Sunshine, does your bobbin have 2 cases? If so you need to change it to the other bobbin case. Mine is the 1500 and I have two cases and it makes a BIG difference. Are you using embroidery thread or cotton? If cotton then it needs to be changed if you are embroidering.If all else fails check your manual or call the company you bought it from. If it's brand new then it should be under warranty. Keep us informed.Terre

Could be that darn bobbin tension that had me out of condition and out of my mind for 2 weeks. I had to have a service man adjust the tension on the bobbin. There is a little screw on the bobbin case that he adjusted, I was afraid to do it myself and mess it up. My machine almost went out the window!

First check that you've seated the bobbin thread properly through the little tension thingy in the bobbin area. It sounds like either your top thread tension is too tight, or your bobbin tension is too loose...and perhaps as simple as you didnt put the bobbin thread thru its tension guide.

This might sound silly, but did you put the bobbin in up-side-down? Sometimes the small silly things are what drive us insane. I'd suggest rethreading the upper thread path, and taking out the bobbin and making sure everything is threaded as your manual suggests.

Its odd that you've never had to adjust the settings/tensions in the two years you've had your machine. I do a tension test every now & again because as your machine ages, the tension springs ..well they're less springy lol.

Hope the solution is simple and you can get back to sewing :) xXx

You can try to thread all from scratch, usually the top thread pulling tight could cause the problem too. N.B. bobbin must be in the right way, and the tread also pulled into its tension spring.
Hope something works for your problem.
Please give update as to what you find? I have the brother Innovis 1500 ,so am very interested in all these type problems.
From Bev

I have seen that in the past and it has been due to the top thread getting twisted on its own pole...due to the place holder. Once I unwound the thread and made sure the place holder was pushed against the thread...then it fixed itself.

This post in dated 3 September. Hope it is sorted by now.

When my brother did this we weren't able to fix it until I got a new bobbin case. A small piece had chipped off of part of the case. After we replaced it, have had no more problems.

Surely sunshine, you solved this problem one way or another. How about telling us how it was fixed. I've never had that problem but if I did I would like to know what to do.