I was using a brand new dremel 4200 with a diamond circular saw attachment and it quit after 5 minutes after cutting about 4 inches of floor tile. The blade seemed to go through the tile easily enough and it did occasionally slow down if you applied too much pressure but i was careful about that. I was hoping maybe it overheated and had circuitry to automatically shut it down but it is not starting up again. So either it is defective or maybe i did something wrong but if that is the case I would say the design is flawed if it breaks that easily. I had dremel tools years ago that never quit like this.
No.. the issue issue is the switch inside. when your Dremel 4200 stop working, press firmly the grey area between the speed selector and the brush housing. I think this a defect in the design of the 4200. 
How did you figure this out?? Mine just died and you suggestion worked. Very odd but I am happy as I didn't save the receipt.
Ok.. if you are frustrated because your dremel 4200 stopped and you did anything and still not working. today you are blessed because i found the real reason on the defect of the early 4200. since you have a dremel and means that you are a fixer, you need at least 2hrs for this fix, maybe less. all is fine.. brush, switch etc. the real culprit is the stator. The port is made of aluminum, and the stator coil is made of copper. since these two metals are not the same, the design is to clamp the stator coil into the aluminum port. the reason is you cannot solder aluminum in copper. believe me, if you want to save your dremel take a look in the end of the coils of the stator and you will see that the copper wire snapped in the aluminunm port due to intense vibration. see figure below to see the exact location. believe me, in my case, all four terminals snapped.
Now it'S up to you how to reconnect the copper wires in the aluminum terminals. what i did is since the copper wire was already short to re-clamp in the terminal, i soldered a new piece of a little bit larger diameter wire in the end of the coil and re-clamped it in the aluminum port. goodluck in your fix. let me know if this helpful. regards...
Thanks, that's exactly what the problem was; I didn't bother soldering on an extension to the broken copper wire, I just unwound it once off the winding and rejoined it at the connector, it might have made a very tiny difference to the power output but nothing noticable.
Very helpful the wire afterwards was fixed in place with lacquer
thats weird as F! It worked. Thanks for sharing!
Wow. I mean WOW. That worked. Thanks!
Man, you're awesome! I have a Dremel 4000 and your advice fixed my problem. Thank you for sharing.
My Dremel was also busted: either intermittent spin or it died when under any load. I disassembled the unit and noticed a tiny piece of metal fell out. This turned out to be part of one of four slide contacts between the circuit board/switch assembly and the external main coil assembly (Stator). These 2 main parts connect together via 4 pins and 4 sliders. Two connectors had broken so the contacts were loose at best but mostly non-existent. The copper wire was still connected but the aluminium connector had broken. I was able to give it a McGyver fix with thin slithers of metal that help to maintain the contact. How did this happen? I do not know. Maybe a sharp drop (which I do not remember) or the vibration from usage.
Hope that description helps someone else fix their Dremel.
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Same thing happened to me brand new. Went to check the brushes, one was stuck, pliered it out, put it back in, started working.
2610005646 is the part # for the brushes on the 4000 series. I had one break also with very little use. I'm trying replacement brushes first, but if I ever need another one I'm getting it from Wal-Mart for the 90 returns instead of HD or Lowes.
Stuck brushes seem to be a common problem on the 4000 series from the reviews on the Walmart site. My 4200 quit after a few uses but Dremel quickly provided a replacement. If yours is out of warranty, check for a stuck brush. If you can get it out, a little cleaning with a Q-Tip will probably restore operation. The 4000 series is supposed to have improved cooling but I think it blows cutting dust into the brush holders. The dust melts and acts like glue to stick the brush.
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The earlier 4200's seem to have a lot of stuck brush problems but I think they changed the housing material to at least make that less likely. If you find that one of the brushes will not come out easily, it is most likely the stuck brush problem. The tool is hard to disassemble but you can do that and clean out the brush holders. I think the problem is actually too much clearance and the brush dust causes the brush to stick. I cleaned out mine and was able to put some copper tape on two sides of the brush holder and the brushes still fit. However copper tape is not something most people have lying around.
There have also been a lot of reports of switch problems. If the brushes slide in and out easily, you probably have the switch problem.
Complain to Dremel even if your 4200 is out of warranty. They do want to make their customers happy and the 4200 is not doing that.
I have had my dremel 4200 just since Christmas 2014 (today is 07/23/15). It quit during a normal small project. Read online it might be brushes, though didn't think it should be that so soon as I am a VERY casual user. The brushes look like they are melted in there. Had to yank on the brush and it came out with nothing attached. Bought new ones but they don't seem to fit as if something is still in there. Anyway to know? Any way to clean it out?
As
fingloid has said its the switch,
i just got on that would not work,and i tried what he said, and i also had the grey cover off and pressed the switch with a small screwdriver and it worked just fine, now i need to see how to fix this flaw ,,godbless
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absolutely astounding! Had my Dremmel for 10 years and abuse it and use it it has been wet and its out in the shed. Never had a days trouble.
Now when it was in the case was the case shut? My thoughts are mice piddle which if it gets inside will corrode everything. I say this because a bigger drill of mine got damaged in that way. No external signs of damage but when opened the damage was there and it could also be then smelled.
My only other thoughts on this is to get you to check the plug to see a wire has not pulled off, after that I would suspect the dremmel switch has a fault.
all shots in the dark! but have to start somewhere when you are riding blind.
Thanks for using FIXYA
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it is the coupling inside of it called a flex coupling and it seem s like it is made of wax or something. tomorrow i will go to home depot to see if they carry metal ones that won't break.
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You can go to any repair facility and buy a replacement cord making sure of the wire guage and conductor (2 or 3) what you can do is make a wiring diagram and remove the old cord and holding the cord about 10 inches from end pull one wire at a time and if there is a break it will pull out to confirm your suspicion. Let me know if you need any more help and if I have answered your request would you please rate this response accordingly and thank you.
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hello. You loosen the arbor at the base of the shaft closest to the tool. There is a tiny wrench in the kit that came with the dremel, or you can use a pair of pliers to loosen it. Joe
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