ToraDog I've the same problem switch on and the Dremel is at setting 2 speed wises. Where I win is it gets into very small spaces. Doing a investigating into fault finding with the 965 Dremel

This is a bit off the mark, but it's Dremel related. I have always objected to to the speed of Dremel tools, especially when working with really small bit. I was in a large box store the other day and stumbled upon this:
https://us.dremel.com/en_US/products/-/show-product/tools/hses-01-cordless-electric-screwdriver
It is quite nice with some feature I really like, such as adjustable torgue setting, and especially a trigger that is activated by simply pushing the tool onto the work. However the real reason I bought it was the slower speed. Much better control for drilling and a nice power screwdriver. It cost around $45 US and recharges via a USB cord from a computer of the supplied transformer.

I bought two spare drill triggers from Ali Express. Didn't realise they were in the USA 3 month waiting for delivery but the only cost 6 dollars for the two. They can keep them if they want import tax and vat Comes back again and again the old stuff does last longer.

Sounds good, very handy tools for the small stuff. I still have a tiny French made Precision Petite hobby tool which was given to me 56 yrs ago for my 12th birthday, and it still works perfectly, and is super handy, (pic of one on EBay) mine has a different box. You can buy similar things on Ali Express which are just 550 motors with a chuck screwed on the shaft,- handy for small spaces, or with a mount as a dowel borer or cutoff wheel etc.

JB

Bought one off EBay yesterday seems it is hardly use with accessories. Don't need the accessories just the Dremel. It looked a really good. Any kinda big job I 'll use the Macalister combi drill.

The one that went boom is made in USA the other in Mexico

An up to date one is probably a better option. Mine are Chinese and work fine, (about 15yrs old) but not fantastic quality. Good thing is, you can buy 2 or 3 for the price of a Dremel, (which is probably made in China these days anyhow)? I bought my son a Stanley hobby tool set, and that's Chinese made. All made to a price.

JB

Yes the dremel is for hobbyist and it doesn't have much torque nor does it like long running times. I can get spares once I have a more in depth look at it. Surprise its AC straight in to it I am use to it being a knocked down voltage and DC. Also have another spare one on the workstation. Spares money, effort , time doesn't outweigh buying a good one off EBay. Have my eye on one at the moment. Also the 3000 is a reasonable price and it fits the workstation. Just finished fitting a new electronic trigger to my Macalister drill Just keeps happening doesn't it. Seems like the 395 is similar to the 965

https://www.sparetoolparts.co.uk/dremel/dremel-395-f-013-039-5fr-spare-parts-list.html

Re,- I think we perhaps expect more from them than their design allows.
Quite true Dave, - not sure what the Dremel is, (125w?) but mine are similar and only 135w (not much more than a big light bulb) so not really for leaning on, (rely on revs not torque to get things done) If it's your switch that's dud, and if this is the switch, buy a sack full for spares.
220v 5 speed just not linear. Cheap enough to just buy one to try.

JB

I have a couple of Dremels but avoid using to sand fibreglass and use the hoover to clean the air vents frequently. Running at high speed is also useful as it helps clear any dust and cools the motor. Erratic slow speed often occurs after continuous use probably due to heat problems and usually clears if left to cool and then run at fast speed for a few mins. Very useful piece of hobby kit but I think we perhaps expect more from them than their design allows.

I have 3 similar hobby tools (only one of which has the speed control working) The problem is usually on the speed control (as with electronic drills) as they do not like being loaded up on slow speed (causes heat and eventually kills the controller) For heavy use it is better to run them on full speed as they are getting full power and cooling better. What I have done, is bin the speed control and wire the motor directly, and they work fine (full power all the time, ) of course -making sure the tools are seated fully to avoid bending the shafts and creating a nasty 90deg rotary slashing device😁

If you can't find parts and yours is definitely 240v, you might be able to do the same thing to preserve it. If ever I do things like this, I make sure there is an RCD in the supply system which will make things safe, (just in case) shouldn't be a problem as they are all double insulated these days. The stator shouldn't be a problem, and if the brushes are ok, it should be all good.

You can check the commutator for shorts between the segments and the rotor shaft as well, but these small motors don't burn often, (unless they are stalled). If you get loads of sparks and electrical 'grinding' noises when wired direct, that might mean it's had it, but an RCD will tell you that anyhow, and cut power before anything happens. If an RCD cuts more than once, bin the drill for safety (after making sure it's not just your supply cord shorting somewhere as Hillro mentioned).

Not sure how you could wire yours direct, as they have an odd plug in switch assy, but there will be a way round it if necessary.

JB

Very few videos of the 965 but compared to some of the newer ones 965 looks basic. Here is one of the 395 another early one and basic looking to cheers Hillro

Thought it should be AC but didn't get any readings on meter got a DC reading of 6 v funny. Havre another crack at it tmo cheers Graham93

Check out YouTube
Several videos on dremel repairs

I don't under stand your Voltage readings.
I would have thought you would measure 240volt not 6 volts.
Have you checked the supply lead conductors for continuity.?

Looking at the photos, it looks like a universal AC motor. These have the armature and field connected in series. The little white box looks to have just two connections and is likely to be an interference suppression capacitor. A bridge rectifier would have four connections.

I don’t understand the voltages you have measured.

Graham93

Just cant find any circuits about to have a go. Saying that by the time you buy a switch and an armature and a field you'd be better buying a Dremel 3000. Just thought I'd give it a go. Not many 965s about now which I think were the best Cheers mturpin013

I had exactly the same issue, Its still on the shelf waiting for repair (by someone better qualified in electrical/electronics).