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

  • Advertise with us

« back to Power Tools, Hardware and Accessories forum

Forum topic by woodworm posted 06-29-2012 02:56 PM 9161 views 0 times favorited 23 replies Add to Favorites Watch
View woodworm's profile


14468 posts in 3617 days

06-29-2012 02:56 PM

Topic tags/keywords: router

Router Info : Wattage 2,100w, 10A, 220-240V Makita Model RP2301FC Made in Japan Year of manufacture 2009
The problem : I was cutting mortise (3/8”W x 2”L x 1-5/16”D) yesterday when I found that I had to stop many times. After I turned off the machine, I cleaned the wood chips in the mortise hole. Then I continued to use the machine but it did not start. I have to wait few minutes before I able to turn it on again. At one time after I completed one mortise I took about 10 mins rest with machine in the “OFF” mode but the mains power plug in the “ON” mode. After that I my nose caught very strong burning smell (like burning plastic/rubber) and I saw smoke came out of the motor casing. I immediately switch off the mains power plug.
Today I went to the shop (my second home actually which is 20KM from my home I live in) to test if the machine is still working. Yes I did start., but once I switched off the machine, I also had to switch the mains power plug off.
I just wonder how that happen. How could it be possible that current is running into the motor with the machine’s switch off? What goes wrong with my Router?

Thank you for reading. Any info is much appreciated.

-- masrol, kuala lumpur, MY.

23 replies so far

View GMman's profile


3902 posts in 3724 days

#1 posted 06-29-2012 03:07 PM

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.

View Tennessee's profile


2873 posts in 2541 days

#2 posted 06-29-2012 03:10 PM

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.

-- Tsunami Guitars and Custom Woodworking, Cleveland, TN

View woodworm's profile


14468 posts in 3617 days

#3 posted 06-29-2012 03:17 PM

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.

View pintodeluxe's profile


5706 posts in 2840 days

#4 posted 06-29-2012 04:26 PM

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

View Loren's profile


10476 posts in 3674 days

#5 posted 06-29-2012 04:53 PM

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

View MrUnix's profile (online now)


6766 posts in 2225 days

#6 posted 06-29-2012 08:05 PM

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.


-- Brad in FL - In Dog I trust... everything else is questionable

View EdwardR's profile


66 posts in 2280 days

#7 posted 06-29-2012 09:45 PM

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..

View a1Jim's profile


117120 posts in 3603 days

#8 posted 06-29-2012 10:33 PM

I tend to agree with Edward.

-- wood crafting & woodworking classes

View 404 - Not Found's profile

404 - Not Found

2544 posts in 2995 days

#9 posted 06-29-2012 10:45 PM

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.

View GMman's profile


3902 posts in 3724 days

#10 posted 06-29-2012 11:13 PM

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

View Schwieb's profile


1858 posts in 3488 days

#11 posted 06-30-2012 10:51 AM

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.

View KenBry's profile


484 posts in 2474 days

#12 posted 06-30-2012 11:00 AM

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.

View Howie's profile


2656 posts in 2949 days

#13 posted 06-30-2012 11:37 AM

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

-- Life is good.

View woodworm's profile


14468 posts in 3617 days

#14 posted 06-30-2012 12:48 PM

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.

View dhazelton's profile


2771 posts in 2323 days

#15 posted 06-30-2012 01:50 PM

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.

showing 1 through 15 of 23 replies

Have your say...

You must be signed in to reply.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics