Sinclair Community College Engineering Design Electric Guitar Service Manual Written by: Sam Schulze, Brian Stebbins, Henry Merrill Sinclair Community College | ETD 110 Guitar Service Manual 1
Contents: pg. 3 � Overall Assembly � Wiring Diagram � Parts List pg. 4 pg. 5-6 � � � � � � � � � � � � � � � pg. 7 pg. 9 pg. 11 pg. 13 pg. 15 pg. 23 pg. 26 pg. 28 pg. 30 pg. 32 pg. 34 pg. 36 pg. 37 pg. 39 pg.
Recommended Tools: For routine maintenance only a set of basic hand tools is required. However for jobs such as nut and tuner repair, specialty tools may be required for correct results. If the special tool is required, it will be noted on the page describing the repair process. If you do not feel comfortable attempting any of these repairs, we recommend taking your guitar to a professional luthier in your area to have the work done.
Overall Assembly: Sinclair Community College | ETD 110 Guitar Service Manual 4
Wiring Diagram: Sinclair Community College | ETD 110 Guitar Service Manual 5
Wiring Diagram - Mighty Mite Pickup: Sinclair Community College | ETD 110 Guitar Service Manual 6
Restring: Restringing a guitar is one of the most common repairs you will have to do to keep your guitar in top playing condition. It is very simple to do and should take no more than a half hour to complete. � � � � Guitar strings Wire cutters Powdered graphite (optional) Tuner 1.) Loosen the strings by slowly turning each of the tuners on the headstock clock-wise. Only loosen each string, do not remove yet. 2.
5.) Continue threading each string from the 5th to the 1st. Make sure not to over tighten any strings as they will snap. 6.) Trim the long ends of the strings above the tuning posts.
Tuner Repair and Replacement: � Philips screwdriver � Sewing machine oil � Calipers There are two ways to easily maintain your tuners to ensure that they will operate properly for the life of your guitar: Keep them tight and keep them oiled. Before you perform any maintenance, be sure to first remove the strings from the tuners. There are two screws on the tuners that will need to be tightened.
the tuning button. Your gears should turn smoothly now, and last for the life of your guitar. Generally there are only 2 parts you’ll have to replace tuner-wise, those being the tuner button, or the entire tuner assembly. Replacing the tuner button is simple, all you have to do is take out the screw that holds the tuner button in place and the button will slide off its post. Simply slide the new one on and put the screw back in place and you’re done.
Pickup Adjustment: � Regular or Philips screwdriver There are literally hundreds of styles and configurations for guitar pickups, the majority of which are called “floating pickups”, named because they do not mount directly to the guitar body but are attached to a pickup ring with springs between the ring and pickup frame holding the pickup in place. The springs allow the pickup to “float” in place.
there is any difference; adjust until the bridge and neck pickups are the same volume. Another way to easily check if the pickups are adjusted correctly is to measure the height of the strings on each side of the pickup and adjust till they are the same height on each side. Fine tuning can now be done my testing the volume just like we did before.
Pickup Selector Repair: � Screwdriver � Wire clippers/strippers � Soldering iron and solder The pickup selector is simply a toggle switch that is used to control which pickups are being used when playing the guitar. Since most guitars have at least 2 separate pickups, the pickup selector switch is crucial to finding the perfect sound to suit your playing style. While there are various types of pickup selectors available, the ones used in our guitar are known as a 3-way selector.
Pickup Selector Repair: Pickup selectors can wear out over time. The lugs and the rotating switch can lose their tight connection with years of use. Replacing the switch is pretty simple and only requires a few steps. Most pickup selectors are either mounted to the top of the guitar through a cavity routed in the back of the body or mounted to a pick guard. For pickup selectors that are mounted to the top of the body, simply take a screwdriver and unscrew the pickup selector.
Fret Repair and Replacement: � � � � � � � � � � � � X-Acto knife Calipers Feeler gauge Radius gauge Fret wire bender (optional) Fret press Fret hammer Screwdrivers (various sizes and types) Fret bevel End nippers Chisel Guitar Wax The is the part of the fret that comes into contact with the strings at the top of the fret. The is the bottom of the fret wire that is set into the fret board. The are the protrusions that stick out of the fret tang to hold the fret wire in the fret slot.
Fret Repair and Replacement cont: Fret wires are commonly made out of nickel and stainless steel, although they can be made out of several kinds of materials. Stainless steel is much denser than nickel which helps prevent wear. On the other hand stainless steel is much harder to install than nickel due to its density. Nickel is often recommended for the average player. After your frets have been removed from the guitar you need to measure the size of the crown.
Fret Repair and Replacement cont: Fret boards have a slight curve to them known as the radius and this will have to be measured if you want to install new fret wire. To measure the radius, you will have to take the strings off and place a radius gauge against the board. Turn the gauge until you don’t see any light coming through when you have the gauge placed on the board. Radius Gauge Fret wire will usually come in 1 or 2 foot sections, although they can be bought pre-cut.
