I found this thread extremely helpful. I have the Skil HD77 and had sparks shooting out of the back. After reading several threads I tried several things. 1st: Replaced the brushes. Result - Still had sparks. 2nd: topped off the saw lubricant. Result - Still had sparks. 3rd: removed the new brushes and inspected the armature and did find discoloration on one of the bars, I fired up the air compressor and sprayed out the brush holes, and every other cranny that I could. Put the brushes back into the saw and gave it a try. At first it kind of sparked and I thought maybe some of that lubricant needed to work into the mechanism and I continued to hold down the trigger and the sparks went away and I gained full power after about 15 seconds. Saved $80 on a new armature! Thanks for all the help!
You have a problem with worn brushes or the armature might be failing. UNPLUG the tool and remove the brushes to check their condition length and look at the face of the brush for any unusual wear. Then look into the brush tubes themselves and slowly rotate the armature for discoloration/raised commutator bars.
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