Why take apart a Geek Bar?
The honest answer is: battery disposal. The Pulse X 25K contains a rechargeable lithium-ion cell. Standard trash bins are not the right place for a lithium battery — the cell can short-circuit, heat up and ignite in a compactor or landfill. The legally and environmentally responsible move is to drop the battery at a local e-waste collection point, which means separating it from the chassis first.
The secondary reason buyers ask the question is curiosity about the chassis design. Either way, the steps below are written for a fully depleted device only. Disassembly always carries some risk because the device is not designed to be reopened.
How to take apart a Geek Bar Pulse X — 5 steps.
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Confirm the device is depleted.
A blinking light or the absence of vapor on draw confirms the Pulse X is end-of-life. Do not attempt disassembly on a partially charged device — short-circuit risk goes up sharply when the battery still holds energy. If the screen still shows charge, run it down or simply do not open it.
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Remove the mouthpiece.
Pull the mouthpiece straight up off the top of the chassis. On the Pulse X 25K it is friction-fit with no glue — a small flathead screwdriver or a plastic pry tool helps if it has settled tight. Take it slow; the plastic can crack.
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Pry open the chassis.
Insert the flathead into the seam along the long edge of the chassis. Work the tool along the seam length, releasing the internal clips one at a time. Patience matters here — the chassis is not designed to be reopened, so the clips are tight. If a clip resists, switch to the other side and come back.
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Lift out the battery and pod assembly.
The lithium cell sits in the lower half of the chassis, connected to the coil and pod by two thin wires. Use pliers to cut the wires close to the solder joints on the battery side. Do not tear the wires off — yanking can damage the cell casing and create a short.
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Recycle the battery separately.
Drop the lithium battery into a battery-recycling container, an e-waste collection bin or a Best Buy / Home Depot battery drop-off bin. Most US municipalities have an e-waste pickup or drop-off program — call 311 or check the city website for the nearest location. The plastic chassis and pod can go in regular recycling or trash per local rules.
Can you refill a Geek Bar?
Most Geek Bar devices are non-refillable single-use disposables. The Pulse 15K, Pulse X 25K, CLR 50K and Pulse Zero Nicotine are sealed at the factory and not designed for refill. Disassembly is physically possible (the steps above prove it), but the device is not engineered to be reopened — opening it breaks the seal, voids any warranty, and the chassis often will not close cleanly afterward.
The one Geek Bar device that supports refill by design is the Mate 60K Kit, which uses replaceable pods (Mate 60K Pod). If refill is the goal, the Mate 60K Kit + Pod combination is the supported pathway.
Tools you will need.
- Small flathead screwdriver or plastic pry tool — for releasing the chassis clips. A guitar pick or credit card edge also works.
- Pliers — for cutting the battery wires cleanly near the solder joints.
- Battery recycling container — for the lithium cell. A clear plastic bag works if heading directly to an e-waste drop-off.
What is inside a Pulse X — component reference.
You should not have to take apart a Pulse X unless you are recycling it, but knowing what each part does helps when troubleshooting a low-vapor draw or a faint flavor. The Pulse X 25K is built from four functional sections, each playing a specific role in how the device fires and tastes.
| Component | Function | What you would notice if it fails |
|---|---|---|
| Mouthpiece | Delivers vapor to the user. Built with an anti-condensation chamber for smoother draws. | Gurgle on inhale, condensation droplets in the airway, occasional spit-back. Cleanable from the outside without disassembly. |
| Mesh Coil Chamber | Houses the dual mesh coil and the VPU Chip. Heats the e-liquid evenly across the coil surface. | Faint or burnt flavor, weaker vapor density. Coil failure is end-of-life — there is no service path. |
| Battery Section | 820 mAh lithium-ion cell powers the device. Provides consistent output across both Regular and Pulse modes. | Will not fire on draw despite charge indicator showing battery. USB-C port damage is the most common single failure here. |
| Airflow Base | Regulates air intake. Adjustable ring on Pulse X tunes draw resistance from MTL-style (mouth-to-lung, tighter) to DL-style (direct-lung, looser). | Restricted draw or whistling sound. Usually a debris obstruction — tap the device gently on a soft surface to clear. |
The factory seal on a Pulse X is intentional — leak-proof design keeps the 16 mL of e-liquid stable and uncontaminated for the device's full 25,000-puff lifetime. Disassembly breaks that seal and exposes the coil chamber to air and contaminants. If the device is still firing, leave it sealed and use it as designed.
How to unclog a Pulse X without taking it apart.
Condensation can block airflow on any disposable vape — it is not a Pulse X defect, it is a function of how vapor cools inside a sealed mouthpiece. Before considering disassembly, three steps almost always clear the clog.
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Take three or four gentle puffs.
Short and slow draws can help clear the airway naturally without forcing condensation deeper into the coil chamber. Avoid hard pulls when you suspect a clog — they pull condensation toward the coil, which makes the issue worse and can produce a brief burnt note.
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Warm the device in your hand for 60 seconds.
Cold air inside the airway is what triggers most condensation events. Holding the device in your palm for a minute warms the airway enough to vaporize the trapped liquid back out on the next draw. This is the single most effective unclog fix for vapers in cold climates.
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Tap the mouthpiece down on a soft surface.
Hold the device mouthpiece-down and tap it lightly on a folded towel or the heel of your hand. Trapped fluid drops out of the airway into the mouthpiece chamber where it evaporates on the next session. Do not tap on a hard surface — that risks cracking the chassis seam and is not recoverable.
If all three steps fail and the device is still drawing weakly, it is likely reaching end of life rather than clogged. The Pulse X 25K's dual mesh coil paired with an optimized airflow chamber keeps clogging rare in normal use — most clog reports trace back to either very cold storage or to drawing on a near-empty device.
Where to recycle vape batteries in the US.
Once the battery is out of the chassis, the lithium cell needs to land somewhere safe. Standard household trash is not an option — lithium cells can short-circuit in compactors and have been linked to landfill fires across multiple US municipalities. Three drop-off paths work for most US zip codes.
Retail battery drop-off bins are the easiest path. Best Buy, Home Depot, Lowe's and Staples all run free battery-recycling programs in the entrance area or near customer service. Most accept loose lithium cells under 11 lb without questions. Call ahead to confirm the local store still participates — the programs are continuous but not every store has the bin in the same spot.
Municipal e-waste collection is the second path. Most US cities run quarterly e-waste pickup events or have a permanent drop-off point at the city public works facility. Call 311 or check the city website under "household hazardous waste" for the nearest location. New York, Los Angeles, Chicago, Houston, Phoenix and most major metros all have permanent drop-off sites that accept lithium cells.
Call2Recycle is the third path — a nonprofit that maps free battery drop-off sites by zip code at call2recycle.org. Coverage is strongest in the Northeast and California; in some rural zip codes the nearest drop-off can be 30-50 miles away, in which case the municipal e-waste route is usually closer. Whichever path you take, transport the loose battery in a sealed plastic bag with terminals taped to prevent contact with metal in the bag.