Circular Saw Repair Troubleshooting: Common Errors And Solutions

Last Updated On May 3, 2023

This versatile metal-cutting tool is the king of wood-cutting tools. But a circular saw can sometimes be tricky because it requires much attention to prevent errors. The most common error with this tool is it stops working unexpectedly.

Therefore, you need to know the circular saw repair troubleshooting process to fix it. Usually, improper blade settings, unsuitable workpieces, grease issues, and dust build-up are the real culprit behind this saw’s problem.

But how to fix these issues to run the saw steadily? Fortunately, fixing these issues is simple and quick. Read along to learn the solution.

10 Common Errors And Solutions Of Circular Saw

What to do if your circular saw stopped working suddenly? Don’t worry; unless your circular saw has been damaged completely, you can easily fix your machine with a few inspections and diagnoses.

Here are some of the common reasons behind circular saw error and their quick solutions:

1. Unsuitable Work Piece

Unfortunately, circular saws aren’t suitable for working on every type of workpiece. For example, this machine may not be your best pick if you want to cut steel with a circular saw.

So when you use the circular saw on an unsuitable workpiece, it subsides on one end and puts the saw blade under high pressure and weight. As a result, your circular saw can stop working in the middle of the process.


Before you start working, always ensure that the workpiece is supported at the ends of the circular saw. A Circular saw is mostly suitable for cutting through lead, wood, copper, aluminum, and various non-ferrous metals.

2. Dead Battery (For Battery-Powered Models Only)

Most people who own a battery-powered circular saw skip this inspection. They assume that a dead battery means the saw won’t start at all, which is true indeed. 

But, sometimes, your circular saw with a dead battery will start too. But the blade will run only for a few minutes, then shut itself off.


The obvious solution to this problem is recharging your circular saw battery. In case charging the battery doesn’t solve the problem, you can swap the battery with a new one and see if it works.

3. Defective Power Cord Or Cable

The chances of a defective power cord or wires are mostly high if you have an old circular saw. This is because the cord consists of multiple small wires protected by an outer shell. 

Over time the shell deteriorates and eventually impairs the internal functions of the cord. And that’s when your saw will struggle to start.


First, open the cord and inspect every wire to ensure proper connection. Then look for any kind of tears in the wires. If you found one, repair the power cord. 

However, you may need to take help from a professional in this case since it requires you to have basic knowledge of wiring and electrical functions.

4. Rotor And Stator Failure

Your circular saw will stop working when the rotor and stator compartment of the machine fails to function properly. When the rotor and stator fail, you may notice smoke or burning odors.


Sometimes your saw may still work with the failure, but as soon as you notice the indicator, turn the machine off immediately. In this case, you will need to replace this part to fix the problem

5. Grease Issue

If everything is functional and fine, but still your circular saw stops working frequently, it may have a grease problem. Usually, old grease inside the motor sometimes prevents it from working properly.


Change the previous grease with a new one to make it work functionally. If you want to avoid this issue, consider changing grease a habit.

6. Not Using Proper Blade

If you want to cut metal with a wood-cutting blade, then no doubt your metal-cutting attempt will fail. It can also damage the wood blade. Hence, your circular saw will start stalling in the middle of the cutting process.


Before cutting the workpiece, change the blade and ensure the blade type you’re using is suitable and durable enough to cut through the material.

Note: Here you can see how to change the circular saw blade.

7. The Blade Isn’t Set Properly

This can also be the reason; your circular saw is stalling out of nowhere. If the blade isn’t protruding enough, or in simple words, not set far enough, the blade won’t have sufficient support to cut through the workpiece. 

This issue can also cause dangerous situations besides stopping the saw from working smoothly.


The solution is to reset the blade to set it correctly. Double-check every time that the blade is protruding properly before starts working.

8. Bad Carbon Brushes

The carbon brushes are working behind to rotate the shaft properly. But this element wears out eventually and becomes damaged. Due to damage and wear out, carbon brushes fail to rotate the shaft functionally; consequently, your circular saw stops working abruptly.


In this case, you need to replace the old carbon brushes with new ones to solve the problem.

9. Damaged Or Loose Clutch Bolt

If the clutch bolt or the arbor that connects the blades with the entire saw is damaged or loose somehow, it can prevent the saw from running smoothly. In some cases, the saw won’t start at all until you fix the bolts.


If the bolt or arbor is loose, consider tightening it to fix the problem. And in the case of damage, you’ll require to replace it with one.

10. Dust Build Up

The last common reason in our list is dust build-up on the motor and blade. If you don’t follow a maintenance routine for your circular saw, then the motor can get clogged with dust and debris. 

It’ll prevent air from flowing in and out, which will lead to overheating and unexpectedly stops the machine from working.


Detach the blade and open the machine. Now take a piece of cloth and cleaning solution to clean the blade and the motor. If possible, oil the motor too. 


1. How do you test a circular saw switch?

To test the switch of your circular saw, you need a multimeter. Place the probes on the ends of the switch and check the multimeter.

2. What causes a circular saw to bind?

Improper blade depth causes your circular saw to bind. If you set the blade deeply, more blades surfaces will be exposed while cutting. Hence, the saw will kick back and bind during the process.

3. Why is my circular saw burning the wood?

When your saw has a dull blade, it can’t make the cut quickly, and you’ll need to run the blade through the workpiece more than the usual times. Therefore, it’ll create more friction against the wood and cause them to burn.

4. How do you sharpen a circular saw blade?

Set your blade in a steady place. Now apply any lubricant to the sandpaper and rub it back and forth on the blade teeth. Cover each tooth more than 5 times to ensure proper sharpening.

5. How long do circular saw blades last?

The lifespan of your saw blade depends on its quality, how often you use it, and your maintenance. Usually, a saw blade lasts for a maximum of 120 hours of use.


You’ve learned the circular saw repair troubleshooting process from the above discussion. As you can see, sometimes a small issue on your saw can prevent it from running smoothly. However, the solution to that specific problem is pretty straightforward too. 

Besides, while inspecting and working with the blade issues, stay careful not to get hurt. Take your time and solve the problem slowly.

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