Fret Repair and Replacement cont: A fret that is improperly seated in the fret board will most likely cause string buzzing. To tell if a fret is seated properly you can look at the base of the crown and the fret board. The crown should lay flat against the fret board so there is no space in between. If the fret is improperly seated then it needs to be removed and reseated properly.
Fret Repair and Replacement cont: Unlike early Fender’s, today the frets are directly place into the slots in Fender guitars. They also held into place by glue so that will have to be heated up to be able to remove the fret. Here are the steps for moving this kind of guitar. 1. Remove the strings from the guitar 2. Unscrew the neck and remove it from its pocket on the body. 3. Take a soldering gun and file a notch in the so that it can fit the fret wire in. 4.
Fret Repair and Replacement cont: With these types of guitars, the frets are usually installed before the lacquer in put on. This means that if you try to directly remove the frets than you could create cracks in the lacquer. To prevent this, score the edges around the base of the fret with an Xacto-knife. Now when you remove the fret, it won’t be attached to the lacquer and cause it to crack or chip. The rest of the steps for removing the fret are the same as above.
Fret Repair and Replacement cont: A fret can be put into a slot with either a fret press or a fret hammer. If you are using a fret press then lightly hammer both ends of the fret when setting it in the slot. You can then press the fret in with the fret press. If you only have a fret hammer then lightly hammer both ends of the fret as before. Then lightly tap all the way across the fret. Make sure the fret is all the way in the slot and there is no space below the crown.
Fret Repair and Replacement cont: Make sure you remove the excess glue on the fret board before it dries. To do this take a dull chisel and scrape it off, this can be done on both finished, and unfinished fret boards Chisel After the glue has dried, you can take a pair of end nippers and cut off the edged of the frets that are hanging off the sides. After they are nipped off, you should take a file and smooth down the edges. Make sure to file downwards on the side of the board.
Action Adjustment: � Feeler gauge � Allen wrench to adjust truss rod � Radius gauge The action is the height of the strings from the fret board and is usually measured at the 1st or 12th fret. Strings that are set high above the fret board are known as “High-action” the opposite goes for strings that are set low. The Action of a guitar is important when determining its playability. If the action is too low, then it can cause string buzzing.
Action Adjustment cont: Most of the time adjusting the action can be as simple as adjusting the truss rod. For more serious action problems you may have to adjust the nut or bridge of your guitar. Just know that the three main areas to go for adjusting the action is the truss rod, nut and bridge. Adjusting the truss rod will straighten and flatten out the neck which will bring your action back to its normal level.
Action Adjustment cont: 7. The distance between the bottom of the high E string and the top 12th fret should be set to 2/32”. If the string is higher or lower than 2/32” then you will have to adjust the saddle piece with an Allen wrench. 8. Set the low E string to 3/32” at the 12th fret by raising or lowering the saddle. 9. Place a radius gauge that corresponds to the radius of the fret board radius on the strings. The gauge should sit on the low and high E strings while touching the middle strings.
Bridge and Intonation Repair � Small Philips screwdriver or 1.5mm Allen wrench There are many different styles of bridges. All bridges are made of hard metal; therefore, they are extremely durable and rarely have to be repaired. Most often you can maintain the function of your bridge with just proper set up. In this manual we will discuss the Fender style guitar bridge. The bridge consists of a base plate and six saddles. These saddles can adjust the string height and intonation of your strings.
Bridge and Intonation cont: Poor intonation is when your strings sound out of tune as you play up or down fret board. The best way to adjust the intonation of your guitar is to adjust the scale length of each string. Before we talk about adjusting intonation with the bridge, we must first define scale length. Scale length on a guitar refers to the distance between the edge of the nut and the top of each saddle piece. The most common scale length on most Fender is 25.5 inches. Gibson and others are 24.75”.
Nut Adjustment and Replacement: � X-Acto knife � Vice grips or End nippers (optional depending on guitar) � Super glue Nuts can become damaged over time and affect the playability of your guitar. When this happens you are going to want to replace the nut. If the neck of your guitar is finished then you are going to want to score the edges of the nut with an X-acto knife. The reason for doing this is to prevent chipping when removing the nut.
Nut Adjustment and Replacement: The pull method is a little more risky as it can cause chipping in the fret board. To pull the nut out use a pair of fret nippers or vice grips and pull it out slowly and carefully. To prevent chipping of the fret board, put protective tape of both sides of the nut. If you can’t manage to get the fret out with the previous two methods then you are going to have to cut it out. Using the cut method will destroy the nut so try to use the other methods if possible.
slightly smaller and shorter than the screw. After you have drilled the holes you can put the nut back in the slot and screw it into place. Strap Button Repair � Screwdriver � Wood glue � Dowel rods or toothpicks (depending on situation) � Sandpaper (400 grit+) One thing that doesn’t come up much when talking about guitar maintenance, but is extremely important, is strap button repair. The last think you want is your guitar to fly off while you are playing.
