How to Know When Your Motor Needs Rewinding

If your equipment is acting up, but you’re not ready to shell out for a brand-new motor, you’re not alone. Many of our customers here in Coldwater come in wondering the same thing: Can my motor be saved? In many cases, the answer is yes—and it starts with rewinding.

Motor rewinding isn’t just a cost-saving fix. It’s often the smartest, fastest way to restore performance without downtime or replacement headaches. So how do you know when rewinding is the right move?

Let’s break it down.

1. The Motor Suddenly Shuts Down or Trips Breakers

This is one of the most common symptoms of winding insulation failure. If the windings short out or degrade, it can cause excessive current draw, which trips the breaker. If the motor used to run fine on the same circuit, but suddenly doesn’t—it’s a red flag.

2. It Smells Like Burnt Insulation

That smell isn’t your imagination. Burnt winding insulation has a distinct odor, especially when the motor heats up during operation. If it smells like something’s cooking—but shouldn’t be—it might be time for a rewind.

3. The Motor Runs Hot, Even With No Load

A motor that overheats when it’s not doing much work is probably working harder internally than it should. Electrical resistance inside the coils increases when the insulation starts to break down. This causes excess heat, even when the shaft is barely turning.

4. Unusual Noises or Vibration

Bearings get blamed for everything—but sometimes the noise is coming from electromagnetic imbalance caused by winding issues. If your motor is vibrating more than it used to, or making strange humming or buzzing sounds, it’s worth checking the windings.

5. You’ve Already Replaced the Bearings, But It’s Still Not Right

We’ve had many customers replace bearings, realign pulleys, even replace belts—and still the motor struggles. Often, the issue is internal. A proper inspection can reveal whether rewinding is the next logical step.

So… What Happens During a Rewind?

At CEM Industrial Supply, our rewind process involves:

  • Carefully disassembling the motor
  • Removing damaged windings
  • Cleaning the stator core
  • Rewinding new copper coils to match OEM specs
  • Re-insulating and varnishing for long life
  • Full load testing to ensure everything runs smooth before it gets back in your hands

Our team has decades of combined experience, and we’ve brought motors back to life that others had written off.

When It’s Time to Replace Instead

Sometimes a rewind just doesn’t make sense—like when:

  • The stator core is damaged
  • It’s an inexpensive motor (and a new one is cheaper)
  • The application requires upgraded specs or efficiency

That’s where we’ll be honest with you. We’ll assess the motor and walk you through the pros and cons. If it’s better to replace it, we’ll tell you—and even help you find the right one on the spot.

Final Thought

If you’re unsure whether your motor is worth rewinding, bring it by or give us a call. We’ll test it, inspect it, and give you a straight answer.

We’ve helped hundreds of local businesses and homeowners get more life out of their equipment—and we’re happy to help you too.

Visit us in-store at 178 W. Garfield Ave., Coldwater, MI
 Call: (517) 278-7451
 ️Learn more: Industrial Motor Repair Services