I'm having the same problem with my 560 after a day of use. For me, it's caused by the little yellow spacer that's clipped onto each side of the bristly brush. When the brush assembly is closed, it wedges rather tightly next to that yellow spacer on the left. This causes a lot of friction and heat, and mine's worn away quite a bit already.
My solution was to just unclip that spacer and leave it off. It's probably not an ideal long-term solution, because dirt and hair will be more likely to get into the drivetrain. But at least it works now.
Another thing that these roombas apparently suffer from is clogged up gears. If you aren't having the same problem as me, you could try the instructions here to clean the gears:
http://www.robotreviews.com/wiki/cleaning
Hope that helps!
In the case of my Roomba, this was caused by hair wrapped around the rod between the little yellow doohicky with the tab end and the rest of the brush. The brushes have the end with the square knob and the end with the complicated little yellow doohickey (I really have no better way to describe it). Unclip the doohickey by squeezing and pulling (you may have to try a couple different places until you get the right angle), then pull the hair off of the metal rod. Any **** in there can make the brushes jam, so clean them out regularly.
I wasn't cleaning them for the first couple weeks because I couldn't figure out how to get them off, and it caused this problem pretty quickly. (Older Roomba you matched tabs with notches and pulled it off, this one has a couple tiny tabs grasping the metal rod and you have to grab the outside of the doohickey in line with them and squeeze to pull it off).
From the iRobot help line,
1) Clean the brushes thoroughly including this area, then run and see if everything is OK. If so, just remember to clean them well and regularly.
2) Run the Roomba with no brushes, no cage, and no dustbin. If it still jams and misbehaves like this, the cleaning module is the problem, and you will either need to clean it out yourself or send it to them for repair.
3) Run the Roomba with just one brush (including cage and dustbin), and if that's OK, with just the other brush. Whichever brush is causing issues may need to be replaced because something is warped, or maybe you need to inspect it carefully for crud.
Mine was also the spacers but I found that when I swapped them to the opposite ends it no longer made the noise. So maybe try swapping ends before removing them completely.
I tried switching and it worked for a short while, but the problem reappeared, so now I've tried to smooth the yellow piece with some sandpaper, and it seems to work...
Ya gotta disassemble the gear box and clean the crud out. Go to this You Tube video and he shows how to do it.http://www.youtube.com/watch?v=7QWhsu4c0...
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SOURCE: Brushes are clean, but Roomba stops and says clean brushes
I decided to take it apart and see if I could fix it because even if something inside went "SPROING" and I couldn't get it back together, it wouldn't be any worse than it was already.
FIrst, remove the dust bin part and the brushes. Then, there are four screws on the bottom gray panel which have to be removed first in order to get to the gears which hold the brushes. I did not remove the little sweeper brush on the front, but I just slide it through the hole in the gray panel.
Then in order to get out the orange section which actually holds the brushes, there are four screws which must be removed. The orange section is attached to a blue section. This entire unit comes out by sliding it toward the area where the dust bin goes, being careful not to tear the light gray rubber gasket which covers the side.
Once that section is removed, there are two screws on each side. These screws hold the orange thing to the blue thing. Once the screws are removed, lift up only the side which has the white squares into which the brushes are inserted. These are actually the back side of little gears. There is a face plate on the outside of the orange part on this end. The other end contains a bunch of wires and I was careful not to disconnect any of them.
The face plate has six screws which must all be removed. Use caution when removing the face plate. Hold it up so that all of the stuff doesn't fall out. It has a bunch of gears, little brass looking fittings and grease. Take care to only remove the gears which have the squares which hold the brushes AND do it one at a time unless you like working jigsaw puzzles. I used tweezers and a pin to clean the "gunk" consisting of hair, fuzz, etc., out of the little gears.
Reverse the process to put it back together. Hazel, my little Roomba, played me a happy little song and immediately went back to work. She seems as good as new.
SOURCE: roomba keeps saying clean brushes yet are clean!
Remove the Yellow connectors on the end of the brushes and clean around the pin well. If there is too much there, the roomba thinks there is something stuck and goes into clear mode (as if there is a chord stuck).
SOURCE: roomba keeps saying clean brushes yet are clean!
Make sure you take off the little cap at the end (the one that spins -- just grab it and pull it straight off) and clean under it too. The rest of the brush may look perfectly clean but what happens is that hair gets stuck under spinning cap and, like a slowly growing washer, it pushes the whole brush toward the gear box. When it gets pushed over enough, the large yellow ring starts to rub against the side of the brush deck making it harder for the motor to turn the brush and you get that "remove and clean brushes" message.
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