How to Take Apart and Re-assemble a Leatherman Wave

This Instructable will demonstrate a full break down and reassembly of a Leatherman Wave tool. The focus is on the proper placement of parts along with some tips and tricks to make it go easier. We'll be using a couple specialty tools, but you can make do at home with the basic "required tools" list.

Please be warned that tampering with your tool may void the warranty. If you're having an issue with your tool, Leatherman has a great warranty repair program, and in most cases you can send your tool in for factory repairs.

If you're looking for a specific modification to your tool and would like to have a warranty, please check our our website. We will mirror the original factory warranty on the functionality of all of our modified tools.

Step 1: Materials and Tools List

Basic Tools List

2x torx 10 security bits (must have the hole in the tip)
1x 1/4" bit driver holder
vice or clamp to hold one of the torx bits
a "poking" tool of some kind - an old worn torx screwdriver is used in the demo
lubricating oil (optional, as necessary)
loctite (optional, as necessary)

Advanced Tools List

a stable platform for holding your torx bit steady
an assembly pin for aligning the exterior functions

Quick bit of advertising
You can find replacement parts and modified multi-tools on our website:

txtoolcrafters.com

Here are some shortcuts to the blades for the Wave:

Charge/Wave 420hc Plain Edge Blade

Charge/Wave 420hc Serrated Blade

Charge/Wave 420hc Serrated Blade (Black Oxide)

Charge/Wave s30v Plain Edge Blade

Charge/Wave Damascus Plain Edge Blade

Charge/Wave Damascus Serrated Blade

Charge/Wave s35vn Super Steel Blade

Please feel free to contact us directly for any other parts you might need for your Leatherman tool:

customer.support@texastoolcrafters.com

Step 2: Remove the Exterior Screws and Functions (side A)

We're defining side A as the half of the tool with the plain edge blade and file. The handle measurements should start with 1" on this side.

Align the tool in the holder as photographed. This orientation is recommend as you can hold the pin steady on the torx bit mounted on the table while rotating the screw with your screwdriver.

When the screw is removed, use your poker to push the pin the rest of the way through the tool. You may need to pinch the exterior functions together to prevent them from binding on the pin.

You'll be left with a screw, a pin, two brass bushings, the plain edge blade, file, and two remaining assemblies.

Step 3: Remove the Exterior Screws and Functions (side B)

We're defining side B as the half of the tool with the serrated blade and saw. You'll see 5" - 7" markings on this side of the handles.

The procedure is the same as side A:

Align the tool in the holder as photographed. This orientation is recommend as you can hold the pin steady on the torx bit mounted on the table while rotating the screw with your screwdriver.

When the screw is removed, use your poker to push the pin the rest of the way through the tool. You may need to pinch the exterior functions together to prevent them from binding on the pin.

Step 4: Remove the Interior Screw and Functions (side A)

On the interior, side A is the side with the 1"-3" markings, the removable bit holder, and the can/bottle opener.

About this pin

The pin for the interior functions is keyed. It is not cylindrical -- there is a flat area on opposite sides of the pin. This key correlates with the shape of the steel bushings between the functions, and the handle bracket.

It is important to orient the tool as photographed so that the pin is not rotated. If the pin is rotated while the functions are held still, it is possible to "round out" the steel bushings and misalign the key, making it difficult to remove the pin.

After the screw is removed, you should be able to easily push the pin out with the poker.

If you can't easily remove the pin

This can be common for heavily used tools and if you accidentally rotated the pin when removing the screw.

First, try gently rotating the pin back and forth a bit. If it feels like you can rotate a few degrees in either direction without resistance, the pin is probably still aligned properly and you can try using a bit more force with your poker to remove the pin.

If you feel resistance immediately, most likely the key is misaligned with the bushings. You'll need to keep rotating the pin until you feel an area where the resistance lowers. Once you feel this ~3 degree region, try removing the pin with your poker.

On very old/well used tools, sometimes this step is a hassle and force is the only option.

When you're finished with this step, you'll be left with the interior functions, two end caps, and one steel keyed bushing.

Step 5: Remove the Interior Screw and Functions (side B)

On the interior, side A is the side with the 5"-7" markings, the scissors, eyeglass driver, and standard screwdriver.

The procedure on this side is the same as on side A. It can be slightly more difficult, as there are two keyed bushings instead of one.

When you're done, you should have the interior functions, end caps, and two steel keyed bushings.

Step 6: Re-assemble Interior Functions (side A)

Use your poker as a "threader" to load up the functions and bushing.

Orient the handle bracket horizontally so that the interior cavity is parallel with your workspace. Hold the functions together and slide the bunch into the handle. If you're holding it correctly, gravity should be holding the functions together at this point. A drop of oil can also help keep things in their place.

Remove the poker and slide the functions the rest of the way into the handle bracket. If you've done it cleanly, things should be pretty well aligned looking down the hole.

Step 7: Re-insert Interior Pin (side A)

Maintain a horizontal position during this step to keep everything aligned.

Position the bottom end cap (only one will fit properly) and hold it in place between your thumb and index finger. If you're right handed, do this holding with your left hand.

With your other hand, feed the pin up through the bottom.

The steel bushing is probably not going to be oriented perfectly. Sight down the hole from the top and gently rotate the pin. You will be able to see the bushing -- ensure that the pin goes through and does not slide off to the side. Gentle rotating will align the bushing and it will feed through.

If desired, reapply loctite, position the end cap, and reinsert the screw.

Tension as desired -- we recommend tightening hand tight and backing off 1/4 turn.

Step 8: Re-assemble Interior Functions (side B)

The steps are the same for side B, with the added complications of extra functions and the lanyard loop.

Here are some tips:

ensure that the two pieces of the scissors function are meshed together properly before sliding into the tool
double check that both of the steel bushings made it around the pin before reinserting the screw
refer to the photos for the orientation of the lanyard loop

Step 9: Re-insert Pin (side B)

Again, same as side A, just more difficult because of the extra functions.

Step 10: Add Pliers and Exterior Functions to the Interior Assemblies

Position everything as shown, roughly aligning the holes. The liner lock mechanism holds the exterior blades in place during this step.

Here's where the blades go, using the ruler as a guide:

1"-3" : main blade

2cm - 8cm : file

12cm - 18cm: serrated blade

5"-7" : saw

Step 11: Assembly Pin (optional)

This is a special pin that makes assembling this side of the tool quick and easy. You can make your own out of 5/32" diameter rod or send us an email and we'll sell you one.

It's not necessary, but expect a bit of frustration finishing up the assembly without it.

Step 12: Re-insert the Exterior Functions Pin (side A)

Orient the tool horizontally as shown.

Slide the brass bushings into place between the function and the handle bracket on both sides. A drop of oil can help keep them in place.

If you have an assembly pin, slide it in and push the pin through behind it.

If you do not have an assembly pin, here are some tips:

use rotation to help guide the pin through the tool
pinch the sides of the tool to help orient the holes (there are some springs that need to be compressed for perfect alignment
ensure that the exterior functions

Once the pin is through, reapply loctite and insert the screw. Tighten to the desired tension.