my saw is smoking a little and smells like burning plastic from near the motor housing.

Diagnosis

The burning plastic smell and visible smoke emanating from the motor housing of the Makita XSR01Z are primary indicators of thermal overload within the armature or the failure of the carbon brushes. Because this is a high-torque 36V XGT tool, the motor generates significant heat when the blade encounters excessive resistance. When you push the saw too fast through dense hardwoods or use a blade with too many teeth for the material, the motor draws maximum current, causing the copper windings to overheat. This heat melts the lacquer insulation on the windings or the plastic housing of the brush holders, creating that distinct "electrical fire" scent.

Alternatively, this can be caused by a "binding" condition where the blade is pinched in a cut, forcing the motor to stall while the trigger is still depressed. This creates a massive spike in amperage that can partially melt the internal wiring or burn the commutator. To confirm the source, remove the batteries and sniff the motor vents; if the smell is strongest near the rear handle (where the trigger and motor control are located), it is likely an electrical component failure. If the smell is coming from the front gear housing, you may have a bearing failure causing friction-based heat.

How to Fix It

Stop operation immediately. Continuing to run the tool while it is smoking will lead to a total motor burnout and permanent failure of the electronic control board. Follow these steps to resolve and prevent recurrence:

1. Power Down: Remove both 18V batteries (or the 36V battery) immediately to kill all current to the motor.
2. Thermal Cool-down: Allow the tool to sit for at least 30 minutes. Do not use compressed air to cool it while it's hot, as this can cause micro-cracks in the plastic housing.
3. Blade Inspection: Remove the blade bolt and take out the current blade. Inspect the teeth for rounding or "burnt" tips. If the blade is dull, the motor must work 3x harder to push through the material, causing the overheat. Replace with a high-quality, sharp carbide-tipped blade specifically rated for the material you are cutting.
4. Ventilation Clearing: Use a vacuum or compressed air to blow out the motor vents located on the rear handle and the main housing. Sawdust buildup blocks the airflow, trapping heat inside the motor housing and leading to insulation melt.
5. Mechanical Check: Rotate the blade by hand (with batteries removed). It should spin smoothly. If you feel "grittiness" or resistance, the bearings are failing, which is causing the motor to overwork.
6. Test Run: Reinsert batteries and run the saw in open air (no load) for 60 seconds. If the smell persists without a load, the internal windings are compromised and the motor must be replaced.

If That Didn't Work

• Replace Carbon Brushes: If the smoke was localized to the brush holders, the brushes may have worn down to the spring, causing arcing. Inspect the brushes for pitting or excessive wear. Replace them with genuine Makita OEM brushes to ensure the correct conductivity and fit.
• Inspect the Trigger Switch: A faulty trigger switch can occasionally "stick" or fail to regulate current correctly, causing the motor to run at an erratic, high-amp state. If the trigger feels "mushy" or doesn't snap back, the switch assembly needs replacement.
• Armature Replacement: If the smell remains after cleaning and blade replacement, the armature has likely suffered a partial meltdown (shorted windings). This requires a full replacement of the motor assembly, as repairing individual windings on these brushless/brushed hybrid systems is not feasible in the field.
• Check Battery Health: A failing battery cell can sometimes cause erratic voltage spikes that overheat the motor controller. Try a different set of fully charged XGT batteries to rule out power supply issues.

Heads Up

• Avoid "Forcing" the Cut: Let the RPMs of the saw do the work. If the motor sound drops significantly (bogging down), slow your feed rate immediately to prevent thermal overload.
• Blade Selection Matters: Never use a fine-finish crosscut blade for ripping long boards. The high tooth count creates too much friction and heat, which translates directly back into the motor housing.
• Regular Air Purging: Every 4-8 hours of heavy use, use a blow-gun to clear the motor vents. Dust accumulation is the number one cause of overheating in the XSR01Z.
• Scent Warning: If you see actual sparks jumping inside the motor housing (visible through the vents), stop immediately. This is a sign of a catastrophic commutator failure and can lead to a battery fire.