A faint burnt plastic smell is actually normal for these when brand new, but that normally disappears after a week or so. As for sparks, a thin trail of blue sparks trailing along the commutator (the uppermost part of the motor that can be seen rotating) is normal. However, if there are blue, orange sparks flying out of it its toast. The motor is dying in that machine.
SOURCE: my hoover dual v steamvac make loud noise and sparks
unfortunately the motor did go out on this machine. the commentator brushes and the armature are burnt and the motor or the machine will have to be replaced
SOURCE: My Hoover carpet cleaner is approx. 7 yrs.
you are correct, the motor is shot. if you like the machine replace the motor. i would get an est. on the machine from your local vac shop and the go price them. in some cases its better just to get another machine.
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