The brush roller stops turning and I can smell the belt burning, then it will catch and start working normal. I looked under the plate to check the belts and they looked okay and no hang ups of string or anything. The only thing that seemed weird was that the smaller belt that actually attaches and turns the roller is a bit loose. The larger belt is tight but looks like its the one that is burning and causing the smell.

Does it smell like burning plastic or burning rubber? Regardless, turn it over and take off bottom plate as if you were changing the belt and examine where it’s coming from. You will see obvious signs of friction with the belt or brush roller rubbing against an object. Sometimes a foreign object will get stuck causing this problem.

Your belt is burning and will eventually wear down and break. The green light comes from copper brushes on your roller creating an electrical current that lights the little green light. As long as the roller is turning, the light will stay on. There may be something jamming the roller (hair, string, paper, etc). Clean the roller off and replace your belt. If you don't replace the belt it will break soon enough. Once you start smelling the "rubber burning" smell it's and indication that your belt has deteriorated at some point and has a weak spot in it. Clean the roller and replace the belt and it should be fine.

Sounds like the belt should be replaced. It maybe turning the brush, but if you smell burning rubber, its slipping and not turning the brush with as much force as it should. Changed the belt. Check the air suction path. If the suction is reduced, something is blocking it. Check the bag (if it has one) and all filters. If the machine picks up any liquid, it will reduce the air flow through the filters and bag. Change the bag and filters. If this is an upright, you may find caked on dirt under or in the area of the brush.

Easy to fix. The burning rubber smell is hair in the roller against the belt! Congrats, you have a healthy vacuum, you are lucky! Unplug the vacuum, remove the screws that cover the belt and roller brush. If you are nervous, take pictures with a cell phone or digital camera as you go for re-assembly. ok, pull the long roller out of it's slot and out of the vacuum. cut all hair off the roller and carefully move the belt from side to side to do the same. If the belt slips off, it slips back on easily. If the area is too tight for fingers guide it back on with any long thin wooden object. You can squeeze the belt to narrow it and slide it back over the thin metal rod that spins it from the motor. Slide the roller through the belt and back into it's slots. If it won't slide back on, turn it a quarter turn. Repeat till it does slide back into place. Put the face plate back on-tighten screws, flip it over, plug itr in and it should work!

Sounds like a bad bearing on roller brush. Most shops give free estimates. Give one a try.

I have had problems with the belts on my Mach 5 overheating (smell of burning rubber) and also with the motor overheating and shutting down.
I learned the hard way that one of the issues might be that the roller/brush on the bottom of the unit has a metal bearing inside the roller/brush that can become clogged with hair (both human and pet hair) which effects performance of the unit.
It’s fairly easy to fix.
Lay the vacuum on the floor so that you can see the roller/brush. Then remove the phillip head screws that hold the protective plastic plate over the roller/brush. (There are about 6 screws that hold this plastic protective plate in place) Also, you will be removing the (1) screw that also holds the plastic plate over the belts. There are (2) belts that you can remove and when in doubt replace these (2) belts for around $9.00.
Once you have the protective plastic plate off that covers the roller/brush disconnect the belt is around the roller. Take the roller and cut off any hair that is wrapped around the roller. Next, grab the roller by each end and twist the ends caps and (1) of the ends will unscrew. Once you have unscrewed one of the ends remove any hair or dust that is trapped under this cap. (Be careful not to lose the small metal washer that sit on top of the bearing)You will notice under this cap is a metal bearing that can become clogged and jammed with hair. The hair should come out fairly easy and allow the brush to spin fairly easy once you have screwed the end caps back in place test that it spins freely. If it doesn’t spin freely replace the roller/brush with a new one for about $23.00.
When you put the belts back on the thick rubber one (Belt # 40201-271) has probably become stretched and should be replaced for about $3.00. The small diameter belt that goes over the roller/brush probably does not usually need to be replaced and does not usually fit very tight. I have heard that people will take the small roller/brush belt and turn it upside down to get a better fit.
I just did this on my Mach 5 and it runs like a new machine. I did end up replacing the roller/brush head.
Hopefully you will find this useful.

OK - so your brush roller is jammed. And yes, the belt is melting! Unplug the machine, remove the belt (you will need another new one anyway) then see if you can turn the roller by hand. If it turns freely without you doing anything else, then you may have put the new belt in incorrectly. However, you will probably find you can't turn it, or it's hard work (it should rotate freely). Remove the roller and check the bearings - there may well be something tangled up at one end of the roller. If you can get the roller rotating freely, all should be well.
Good luck

Look for a missing belt that may have burned off or broken. Was there a burning smell at some point before the roller quit turning? If so, the belt must be replaced. I would also look at the ends of the roller to see if there is any string, hair, etc. that might be binding the roller that needs to be removed.

Hi,
Try removing the drivebelt, and try running it to test like this. The brush bar will not turn, but it should function normally without smell at this point. If it doesn't, you may need a new motor as I think the brushes may have worn down - producing an electrical type burning smell.

If it runs fine without the belt attatched, then there is probably a build-up of hair or threads at each end of the roller stopping it turning freely. With the hoover off, check it turns freely and easily. A small metal nail file or similar is usually a good tool to clear it.

If the roller is stiff, the belt will not turn easily, and overheat on the motor spindle - causing the burning smell.

Flip the vacuum cleaner over and check the roller brush. Is it full of string and hair? If so, unscrew the four phillips-head screws holding the plate on that covers the roller brush; pull out the brush, and cut off/clean off all the hair and string. Replace everything and try running the vacuum. Alternate solution: perhaps the belt that makes the brush go around is broken. If so, follow the above steps to remove the roller brush, then replace the belt.