The saw makes a grinding sound and has a bad vibration. I have cleaned the saw thoroughly and checked the brushes. I have replaced the blade and still get the problem. It sounds like something is grinding inside the motor.
Are you sure blade is straight, and mounted on arbor correctly? that's the first thing to check. Or remove blade and 2 arbor plate's and run saw. If you have a vibration after that you have a bearing problem.( rear bearings go bad on these saw's) other they are the best saw for the price. We have about 50 of the 4000 model. hope that help's Never had a vib problem.
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The first one sounds like an armature bearing - pretty easy fix if you have access to a press or even a bearing / gear puller. Make sure the saw is unplugged, remove the end cap on the motor and the 2 carbon brushes. remove the 4 screws holding the motor housing to the saw and pull it off. Then, pull the armature straight out - replace the bad bearing, and reverse process.
The second one sounds like it is missing the arbor bushing #152636-00 or it has a bad blade bolt #145344-01.
This problem can be caused by the brushes wearing out. Check brushes first. If you need to clean the commutator it is best to remove the armature completely and use a scouring pad similar to what you would wash your plates with. You can use wire wool, and if you do (it is quicker and a bit more thorough) make sure you clean between all the comm segments after with a stanley knife or something so there is nothing left to short across them. The really professional way to sort the comm is to 'skim' it on a lathe, which would mean spinning it up on a lathe and smoothing it out with a hardened cutter. This also leaves the comm nice and flat, ready for new brushes, but should only be done by a competent person as it can go wrong quite easily. Also after skimming you should cut back the insulation slightly so there is a nice step between segments.
Sounds like you have bearings going/gone bad. If it's a direct drive model, check the bearings in the motor and on the arbor. If it's a belt driven model check the bearings on either end of the arbor shaft. As bearings go bad, someone using the saw regularly will notice a different tone in the tool. If you are getting vibrations that bad, the bearings are already loosing balls or the race is tore up and all the balls are on one side and can't doing their job correctly.
I take it you have a gas powered saw. Before starting any work on the machine, remove the plug lead.
To service it, remove the blade and guide and clean them all thoroughly. Clean the drive sprocket and its recess, this is best done with compressed air or at least a stiff paint brush. Inspect the chain cutting blades for damage and also the guide links and the groove they run in. Lubricate everything lightly with a thin oil before reassembly.
Check the spark plug, clean it thoroughly (not on a rotary wire brush) or replace it. Clean the air filter by blowing it with compressed air or a vacuum cleaner. If it is too soiled, replace it. Drain the fuel from the tank and check the fuel filter in the fuel tank and clean it if it appears to be dirty or contaminated. Blow the cylinder and the head cooling fins clean with compressed air, this can be done with a brush, but will require the cooling duct to be removed.
That is about all that can be done on a cursory service, anything further will require stripping the carb and removing the exhaust, neither really necessary unless a problem is being experienced. Everything is relatively simple to carry out and should not take too long. Please rate this response.
You say it spins freely but is it smooth. If not it could be one or both of the bearings the armature spins on. More likely than not you have one or more fan blades broke or missing. Not much weight by themselves but at the speed these things spin the more blades broke off, the worse the vibration. You have to romove the brushes, take off the gear housing and remove the armature to check both the bearings and fan.