up work. (I once worked as a professional jeweler, and have had much experience doing electrical work. YMMV..). One additional tool is a "third-hand," (http://store.yahoo.com/internettrains/exhotoexha.html) a hobby/craft device with clips to hold your work while you solder.

Disassembly

The first stage is disassembling your adaptor. You need to first cut away the clear covering on the connector; carefully cut lengthwise along the top side (away from the nub that fastens the cable end to the housing). Then cut around the connector so you can separate this piece into two sections; one will slip off the end of the connector, the other will slide back along the cable away from the end. Put these pieces aside so that they may be reassembled later. (Figure 1)


Figure 1. Initial stage of disassembly

(I apologize for not showing earlier stages of the disassembly; the idea to write the article occurred at this stage of the project).

Connector Surgery

Once you have the covering off, you will find a metal slug through which the cable threads. Pull this back to expose the tail end of the connector shell itself. Before disassembling the shell, you will need to de-solder the grounding resistor (Figure 2).


Figure 2. De-solder resistor from connector end before pulling apart

Now that you have the resistor de-soldered, bend the lead back carefully so that the connector end may be detached from the connector itself. A slight tap may be needed to separate the parts. Now the area where most of the work happens is exposed. (Figure 3).


Figure 3. Connector innards exposed.

Here you will need to cut away all the clear "potting" material so that the wires may be de-soldered from the connector. Carefully cutting into the material with your X-acto knife, you may chip the material free from the connector while taking care to NOT slice into the resistor. This one piece needs to be intact when re-assembling your power-supply cable.

After you have cleaned out all the potting material (Figure 4), you will be able to de-solder the wires from the old (broken) end of the cable.


Figure 4. Connector innards un-potted.

Here is where the "third-hand" becomes a valued tool; you need to hold the soldering iron in one hand, have a tool in another hand to pull the wire free (tweezers or a metal pointed tool) and be able to hold the work being de-soldered so that you don't get burned.

Reassembly

Now that you have removed the old wire from the connector, we can deal with the broken end of the cable to be reused. Before going further, you will have to thread back onto the cable the external parts of the assembly that were initially cut free. (You did cut them free carefully so they could be reused, and did not throw them out, right?) Make sure they go back in the order shown in Figure 5. (Additional note: one piece in the illustration did not belong; I had to remove it later. It is the piece with the "nub" that holds the cable end to the housing you wind the cord into). At this time you should also thread onto the cable a 1.5-inch segment of shrink-tubing which will later be used to protect the braided ground shielding.


Figure 5. Re-assembling the shell begins...

Now that you have threaded those parts onto the cable, you need to prepare the end for re-soldering. Cut the end clean where the cable had gotten frayed, then strip back about two inches of the outside insulation. Carefully push about an inch of the braided ground layer back from the end, and twist it off to the side (Figure 6). Twist up about 1/2 inch of the braiding and lightly "tin" the end with solder (this will help to attach it to the connector). Twist up 1/4 inch of the inner conductor and "tin" the end.


Figure 6. Preparing the end for soldering.

Now you should slip a 1/2-inch section of shrink-tubing over the inner conductor; then you are ready to attach the end to the forward-section of the connector, where it was attached before (Figure 7).


Figure 7. Reattach center conductor.

The tricky bit comes next. You will need to solder both the braided ground and one end of the resistor to the middle segment. (My apologies for not including a photo of this step).

Now that the ends are connected, you may begin to reassemble the shell. Slip the long tube over the end of the connector innards; there is one "right" way it goes on. You will see evenly spaced rectangular indentations on the end where the tip protrudes. And the tip should protrude about 1/8 inch beyond the end of the tube (Figure 8).


Figure 8. Assemble connector.

Before you fit the inner end of the inside portion over the end tube, you will be repotting the soldered area with silicon seal (Figure 9). You should also take care that the tail of the resistor is threaded out the end of the cap back toward the cable; you will need to solder it onto the outside of the shell after reassembly.


Figure 9. Example of RTV (Room Temperature Vulcanizing) silicon seal

Squeeze a small amount into the end of the tube and a little into the inner cap; then using a flat tool, pack the material into both ends of the connector. Slip the cap onto the tube and carefully, while holding the tube end with pliers, press-fit the cap onto the tube (Figure 10). You will see some of the sealant ooze out; this can be cleaned off later.


Figure 10. Press-fit cap onto tube after packing with silicon seal.

Let this assembly cure for a while, and get a cup of coffee. After it has cured, carefully bend the tail of the resistor back over the metal tip and solder it to the shell. (Refer to Figure 2).

Now you can slip the gray metal piece onto the end of the connector, and then slip the outer plastic section over the metal slug. Now slide the portion of the cover with the nub over the end of the connector, as shown in Figure 11.


Figure 11. Reassembly of outer cover.

When the segments of the shell covering are pressed together, you can complete the repair by wrapping in electrical tape. Start at the very end and work toward the cable. Keep the tape tight as you go, as the tape will be a structural member of the assembly; it will serve to keep the shell together and provide shielding to the exposed section of braided ground.

