My Dewalt DW304 corded reciprocating saw is eratic as to the reciprocating motion. The motor always turns when the trigger is depressed but the reciprocating action either doesn't start or it stops & starts (under load or without load). I slightly tightened the brushes but they were not really loose. The motor always runs so I don't think it's the switch or brushes. It almost sems as there is a clutch that engages & disengages but I don't think this saw has a clutch??? Is something just loose? I emailed Dewalt but they just said to bring it in for repair! I want to fix it myself if I could or would just buy another one since the price for repairs would be about the same as buying a reconditioned one. The saw is about 13 years old with moderate homeowner use.
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 craigslist.org, 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.
Sounds worn out, maybe gears don't always mesh or some are missing. You have nothing to loose by taking it apart. I would. After13 years parts may not be available however.
If it were me I'd take it apart, and be prepared to replace it. Dis functional tools irritate me, 13 years isn't a bad service record.
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when done using your saw do you wind thew cord around it and hang on the wall ?? I did that and broke the cord before it goes to the switch , they short out stopping and starting , check cord first
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