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Sawzall 6509-21 stopped running jerks when switch is depressed but will not run new switch and brushes

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Posted on Jan 02, 2017

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SOURCE: My 0719-20 a56a sawzall motor runs well. The blade

I'm afraid this is one that needs to go to the manufacture. You can contact them at this link:
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Posted on Jun 13, 2010

rowdy45176
  • 2176 Answers

SOURCE: The Sawzall runs but has

either worn brushes or an armature problem, I would unplug the tool and look at the brushes first and check the brush spring for collapsing, then rotate the shaft by hand and look into the brush tube for the commutator condition. If it has unusual wear patterns or discoloration then it is probably bad and needs replaced.

Posted on Jun 06, 2011

  • 304 Answers

SOURCE: Milwaukee Sawzall Plus just stopped running

Remove the handle and check there is power going to the switch, if not unplug and remove and repair/replace .the cable.
If there is check the brushes are long enough and are not stuck in the brush holders. Other wise take it to a repair agant.

Posted on Jun 05, 2012

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1 Answer

Does 6509-31 sawzall have thermal overloads


No the 6509 does not have a thermal overload.
Start by checking the brushes & brush springs then test the switch & cord
It is possible you burnt the armature out but brushes, switch, or cord is more likely.

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Milwaukee Sawzall Plus just stopped running


Remove the handle and check there is power going to the switch, if not unplug and remove and repair/replace .the cable.
If there is check the brushes are long enough and are not stuck in the brush holders. Other wise take it to a repair agant.

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The Sawzall runs but has lost power. The brushes are producing a large amount of sparks. The tools motor sounds like it's not coming up to full speed. Got any ideas of what may be causing this?


either worn brushes or an armature problem, I would unplug the tool and look at the brushes first and check the brush spring for collapsing, then rotate the shaft by hand and look into the brush tube for the commutator condition. If it has unusual wear patterns or discoloration then it is probably bad and needs replaced.

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My 18 volt stealth sawzall just started to run slow as if the battery was about to die... would that be the brushes... its the second one I have that problem with


yes, brushes are worn, or more specifically, the springs holding the brushes are. You probably got a set of spares in the box, if not, you can get them as many are standard sized.

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1 Answer

Runs for 5 to 10 seconds at full power after that it barely runs milwaukee sawzall 6538-21


you might want to check, this tool possibly has a 5 year warranty. if not do you see any excessive sparking at the brushes? this could indicate an open on the armature or a stuck brush. Let me know and I will do what I can

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try going to Milwaukeetool.com and under service you can download a wiring diagram for the tool, usually they show the routing.

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could be a couple things, unplug tool and look at the pins on both the cord and the pin housing to make sure none pushed back, next remove handle half and remote electronic and look for a loose flag terminal at the brush holder, look for loose wires on the switch, (give a gentle tug) and remove the brushes and look for unusual wear patterns and possibly a burnt brush spring. Let me know if you need more help.

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1 Answer

No power to saw works sometimes then stops and wont run


check the cord for the pins pulling out and then I would test thru to the brush holders. Also if you are comfortable removing the handle half check for a loose connection to the switch and the flag terminals at the brush tubes. Let me know if you need more help.

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