If it hasn't been used for a while, the contacts on the armature may have oxidized. Use a pencil eraser or 1000 grit emery cloth to make the area where the brushes contact the armature SHINY. If the armature rotor contacts are shiny and it still sparks, make sure that all of the windings measure the same. Excessive sparking is a sign the armature is going
SOURCE: Good armature maybe needs new brushes
Hello,
Carbon brushes wear over time and may need completely replaced...it doesn't cost a lot and i have guides available for the repair. Try my troubleshooting guide....
http://reviews.ebay.com/COMMON-PROBLEMS-WITH-THE-KIRBY-VACUUM-TROUBLESHOOTING_W0QQugidZ10000000003800312
I have the brushes available as well. The changing process is also outlined in my guide for changing the power switch.
http://reviews.ebay.com/REPLACING-THE-POWER-SWITCH-ON-ANY-KIRBY-G-SERIES-VACUUM_W0QQugidZ10000000003752018
Hope this helps...
Marci
SOURCE: Sparks from the Kirby Motor
1. Do you think this may be the problem?
YES
2. How come it continues to rotate?
Motor armature consists of multiple coils and just some of them burned so even though it keeps spinning it does not function properly.
3. Do I need to replace the armature?
We have switch replacement instructions HERE and they will take you as far as accessing the motor. We do not have motor assembly instructions yet but if you get that far - motor is not that hard to reassemble. You may have to spend some time getting tolerance ring back in and make sure you install finger spring properly.
Good Luck
SOURCE: Exesive sparks on the brushes (Bosch GSB 16RE drill)
If you used the drill any amount with a burned field coil there is a good chance that is has burned the new armature out.
SOURCE: replaced armature and brush's and there is alot of
Unless somewhat preformed, brushes have a tendency to arc like crazy and can produce heat and even smoke. I would remove the brushes and use a fine 'keyhole' type file to give them a little inside curve so they have better contact to start with.
SOURCE: Skill Wormdrive HD77 saw sparks
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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