What goes wrong with this Router - Does not start, burning smell & smoke.

Check the bottom and if you get lots of sparks and a burning smell it’s done caput.
You can try to blow air in the bottom where the brushes are.

I believe not only did you overheat the router due probably to failing motor windings, (that is why the overheat sensor kept tripping internally), it also sounds like you might have fused your router switch in the on position.
Either way, repairs are not feasible – get a new router.

-- Paul, Tennessee, http://www.tsunamiguitars.com

GMman, I did notice sparks when I turned it to high speed. For this job, I just used the lowest speed.

-- masrol, kuala lumpur, MY.

I agree with Tennessee, this is way more damage than worn brushes or something easily repairable.
Good luck

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

If you’ve used it in a table a lot, dust in the windings may have
contributed. Table use shortens router life.

There isn’t much that can go wrong with a router.. which is basically just a motor with a collet on one end. Most common cause of failure are brushes, bearings and getting all packed up with sawdust (particularly in the fan blades and between the rotor and windings). I’d pull it apart and check it out. Could be something as simple as just needing to be cleaned out or a $4 bearing gone bad.

Cheers,
Brad

-- Brad in FL - To be old and wise, you must first be young and stupid

I will make this easy on you. Electric motors have epoxy on the windings and when they get hot the epoxy melts and the windings short out. outside of rewinding the motor its trash. the smell is the tell tale sign. just sparks may allow you to clean the motor and brushes and move on. but that all familiar smell means R.I.P..

I tend to agree with Edward.

-- W James Brokenbourgh Custom furniture maker http://artisticwoodstudio.com/

Surprising that a Makita would do that. They are usually workhorses.

If I was in your situation, I’d take it in to get it looked at and see if it was just the switch and brushes. If it was the armature, you might as well right it off.
From experience I know that if you go to the right place, you won’t get charged for it to be opened up if you buy a replacement from them, so there’s nothing to lose.

-- Do or do not, there is no try

I had on that did the same thing if you see large sparks just let it run and it will go dead.

Sounds like it is time to go shopping for a new router. I agree that this one is toast

-- Dr. Ken, Florida - Durch harte arbeit werden Träume wahr.

Yea, your tool is shot, but get ahold of Makita directly and explain it to them. They might be interested in your old unit to see what went south. I had a PC that had a screw inside come loose and get into the windings. They replaced the unit after 5 years.

-- Ken, USAF MSgt, Ret.

I’d junk it. Sounds like a good way to burn your shop down.

-- Don't rollerskate in a buffalo herd

I love this router. It is just about 2ys old from the time I purchased it. Smooth plunge and with no vibration and further more it does not produce much noise or even I may call it very silent in the extreme case (as a comparision, I can even use it while my neighbor is sleeping). So today I sent it to the Makita’s Repair Shop. I will update you all with the results – good or bad not sure how long, 2 weeks maybe, a month or forever.

And at the same time, I order another one – PC since I need to use it with the guide bushing without the need to use adapter.

I am very2 grateful and overwhelm with the opinion, suggestions and info from you all. Thank you, thank you.

-- masrol, kuala lumpur, MY.

I apologize for asking the obvious, but were you you using it with a long extension cord of the wrong gauge? There has to be a reason it died so young.