Strap Button Repair If your strap button is just slightly loose, there are a couple of ways you can go about fixing it. The golden rule when repairing your strap button is NEVER GLUE THE SCREW IN THE HOLE, as this can cause major damage down the road. One way of fixing it is simply by using a toothpick. Unscrew the strap button and place a thin toothpick in the hole. When you screw the button back in the toothpick will give the threads something to hold on to and this may fix the problem.
String Buzzing: One of the most annoying problems to have when playing your guitar is string buzzing. It is not a very difficult problem to solve, but locating the cause may be easier said than done. Before you start doing any major work on your guitar, inspect it thoroughly to determine the exact location where the buzzing is coming from. String buzzing may occur when the neck is warped, the frets are uneven, the slots in the nut are too low, the action is too low, or it is just set up poorly.
String Buzzing: Most other problems are not as serious and do not require any repair work. These problems can likely be solved with proper setup. The following is a chart that may help with any other buzzing problems that might occur. Symptom Possible Cause(s) Remedy Open String Buzz Nut Buzzes when played open, stops when string is fretted. One Spot Buzz Worn or poorly cut nut slot is placing the strings too close to the frets near the nut. Frets Replace nut or shim to add height.
Pot Repair and Replacement: � � � � Screwdriver Wire cutters Guitar pick (optional) Soldering iron and solder One of the parts commonly mentioned on electric guitars are the pots, but what exactly is a pot? Pot is actually short for potentiometer, a small device that controls the flow of electric current making it basically a glorified resistor. A guitar will usually have 2 pots; one is for volume and the other for tone.
Pot Repair and Replacement: First, you need to remove the knob for the pot/s that you want to replace. Some knobs are held on by set screws so look for one before you attempt to remove it. If there is no set screw, the knob is on a split shaft, meaning that it is held on by friction and pressure and can usually be remove by pulling up on the knob. If it’s stuck, try prying it up with a thick guitar pick. Once removed be careful not to drop it on your guitar. 2.
………….Common Electronics Problems and Repairs: If your guitar is constantly cutting out, it’s a very common symptom of a simple wiring issue, usually caused by a faulty solder joint in the electronics. The most common reason for this is the output jack becoming loose in its socket and rotating, causing the connections inside to break off. This is why it’s very important to make sure your output jack is always tight. Fortunately, loose wiring connections are simple to fix, the trouble is finding them. 1.
Truss Rod Adjustment: One thing every guitar owner should know how to do is adjust the truss rod. The truss rod is a metal rod that is inserted into a channel in the neck of the guitar. Its main purpose is to counteract the pull of the strings on the neck. Over time the tension from the stings tend to warp the neck of the guitar. The neck can warp due to temperature and humidity changes as well.
and the fret will be about a tenth of an inch or the thickness of a business card. If the gap is less than this, the strings may buzz when played due to the neck being back bowed or too straight. A straight neck will be easier to play but a slight bow is ideal to get the perfect tone out of your guitar. Remember you can always adjust to your specific playing style. As mentioned, the truss rod can easily be adjusted with an Allen wrench or a screw driver. First you must locate the nut for the truss rod.
Finish Repair: Over the years, your guitars finish can experience many different problems. This is mainly due to the use and abuse on your guitar. You can re-finish your guitar but it tends to be a hard thing to, so you want to be careful. Drastic changes in temperature will usually be the cause of cracks in the lacquer. When the temperature is changing, the wood will want to expand and contract. The lacquer will want to stay stiff, so when the wood is changing shape, the lacquer will crack.
How to Solder: Being able to solder your own electronics is something every guitarist should know how to do. You never know when you may have to repair a broken wire, replace your pickups, pots, or whatever else may break or wear out over the life of your guitar. Soldering is very easy and only requires a little practice to become good at. Soldering is the joining of two metals by using a third metal, such as attaching a wire to a pot using the third metal which is the solder.
2. Solder Choosing solder is very important since it is what will hold your wiring together. For this type of work, you will want to get a 60-40 rosin core tin/lead solder. It’s the industry standard for electronics soldering and will melt quickly and produce a solid joint. This type does give off toxic lead fumes when used, so many companies produce a rosin core solder that is lead free. Either of the two types will work fine for your guitar. 3.
How to Solder Electronics: Soldering is very simple and easy to learn, however it will take some practice to fully grasp. I recommend that you gain some practice before you dig into your guitar if this is your first time soldering. You may realize it will be nice to have an extra set of hands in some cases, if that’s not available just take your time and go steady. This is a step by step, how-to on making a clean solder joint. 1.
4. Soldering the joint Now take the piece that you will be soldering to, such as the back of a pot. Take the soldering iron and move it slowly around on the pot until it is heated just enough to melt the solder. Now take your tinned wire and hold it on the pot until the solder melts. This is where another hand comes in handy. While holding the wire on the pot, don’t remove the iron, take your spool of solder and melt a little on top of the wire until it flows evenly across the wire.
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