How to Replace the Motor Brushes on a Skilsaw

Saw won't turn on? Is it sparking near the brushes? If so, you probably need a new set of carbon brushes. The carbon brushes transfer electricity to the motor's armature. They consist of a carbon brush, a wire lead, and a spring that keeps the brush pressed tightly against the armature. The carbon brush is soft, and will wear down over time from constant contact with the spinning commutator. When the brush is worn out, it will no longer make good contact with the armature, and the saw won't turn on. Often, when a brush is nearly worn out, it will cause excessive sparking around the commutator. This can also be a symptom of a bad armature, so if you see sparks, you will want to inspect the armature as well.

Let's get started.

REMOVING THE MOTOR BRUSHES   1. Unplug the saw.

a. Disconnect the saw from its power source.

  2. Remove the motor brushes.

a. On the motor housing locate two brush caps.

b. Use a flat-head screwdriver to unscrew the brush caps.

c. Remove the motor brushes from the brush holders.

INSTALLING THE NEW MOTOR BRUSHES

  3. Install the motor brushes.

a. Install the new motor brushes into the brush holders.

b. Compress the brush springs into the holders and hold the brushes in place while installing the brush caps.

c. Secure the brush caps with a screwdriver.