If your Zen is in need of repair or you just feel like looking at its guts, take a look at this simple guide. The method of opening the Zen is non destructive and can be opened with a few simple tools. You will need a #0 Phillips head screw driver, a slim pocket knife and/or a set of plastic pry tools. A credit card or driver’s license will work in place of the plastic tools.
The difficulty of this disassembly is moderate with nothing overly difficult, but it’s more getting the guts to dig into your fully functional Zen.
I initially used a pocket knife to slightly separate the back of the Zen from the face. I then slid the pry tool underneath the back to pop the clips. Once at least one clip is popped you can ditch the knife and relax a little cause the player will stay apart until you snap those clips back in.
Now run the plastic tool or card along the sides. (You can use the knife too, but you will be less likely to damage the player.) Several clips will pop on each side. Do this to the three sides that do not have the USB port.
Once you separate the back from the rest, there are several screws. You will have to remove the board in order to get to one of them. The board is clipped on one of the sides. Gently pry back the clips and remove the board.
The last part which you may get hung up on is the button array. There is a small nub that keeps it in place. Just make sure you don’t break that nub.
You are done. Marvel at its hi-tech glory or fix what you need to fix.
PS. Don’t drink a Redbull like I did before opening. As you can see in the video I am a bit shaky. =)
Just for the heck of it, here is the reassembly video. I cut out the boring screw insert part. I was paying more attention to the player at times so there are a few lame camera shots.