Motorized brush bar not turning on Dyson Vacuum

Apparent common failure is that either the thin yellow and or blue motor drive wires that run from the LH side of the vacuum where the "control board" is located down into the hinge / ball area become stretched and then fray and eventually break. Happened to my Dyson twice. First repaired under warranty, second took about 20 minutes. You need a Torx screwdriver to remove the LH panel ( 4 screws) and also an access panel (2 screws) at the side of the ball which permits access to the blue / yellow wire connectors. I replaced with a new wire and connectors having fed the wires through the access hole making sure sure enough wire was available for the movement of the handle. Also ensure that when the covers are replaced they do not trap any wires underneath.

There are other ways the brush bar could stop working, So this will not fix everyones problems but as I posted before I had a feeling there was an open in the brush bar circuit. And since there is a pivot point I was almost positive that was my problem.

Today I opened up, two caps on the left side and found a broken wire, I really don't know how it worked at all, since it wasn't just partially broken it was completely broken.

[IMG]http://i471.photobucket.com/albums/rr74/NinjaRider08/Dyson_DC15.jpg[/IMG]
<a rel='nofollow' href="http://s471.photobucket.com/albums/rr74/NinjaRider08/?action=view&current=Dyson_DC15.jpg" target="_blank"><img src="http://i471.photobucket.com/albums/rr74/NinjaRider08/Dyson_DC15.jpg" border="0" alt="Photobucket"></a>
http://i471.photobucket.com/albums/rr74/NinjaRider08/Dyson_DC15.jpg

All in all it took about 15 minutes, for me but I'm an electronic engineer, now it works good as new

With our DC25 Animal machine, the brush quit turning after it got jammed while trying to vacuum something it didn't like. After waiting the required 60 minutes, as the solution in the book, the brush still did not start. I checked for blockages and cleaned both filters, emptied the canister, and it still would not turn the brushes. Everything else worked. I finally called the customer service line and she had me turn the machine on, lower the machine in the position to vacuum and then press the secret GREY button on the handle for five seconds and the brush motor will reset. I followed her instructions and sure enough the brushes started to turn. McGyver I am not, nor am I James Bond, so whoever printed this instruction manual needs to find another job. Before taking the machine apart to check the wires others are writing about here, try pressing the super secret problem solving grey button on your machine, next to on/off button, and your brushes may start turning again.

I had exactly the same problem, took the lower handle cover off and found the orange wire had snapped inside. I ordered a new pair of wires from a local Dyson specialist for £4.25. The part is called Loom BB Over Current , part number 907280-03 

The issue with the plastic "female" ends of the bar appearing too large is due to the brush getting stopped by something (usually long carpet fibers or string you may accidentally run over). While most vacuums have a belt driven brush bar, which would allow the belt to slip when this happens (remember that burning rubber smell on your old vaccuum?) the Dyson uses a gear.
This allows the "male" metal ends to continue to turn when the bar is stopped, which will quickly **** out the "female" ends, since they are plastic.
If they were metal as well, the motor would burn up. In this case, the only solution is to replace the bar. Perhaps in newer models, Dyson will include a clutch that will allow the motor to slip when the bar gets stuck.

This can happen if two tiny wires that are connected to the circuit board and lead to the beater bar are broken. These wires brake where they go through a black rubber grommet. You need a torx screwdriver tx 15 to remove two plastic covers to access these wires . When looking from the front of the vacuum, the circuit board is located under the gray covers located on the right side of the vacuum (Photo 1). There is one big cover with a black rubber gasket and other small gray cover is on the rotating ball area.

Thank you everyone for you help. I was able to read your post and comments and fix mine the exact same way. The problem that I noticed is the rubber gromment that they use does not give any play for the wires to slide back and forth. By the naked eye it looks like they are still together but with a small tug the wires seperate. I replaced the small gasket and fixed the wires and the machine works amazing.

Happened to me, too. From what I can see, the plastic female end of the endcap was worn too large from the metal male end that the brushbar fits into. Mine lasted about 2 years before this problem. I ordered a new brushbar and the problem is gone. Good luck.

Has the belt snapped

Bad connection

Was ready to buy new vacuum, your comments were the solution, yellow wire busted. I picked the ruber seal out and used ice pick to expand hole; made it easy to get wire through. I spiced wire and used electrical tape. I applied a little water on plug as lubricant.

Mr. James Dyson is a genious but should have continued the yellow/orange wire shroud right through the ball mechanism. Solution # 3 was spot on. Thanks Mike.

Had same problem. yellow wire was broken, blue had bare wire showing. added 3 inches of wire, works again. i messed with spinning brush area looking for these 2 wires but they are in by the ball pivot area where you can remove 2 screws to get to them

Anyone know what size wire? I'm very mechanically inclined but very broke, with bad allergies, and really need to get floors cleaned so any help is appreciated.

Turbobar brush not working on DC 15