Testing

Now that you have completed reassembly, the moment of reckoning is at hand. Plug your power cord into the yoyo housing, and then into the wall socket. Now attach the repaired cable connector to your iBook or PowerBook. If your laptop is powered on and booted up, you should see the battery/power indicator showing it is charging/plugged in. Congratulations! You're an electronics repair technician!

The author of this article has been working with computers for far longer than he would like to admit, and on Macs since late 1984. His wife, two grown children, both parents, and both (older & younger) sisters are all Mac owners as well. When NOT working or playing with their Macs, Mark and his wife enjoy the company of three Yorkshire Terriers, three cats, and five cockatiels. You can reach him at n_mark_jaffe@yahoo.com.

 
AAPL
$98.38
Apple Inc.
-0.64
MSFT
$43.89
Microsoft Corpora
-0.09
GOOG
$585.61
Google Inc.
-4.99

MacTech Search:
Community Search:

Software Updates via MacUpdate

Drive Genius 3.2.4 - Powerful system uti...
Drive Genius is an OS X utility designed to provide unsurpassed storage management. Featuring an easy-to-use interface, Drive Genius is packed with powerful tools such as a drive optimizer, a... Read more
Vitamin-R 2.15 - Personal productivity t...
Vitamin-R creates the optimal conditions for your brain to work at its best by structuring your work into short bursts of distraction-free, highly focused activity alternating with opportunities for... Read more
Toast Titanium 12.0 - The ultimate media...
Toast Titanium goes way beyond the very basic burning in the Mac OS and iLife software, and sets the standard for burning CDs, DVDs, and now Blu-ray discs on the Mac. Create superior sounding audio... Read more
OS X Yosemite Wallpaper 1.0 - Desktop im...
OS X Yosemite Wallpaper is the gorgeous new background image for Apple's upcoming OS X 10.10 Yosemite. This wallpaper is available for all screen resolutions with a source file that measures 5,418... Read more
Acorn 4.4 - Bitmap image editor. (Demo)
Acorn is a new image editor built with one goal in mind - simplicity. Fast, easy, and fluid, Acorn provides the options you'll need without any overhead. Acorn feels right, and won't drain your bank... Read more
Bartender 1.2.20 - Organize your menu ba...
Bartender lets you organize your menu bar apps. Features: Lets you tidy your menu bar apps how you want. See your menu bar apps when you want. Hide the apps you need to run, but do not need to... Read more
TotalFinder 1.6.2 - Adds tabs, hotkeys,...
TotalFinder is a universally acclaimed navigational companion for your Mac. Enhance your Mac's Finder with features so smart and convenient, you won't believe you ever lived without them. Tab-based... Read more
Vienna 3.0.0 RC 2 :be5265e: - RSS and At...
Vienna is a freeware and Open-Source RSS/Atom newsreader with article storage and management via a SQLite database, written in Objective-C and Cocoa, for the OS X operating system. It provides... Read more
VLC Media Player 2.1.5 - Popular multime...
VLC Media Player is a highly portable multimedia player for various audio and video formats (MPEG-1, MPEG-2, MPEG-4, DivX, MP3, OGG, ...) as well as DVDs, VCDs, and various streaming protocols. It... Read more
Default Folder X 4.6.7 - Enhances Open a...
Default Folder X attaches a toolbar to the right side of the Open and Save dialogs in any OS X-native application. The toolbar gives you fast access to various folders and commands. You just click... Read more

Latest Forum Discussions

See All

Note Review
Note Review By Jennifer Allen on July 29th, 2014 Our Rating: :: TOO SIMPLEiPhone App - Designed for the iPhone, compatible with the iPad Note is a note taking app that’s a little too short on features to be worth its asking price... | Read more »
Chainsaw Warrior Goes on Sale & Ther...
Chainsaw Warrior Goes on Sale & There’s a Chance to Win a Copy of the Original Board Game Posted by Jennifer Allen on July 29th, 2014 [ permalink | Read more »
It Came From Canada: Tiny Tower Vegas
If you go to a casino, you might make a lot of money. If you run a casino, you’re guaranteed to make a lot of money. The choice seems pretty obvious. So while waiting for your shady real estate deals to move forward, get prepared with Tiny Tower... | Read more »
Z Hunter Review
Z Hunter Review By Lee Hamlet on July 29th, 2014 Our Rating: :: RIGHT ON TARGETUniversal App - Designed for iPhone and iPad While it might not necessarily break new ground, Z Hunter has enough tricks up its sleeve to ensure that... | Read more »
Huge Update Comes To Duet, Adding 48 New...
Huge Update Comes To Duet, Adding 48 New Stages Posted by Jennifer Allen on July 29th, 2014 [ permalink ] Universal App - Designed for iPhone and iPad | Read more »
Sharknado: The Video Game Available Now....
Sharknado: The Video Game Available Now. Seriously. Posted by Rob Rich on July 29th, 2014 [ permalink ] Universal App - Designed for iPhone and iPad | Read more »
Frog Orbs 2 Review
Frog Orbs 2 Review By Nadia Oxford on July 29th, 2014 Our Rating: :: THIS MAGIC IS A TAD MONOTONOUS Universal App - Designed for iPhone and iPad Frog Orbs 2 is repetitive, but younger players should enjoy it nonetheless.   | Read more »
Puzzix Review
Puzzix Review By Jennifer Allen on July 29th, 2014 Our Rating: :: NICE IDEAUniversal App - Designed for iPhone and iPad A little like Tetris, Puzzix is all about piecing together blocks and watching them vanish. It could do with... | Read more »
Cannonball eMail is Now Live – Works Wit...
Cannonball eMail is Now Live – Works With Gmail, Yahoo, Outlook, Hotmail, and AOL Posted by Jessica Fisher on July 29th, 2014 [ permalink ] | Read more »
To The End Review
To The End Review By Lee Hamlet on July 29th, 2014 Our Rating: :: A VICIOUS CYCLEUniversal App - Designed for iPhone and iPad To The End will test players’ patience, timing, and dedication as they try to navigate all 13 levels in... | Read more »

