80% Arms • Router support

If your new FST-1 router will not start or briefly spins and stops, the carbon brushes may be the cause. New brushes can sometimes need reseating and a short break-in period. On a router that has already been used, worn brushes may cause it to stop or run intermittently.

Follow the steps below for your router. A brush check will not resolve every issue, but it is a useful place to start.

Before you start

Switch the router off, wait for all moving parts to stop, and unplug it before every brush inspection or replacement. Remove any installed cutter bit while the router is unplugged, and keep it removed throughout testing.

Wear eye and hearing protection during the running test. Maintain firm control of the router and do not leave it unattended. “Without a load” means running without cutting or contacting any material.

Use the brush replacement instructions below View brush replacement instructions FST-1 manual • Page 10 (PDF) .

New router: will not start or briefly spins and stops

1. Disconnect power. Switch off, wait for all movement to stop, and unplug the router. Remove any installed cutter bit.
2. Remove and inspect both brushes. Follow the manual to remove the brush caps and assemblies. Check that the wire connecting each carbon brush to its copper plate is intact. If either connection is damaged, loose, or detached, install the included spare set following the manual and proceed to step 4. Replace both brushes. Do not repair the wire or reinstall a damaged assembly.
3. Reinstall the intact brushes. Align each brush with its slot and refit its cap. Tighten the caps snugly without overtightening.
4. Test the router without a load. Finish reassembly and check that the switch is OFF before reconnecting power. Turn the router on. If it runs steadily, let it run for three minutes with the cutter bit removed.
5. If it will not start or stay running, try the spare set. Switch off, wait for movement to stop, and unplug again. If you have not already tried the included spare set, replace both brushes and repeat step 4. If the spare set has already been tried, contact us below. Do not keep restarting a router that stalls or cuts out.

Used router: stopped running or cuts out intermittently

1. Disconnect power. Switch off, wait for all movement to stop, and unplug the router. Remove any installed cutter bit.
2. Replace both brushes. Install the included spare set following the manual. Align the brushes with their slots, then refit the caps snugly without overtightening.
3. Test without a load. Complete reassembly and confirm the switch is OFF before reconnecting power. If the router runs steadily, let it run for three minutes with the cutter bit removed. If it will not start or continues cutting out, stop testing and contact us.

Still having trouble?

If the issue continues after trying the spare brush set, stop using the router and email support@80percentarms.com to arrange a replacement. Tell us whether your router is new or previously used and which steps you tried.

For this troubleshooting issue, you do not need to return the original router.

What if I do not have the spare brushes?

Contact our support team for help. You can also reach out if you are uncomfortable removing or replacing the brushes.