Remove the brush caps and have a look at the brush length.
If they are extremely short, or barely touching the commutator bars on the armature, you will need to purchase a brush set part # (193466-2). The way you are describing it behaving without a load, and charged battery, I can only assume this will fix it. The other thing you can do is open the clamshell housing and with a pick, attempt to move the armature fan and see if it will make several full rotations. I want to know if a piece of the magnet ring broke loose and is rolling around between the armature and the magnet ring causing your varying RPM.
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