Smells like burning
We had this same issue. I noticed it smells like burning plastic. I took it apart and did not find any fundamental problems. Ball bearings on motor are fine, no play.
What I did find was that the motor construction contains lots of plastic. It's made in China. Even the brush holder is plastic. Now, this is unusual to me, as brushes get very hot. However, I did not find any issues of melted or softening plastic when running. I used a laser-guided thermometer and measured about 170 degrees F on the metal portion of the brush holder. Nothing unusual. Some parts reached above 200 degrees F. Again, nothing unusual. The only unusual issue is that many of the parts are mated with plastic parts. That's where I believe the problem lies.
When the motor is new, the brushes don't make full contact. Therefore, full power draw is not achieve until these brushes wear down a bit. After this point, the brushes reach maximum power delivery and reach maximum temperatures. This is why I believe the vacuum didn't exibit any smell until a few months later, at least, for us.
In conclusion, I didn't find anything wrong, except that the motor is cheaply constructed. It isn't going bad and well likely last quite a while, IMHO.
MAJ
×