I would have probably refused to work on it just because the previous owner said he "lapped the valves". The only thing worse is when it's brought to you in a basket.
It was a full movie plot: Exposition: The introduction of the characters, setting, and conflict Rising action: The characters grow and change in response to the conflict Climax: The conflict escalates to its peak Falling action: The story moves toward resolution Resolution: The conflict is resolved and the story ends One of the best videos he’s done to date.
Perfect engine learning video. So nice to see what happens when ignoring the phrase “You could but I wouldn’t recommend it”. You overcame so many obstacles. Truly the journey was the value. You touched every bit of that machine. Thank you for an amazing demonstration of what is possible.
Absolutely favorite UA-cam channel! 1) your calm voice and approach 2) thoroughness and tenacity 3) intelligence and ability 4) how you teach as you fix Thank you for an awesome video!
Your patience and resilience never cease to amaze me. When you broke the aluminium starter cup trying to take the engine apart made me think that was it, end of video. But no, not James. Instead you just got the right part to fix it and got it working like new, despite all the setbacks. Thanks, James. I really look forward to your videos. They make my week.
An EPIC struggle between man and machine! Will James successfully save an inverter generator from the parts bin? Drama, mystery, and intrigue awaits... Better than most movies these days, GREAT JOB James!
I especially want to thank yyou for refraining from playing background music. We can all deal with silence, but we don't all like the same music, besides most of those who do play it play the most motonous crap they can find, and usually too loud.
It is good that you got it running. But, the original owner was sold a bill of goods. Unless it was damn near given to him. It is highly unlikely that the average backyard mechanic could have solved the multitude of problems. Very few would have thought of reversing those two wires. I might have said it before, but; you have an extremely high level of patience. Another nice job.
How cool. I had a Sportsman 1000 that changed my life with how efficient it was. I am presently working on a Yamaha EF2000IS that was given to me, because it has low compression, due to the user using it without an air cleaner. (Turns out rings are stuck. Valves and bore actually look fine! Even the piston looks clean) I used to consider myself an small engine expert, but i found myself, when tearing down the Yamaha, comparing everything I did, "Would James Condon do it this way? Would he be in such a hurry? Would he, etc, etc..." LOL. So, to see this drop today, as I have been ill, is like a little light in my day
I have one of those. It’s fuel efficient but there are models that are larger that use even less fuel per hour and it’s larger. Check generator bible. Great for the price though, I got it shipped from tractor supply for 180 bucks. Ran an inverter window AC all summer. Very handy for charging dead batteries while I’m out in the field or small loads like fans or computers. 100% run it out of gas, the fuel shut off leaks through.
What a wild ride this video was! Like a 2 part movie almost, but the climax is a while in, then keeps going. