How to Replace the Motor Brushes on a DeWALT Circular Saw

Your saw's motor uses two carbon brushes to conduct electricity to the armature. The brushes conduct electricity to the armature through its commutator. The carbon brush will wear down over time, from rubbing against the rotating commutator (and will need to be replaced). Worn brushes can cause excessive sparks around the commutator. The sparks can also be caused by a damaged armature, so you'll want to carefully inspect both if sparks are present.

Let's get started.

REMOVING THE MOTOR BRUSHES   1. Remove the motor brushes.

a. Use a large screwdriver to remove the two brush caps (one on each side of the motor).

b. Remove the carbon brushes from the brush holders.

INSTALLING THE NEW MOTOR BRUSHES

  2. Install the carbon brushes.

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

b. Compress the brush springs into the brush holders.

c. Secure the carbon brushes with the brush caps.