You know you have a bad brush, so the first step is to replace the pair of brushes. Odds are your controller has failed as well, but go one step at a time. If the router is used exclusively in a table you can bypass the controller and use an external speed controller instead. The things that cause controller failure are heat and vibration, and common sense will tell you a larger speed controller mounted to the table as opposed to in the router will get less vibration and dissipate heat faster. This is why I own a pair of Bosch 1617's instead of the 1617EVS models.
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Mike |