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My motor stopped while cutting. I saw sparks coming from inside the engine before it stopped. I want to take the motor out and see if I can repair. Any short cuts to taking the motor out and what the problem might be?

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Not the best idea in the world . you fair better by getting another one and using parts off that one it sounds likje there's internal damadge with out the proper equipment on hand you will most likely have to enlist a machine shop in your effort:)

Posted on Jun 22, 2009


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Posted on Jan 02, 2017


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With the saw unplugged, look at the blade.
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Changing to a sharp blade will fix problem #1. Push the blade into the cut slower, keep it straight (no cutting curves), and maybe set the blade to a shallow cut and make several passes.

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Does the blade actually stop when you try to cut or does it spin but not cut. If it is stopping, and the motor is still running then I am afraid you have stripped gears and will need anew armature and spindle gear (sometimes complete with spindle, sometimes a press fit with a woodruff key to locate it). If the motor is stalling then it would suggest that the field coil is faulty, but you would notice excessive sparking from one brush if this was the case. if you get major sparking from both brushes then the armature is probably faulty, or if you are lucky it could just be brushes wearing low and not making a constant contact.
If the blade is spinning and not slowing when you try to cut I would think it is either blunt or mounted the wrong way round.

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What mode saw do you have?
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Racing on a 2 cycle engine is usually a sign of a lean condition. It could be caused by a few different things including a bad crank seal or a torn intake manifold as some are made out of rubber. I would remove the cutter arm then pull the muffler to inspect the cylinder and piston. If they are scored it will be a costly repair.

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When I turn my saw on it surges from full power to almost no power. This happens contiually while running. I checked the motor brushes and they llok good.

It happens continually while cutting? If you try to cut some that the machine has no power to do the job it will stop.

If you look inside the motor and look if the motor has some burn on the cooper motor wiring?

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Blade stops going once it hits the metal to be cut.

inside the motor/arbor section of the saw, there is a helical gear and worm drive on the motor. the front of the motor is supported by a bearing in the aluminum arbor section. sounds like most of the bearing balls are disintegrated and the worm disengages when a load is put on it but spins when there is no load. I would check and replace the front bearing.

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Pole saw stopped. May be in motor as sparks were seen when it stopped. Should I try to find someone to repair or re-purchase ???

It is probably the brushes that need to be replaced. They should be easily accessible and inexpensive to replace.

Here is a link I think could be useful to you:

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your missing a tooth on a large round gear in the gearbox.

when the gear on the engine rotates into the position where the little engine gear spins because there is no tooth to come into contact with the engine runs but the gearbox doesnt spin, hence no reciprocation, but engine runs.

if you bump the blade it will start going again, but when you cut it will stop offasionally in mid cut. you can repair this but stop using it the engine gear will be destroyed otherwise

I have a dewalt dw303 that you can use for parts, I need a new trigger or something the motor is dead and I found a new saw. go to, rochester ny tools section and look for dewalt dw303 that is my listing. for ten bucks ill sell you all the gears you need. i think it is close to the same model, i am sure it is the same gearbox.

try opening your gearbox, im positive that is what is wrong.

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