So, this may be a bit long winded but I will try to be direct. The router ran for a bit this morning then cut out again. Since owning it, there has always been quite a large amount of sparks inside the machine but really never paid attention as it always ran well. Before the machine cut out this morning I noticed that the heavy amount of sparks only came from the brushes on one side. Upon removing the top cover the one side of brushes did not appear to be set/conformed as well as the other side. There is probably a term that describes this but I am not familiar with it. I applied very lite pressure with a small insulated screw driver on the side that was sparking very heavily. Then plugging in the machine again, it began to run. Again, with the insulated screw driver I applied very light pressure eventually getting the brush to go from very high sparks to very low or the same as the other side. The router ran well for two hours after this. Hopefully, this was the fix from both not working and the heavy sparking. Maybe this can help someone else out there. I will have to see over time if it stays running well or maybe fiddle with the spring to apply a bit more pressure the brush.