Price Scanner via MacPrices.net

WaterField Unveils 15″ Outback Solo & 13″...
Hard on the heels of Apple’s refreshed MacBook Pro Retina laptops announcement, WaterField Designs has unveiled a 15-inch version of the waxed-canvas and leather Outback Solo and a 13-inch version of... Read more
New Roxio Toast 12 Delivers Digital Media Pow...
Roxio Toast 12 is a hub for sharing digital media to virtually any platform or device. has introduced two new additions to its Roxio Toast product family – Roxio Toast 12 Titanium and Roxio Toast 12... Read more
The lowest prices on leftover Retina MacBook...
Best Buy has dropped prices on leftover 13″ and 15″ Retina MacBook Pros by up to $300 off original MSRP on their online store for a limited time. Choose free local store pickup (if available) or free... Read more
Apple Updates MacBook Pro with Retina Display...
Apple today updated its MacBook Pro with Retina display with faster processors and double the amount of memory in both entry-level configurations. MacBook Pro with Retina display features a Retina... Read more
Up to $250 price drop on leftover 15-inch Mac...
B&H Photo has dropped prices on 2013 15″ Retina MacBook Pros by as much as $250 off original MSRP. Shipping is free, and B&H charges NY sales tax only: - 15″ 2.3GHz Retina MacBook Pro: $2349... Read more
Updated MacBook Pro Price Trackers
We’ve updated our MacBook Pro Price Trackers with the latest information on prices, bundles, and availability on the new 2014 models from Apple’s authorized internet/catalog resellers as well as... Read more
Apple updates MacBook Pros with slightly fast...
Apple updated 13″ and 15″ Retina MacBook Pros today with slightly faster Haswell processors. 13″ models now ship with 8GB of RAM standard, while 15″ MacBook Pros ship with 16GB across the board. Most... Read more
Apple drops price on 13″ 2.5GHz MacBook Pro b...
The Apple Store has dropped their price for the 13″ 2.5GHz MacBook Pro by $100 to $1099 including free shipping. Read more
Apple drops prices on refurbished 2013 MacBoo...
The Apple Store has dropped prices on Apple Certified Refurbished 13″ and 15″ 2013 MacBook Pros, with model now available starting at $929. Apple’s one-year warranty is standard, and shipping is free... Read more
iOS 8 and OS X 10.10 To Support DuckDuckGo As...
Writing for Quartz, Dan Frommer reports that Apple’s forthcoming iOS 8 and OS X 10.10 operating systems version updates will allow users to select DuckDuckGo as their default search engine. He notes... Read more

Jobs Board

Sr Software Lead Engineer, *Apple* Online S...
Sr Software Lead Engineer, Apple Online Store Publishing Systems Keywords: Company: Apple Job Code: E3PCAK8MgYYkw Location (City or ZIP): Santa Clara Status: Full Read more
*Apple* Solutions Consultant (ASC) - Apple (...
**Job Summary** The ASC is an Apple employee who serves as an Apple brand ambassador and influencer in a Reseller's store. The ASC's role is to grow Apple Read more
Sr. Product Leader, *Apple* Store Apps - Ap...
**Job Summary** Imagine what you could do here. At Apple , great ideas have a way of becoming great products, services, and customer experiences very quickly. Bring Read more
*Apple* Solutions Consultant (ASC) - Apple (...
**Job Summary** The ASC is an Apple employee who serves as an Apple brand ambassador and influencer in a Reseller's store. The ASC's role is to grow Apple Read more
*Apple* Solutions Consultant (ASC) - Apple (...
**Job Summary** The ASC is an Apple employee who serves as an Apple brand ambassador and influencer in a Reseller's store. The ASC's role is to grow Apple Read more
All contents are Copyright 1984-2011 by Xplain Corporation. All rights reserved. Theme designed by Icreon.