Power Cord 664463-0

Removed saw housing screws.
Power cord connections are in the handle where the trigger is.
Disconnect broken cord from connectors. (Makita had a plastic hub almost like a quick connect but with screws to secure the wire).
Remove the thick rubber that goes over the wire where it meets the saw housing.
Put the rubber on new cord.
Strip the rubber on the new cord and attach to the connects on saw.
Replace housing and insert all removed screws.
Plug in and saw some wood!

Took apart and replaced the old cord with the new one.

You will have to take the saw mostly apart for this repair, but parts cost a lot less than a new saw if you don't mind the repair work. Start by removing the blade, washers, and bolt. Remove the foot from the saw by removing the pivot screw/nut at the front and the adjustment bolt from the rear (remove the set screw on the lever, then the lever, then the nut and bolt. Remove the blade guard by removing the snap ring, stop button, and return spring. Remove the drive pud (what the blade bolts to) by removing the four retaining screws. Remove the blade housing by removing the screws from the backside. Remove the handle cover. Remove the white plastic cover behind the blade housing. Pull the armature out of the field coil (might have to tap on the back of the motor housing to get the bearing out of the bore, otherwise it's held in with magnetic force). Carefully remove the wiring from the handle for the cord, trigger, and light. Remove the field coil screws and the coil (turning the housing over and thumping it against a wood block with release it; it's pressure fit). Reinstall the field coil into the new motor housing (line up the screw holes and tap it in with a drift ot screwdriver until it seats). Reinstall the field coil screws. Carefully route the wiring through the guides in the housing. If the cord needs replacement now's a good time. The rest of reassembly is just the reverse of disassembly. Be sure to test the saw when done. These are relatively simple tools to repair, just take your time and snap some pictures if you need to.

Remove handle half, take note of where all the internal part are. Remove cord clamp. Disconnect cord from switch. Remove the cord relief and slid it on the new cord. Connect the new cord to the switch. Install cord clamp. Assemble handle assembly.
Put new bag on dust nozzle.

1. Removed the switch housing
2. Removed the old cord and guard
3. Trimmed ends on new cord
4. Installed the cord through the new cord guard
5. Installed the new cord in the switch.
6. Tested router worked fine

Removed the access plate from the handle (4 screws), disconnected the old cord and used the cord as a model for cutting the new cords connection points. Installed the new cord and replaced the access plate.

Removed old cord

removed old power cord and replaced.

Removed 2 Philips head screws to expose electrical junction box. Next I loosened 2 terminal connector screws inside junction box and removed the old cord. Attached new cord into the terminal connectors and tightened! Replaced junction box cover screws. This old Makita router was made in 1993 so the cord had seen better days! Works like a champ now!

Pulled Case Apart