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Band new saw. How much brush sparking should there be. The saw sparks inside the motor housing and smoke starts coming out. Stinky smoke. Could bar oil have leaked into motor case?

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Are you just asking about an electric saw and not a gas fired one. Odd smokey smells are normal with any new saw though. Heck, they're normal with just about any old saw too. If its an electric saw, you could possibly see some small blue 'arcing' off the brushes of the motor but not what could be called 'sparks'.

Posted on Apr 21, 2015

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Yes it could have .

Posted on Apr 20, 2015

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How to repair a Challenge Circular Saw


Brushes are very easy to replace, but it sounds more likely that your motor has burnt out. Try brushes first if you have already ordered them though. There are two types of brush fittings on saws.
1] There should be a couple of small removable caps at the back end of the motor, on opposing sides. Just unscrew them and you should see the brass contact plate of the brush. Hook the brush out, fit the new one and refit the cap. Now repeat on the other side.
2] The vent cover at the back of the motor should be held on with a couple of screw. Remove the screws and the cover. You should see a brush on either side of the motor, probably in some sort of removable holder. Just manoeuvre the holder so that you can slide the brush out and replace with a new one. The brush may be connected with a spade connector or something similar to either the field coil or the brush older.
When you run the machine after this, have a look in the vents at the same end of the motor and you should see slight to moderate sparking. This is normal, especially with new brushes. If you see thicker, brighter sparking from one of the brushes, this indicates that the field coil is breaking down. If the sparking is bright and running around the whole back of the motor, and you are getting a sparking/raspy noise, then I am afraid your armature is breaking down. Either of these faults will cause your brushes to wear very quickly, if the whole motor doesn't completely fail in the process, and I would recommend having the machine checked by a professional repair agent.

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2 Answers

Dewalt DW718 Sparks When cutting . just bought it


The people from Lowes were right.
There are two types of motor designs: Induction motors and brush-type motors.
All electric motors that have brushes make sparks where the brushes contact the rotating commutator. They also run less efficiently but they are a bit smaller than induction motors for equal power output. Brushed motors can also deliver greater power at initial startup.
Because the sparks in brushed motors create heat, the housing around the motors typically have ventilation slots for air to go through to keep the commutator cool. This means you are likely to see the sparks if you look in the right place.
Since it's more difficult to get an induction motor turning, they typically have a "start capacitor" mounted on the side of the motor to give an extra kick to get the stator turning. While induction motors use less power when running, the amperage they use at start-up is typically double the running amperage.

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Makita circular saw wont run properly


Something more sinister. I think the armature is bad. (The center part of the motor that spins) Look at the brass bars on the comutator...where the brushes ride....there should be a nice even dark stripe the width of the brush all the way around. If one or two bars a discolored beyond that it's not good. Or if there is heavy pitting in between bars it's also not good. And lastly the more obvious sign is bars missing from the comm..

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1 Answer

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Bad brushes or bad armature. The armature should have a nice wear pattern exactly the size of the brush all the way around it. If any of the bars are discolored beyond that or actually missing it's bad. If the brushes have springs they should have "spring" to them and not be partially or totally collapsed. You can contact Titan at 1-800-386-0191 To check on replacement parts.

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You will need to take the motor out and check the brushes on the back also check the bearings you may need to disassemble the motor to repair.

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1 Answer

Saw motor is sparking


Most of the time sparks in these tools come from where the brushes make contact with the armature. Some causes for sparks are: The brushes are worn down to where they don't make firm contact with the armature. Brush springs overheated and no longer push the brush down on the armature. The comutator on the armature is damaged and causes the brushes to spark excessivly. You can take it apart and try to find which parts are hurt but I don't know if any Clarke Power Products parts are still available. The company went out of business around 2009 so you'd have to find someone with left over parts. It may be easier to buy new and go with a name brand and new warranty.

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1 Answer

I have a dewalt dw364 circular saw. the motor is running slower and sparking internally. The motor also starts smoking while using. A suggestion was to replace the brushes.


I agree with replacing the brushes, and don't use it until you do, so no damage is done to the motor. If it is smoking there is some overheating. Best regards and good luck.

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2 Answers

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the armature is shorting across the commutator bars and a new saw will be cheaper than a new armature

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It sounds like the band is too tight and the smoke is coming from a burning clutch. You need to get your owners manual and loosen the band before you burn the parts up.

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