Sometimes it's difficult to reinsert the chassis after charging. Make sure there's very little resistance when pushing the chassis back into the saber. It should slide in easily.
If it doesn't, there are wires at the top of it going to the emitter that sometimes get twisted or tangled. You might try gently twisting the chassis one way or the other 360 degrees and inserting the chassis again so the hole on the backside line up with the handle.
With the pommel piece off, move the chassis up into the saber and align the holes and try the button. You should feel it click if its aligned correctly. This saber is a little quirky because of the very unique design.
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