A power tool includes a housing having a base configured to support the power tool relative to a workpiece. The power tool includes a handle coupled to the housing. The handle defines a longitudinal axis and includes a first portion positioned between the longitudinal axis. The housing the base and a second portion opposite the first portion and extending away from the base. The power tool includes an activation switch coupled to a side surface of the housing. The activation switch is slidable in a direction parallel with a switch axis that intersects the longitudinal axis from a deactivated state, in which the drive system is non-operable, to an activated state, in which the drive system is operable. The activation switch is slidable toward the second portion of the housing from an intersection point between the switch axis and the longitudinal axis.

A reciprocating saw includes a housing, a motor, and a drive mechanism. The drive mechanism includes a driven gear that is rotated by the motor. The driven gear is vertically-oriented within the housing. The drive mechanism also includes a drive arm coupled to the driven gear to translate rotary motion of the driven gear into reciprocating motion, and an output shaft coupled to the drive arm to reciprocate relative to the housing along a spindle axis through a cutting stroke and a return stroke. The drive mechanism further includes a counterweight coupled to the driven gear for rotation with the driven gear. The counterweight moves toward the spindle axis during a start of the cutting stroke of the output shaft and moves away from the spindle axis during a start of the return stroke of the output shaft.

A power tool includes a body housing including a first grip, inlet facing a front surface of the first grip, first outlet, and second outlet; a brushless motor held on the body housing and including a rotational shaft; an output unit supported on the body housing in a reciprocable manner; a power transmission mechanism between the brushless motor and the output unit in the body housing to transmit rotational motion of the rotational shaft to the output unit; a controller held on the body housing to control the brushless motor; and a fan held on the body housing and mounted on the rotational shaft. The body housing allows air drawn through the inlet and having cooled the brushless motor to be divided into first and second outlet blows respectively cooling the power transmission mechanism and discharged through the first outlet, and cooling the controller and discharged through the second outlet.

A blade clamp is configured for use with a power tool having a reciprocating spindle. The blade clamp includes a cover assembly rotatably coupled to the spindle, and a detent received within a first bore of the spindle. The detent is movable in a radial direction relative to a longitudinal axis of the spindle by engagement with the cover assembly to adjust the blade clamp between a locked configuration and an unlocked configuration. The blade clamp further includes a sleeve in which the detent is slidably received. The sleeve is at least partially positioned within the first bore. A plunger is positioned within a second bore of the spindle. The second bore extends along a longitudinal axis that is parallel with the longitudinal axis of the spindle. The second bore is contiguous with a blade slot of the spindle.

A reciprocating saw includes a housing, a motor, and a drive mechanism. The motor is configured to operate in a forward mode corresponding to a first rotational direction, and in a reverse mode corresponding to a second rotational direction opposite the first rotational direction. The drive mechanism includes a driven gear, a connecting rod, an output shaft, and a counterweight. The driven gear is rotated by the motor and has an upper portion and a lower portion. The output shaft reciprocates through a cutting stroke and a return stroke. The counterweight is coupled to the driven gear and rotating with the driven gear. When the motor is operated in the forward mode, the counterweight moves through the upper portion of the driven gear during the cutting stroke of the output shaft, and moves through the lower portion of the driven gear during a return stroke of the output shaft.

A power tool includes a housing, a motor, and a drive mechanism. The drive mechanism includes a driven gear that is rotated by the motor. The driven gear is vertically-oriented within the housing and has an upper portion and a lower portion. The drive mechanism also includes a connecting rod coupled to the driven gear to translate rotary motion of the driven gear into reciprocating motion, and an output shaft coupled to the connecting rod to reciprocate relative to the housing through a cutting stroke and a return stroke. The drive mechanism further includes a counterweight coupled to the driven gear for rotation with the driven gear. The counterweight moves through the upper portion of the driven gear during the cutting stroke of the output shaft, and moves through the lower portion of the driven gear during a return stroke of the output shaft.

A method of assembling a gearcase cover assembly of a reciprocating saw. The method includes providing a gearcase cover with a cylindrical opening and a receiving portion, providing a shaft with a yoke affixed to the shaft, inserting a first end of the shaft into the cylindrical opening and rotating the shaft such that a second end of the shaft sits in the receiving portion.

A blade clamp for use with a power tool having a reciprocating spindle. The blade clamp comprises a cover threaded to the spindle for relative axial movement thereto in response to rotation of the cover relative to the spindle, an ejector pin positioned within the spindle, and a spring coupling the cover and the spindle. The spring biases the cover toward a first rotational position relative to the spindle coinciding with a locked configuration of the blade clamp. The cover is rotatable against the bias of the spring toward a second rotational position relative to the spindle coinciding with an unlocked configuration of the blade clamp. In the unlocked configuration, the ejector pin maintains the cover in the second rotational position. In response to insertion of a blade into the spindle, the blade clamp is automatically adjustable from the unlocked configuration to the locked configuration.