Last Updated on April 17, 2025
Flashlights are essential tools for everyday carry, emergency kits, and outdoor adventures. However, even high-quality models like those from Coast may occasionally face performance issues. Users may encounter problems such as dim light, flickering, battery failure, or a faulty switch. Sometimes, the issue requires a full disassembly to diagnose and repair the problem.
In this guide, we’ll walk you through how to disassemble a Coast flashlight—specifically the Coast PX20 and Coast G25 models—along with troubleshooting tips and warranty information.
How to Disassemble a Coast PX20 Flashlight
The Coast PX20 flashlight has a unique structure, with a dual-color (white and red) LED and a slightly different internal mechanism compared to other Coast models. Here’s how to take it apart:
1. Remove the Battery
The battery is located at the back of the flashlight. Grip the front and rear parts of the flashlight with both hands and turn the rear section counterclockwise. Once loosened, the battery compartment will open, allowing you to remove the batteries.
⚠️ Note: Some Coast models may have battery packs located in the center or front. In such cases, unscrew the head or tail cap counterclockwise to access the batteries.
2. Unscrew and Remove the Retainer
Inside the flashlight, a circular retainer holds the internal components in place. Using your fingers or a small tool, turn the retainer counterclockwise until it loosens. Once free, carefully pop it out and place it aside with the batteries.
3. Remove the Flashlight’s Switch
Beneath the retainer, you’ll find a small plastic cap and the switch assembly. Remove the plastic piece first. Then, use a small tool or tweezers to gently pop out the switch. If your flashlight has power issues despite fresh batteries, the switch is often the root cause.
4. Disassemble the Inner Assembly
Use a small screwdriver to carefully remove any additional screws or tiny components. Be gentle to avoid damaging any internal parts.
✅ Your Coast PX20 flashlight is now fully disassembled for inspection, cleaning, or repair.
How to Disassemble and Repair a Coast G25 Flashlight
The Coast G25 flashlight features a sleek, compact design with a focus beam and is popular for professional and home use. Its disassembly process differs slightly from the PX20:
1. Remove the Tail Cap
Hold the flashlight firmly and turn the tail cap counterclockwise. Apply slight force, as it may be tightly secured. Once removed, set it aside.
2. Remove and Replace the Battery
The G25 typically runs on standard AAA batteries (often three in a row). To access them, tilt the flashlight slightly downward, and the batteries will slide out. Replace them with fresh batteries in the correct orientation.
🛠 Tip: Always use high-quality alkaline batteries or rechargeable ones to extend flashlight performance.
3. Access and Replace the Switch
If the light still doesn’t turn on after a battery change, the switch may be damaged. You can remove it using a screwdriver or prying tool and then install a replacement switch, which is readily available online or from Coast parts dealers.
Coast Flashlight Warranty Information
Coast Products offers a limited lifetime warranty for most of their flashlights, covering defects in materials and workmanship. However, the warranty does not cover:
- Damage due to user misuse
- Normal wear and tear
- Battery leakage or corrosion
If the flashlight fails under normal use, Coast may repair or replace the unit free of charge. You can initiate a warranty claim on their official website by filling out a warranty service request form.
📩 For faster processing, always keep your purchase receipt and take photos of the issue.
Final Thoughts
Learning how to disassemble a Coast flashlight can save you time and money by allowing you to troubleshoot and fix issues yourself. Whether it’s a Coast PX20 or G25, careful disassembly helps you inspect each part individually—battery, switch, retainer, and inner assembly.
🔁 After the repair, always reassemble the flashlight in the reverse order and test it thoroughly before use.
Taking proper care of your flashlight and using the correct batteries can extend its lifespan. And when in doubt, rely on Coast’s support and warranty services for help.
Related Questions (FAQs)
Q: Can I use rechargeable batteries in Coast flashlights?
Yes, most Coast flashlights support rechargeable batteries, especially NiMH or lithium-ion types. Just make sure they match the voltage and size required.
Q: Why does my Coast flashlight flicker?
This could be due to a loose battery connection, dirty contacts, or a failing switch. Disassembling and cleaning the battery terminals often resolves the issue.
Q: How do I clean the inside of a Coast flashlight?
Use a dry cloth and a soft-bristle brush. Avoid using water or alcohol directly inside the flashlight. If corrosion is present, use a bit of vinegar on a Q-tip.
Q: Can I get replacement parts for Coast flashlights?
Yes, Coast provides replacement parts such as switches, lens covers, and O-rings. You can order them through their official website or authorized dealers.
Q: What should I do if my flashlight still doesn’t work after disassembly?
Try replacing both the batteries and the switch. If it still doesn’t work, the internal wiring may be damaged. In that case, contacting Coast customer support is your best option.
The batteries leaked a week after I got this and the spring was pulled out the first time I took the battery out/ Can I get a new cap for or do I have to throw it way? Thanks.