It always had a finnicky switch, but I could always get it to work. I was prepping a bike for brazing and the switch quit so I decided to check out the inside. I removed the collet, the plastic collar, and the hang loop on the back. The only tool I needed was a little torx bit that was in the back of that handy Irwin screwdriver. I took the brushes out, but they were good and it wasn't needed for the disassembly.
A springy collar for the shaft stop pin flew out when I popped open the case. Here's the inside.
The bearings were nice and smooth. Everything seemed to be connected so I pulled apart the electrical connections and checked all I could for continuity. The cord checked out so I reconnected everything and moved on to the switch. The switch looked like it was OK, so I cleaned it and reassembled. Nothing.
So the Dremel I found in the park on a Northside adventure went in the box and I pulled out my Christmas present from years ago. Always have a spare.
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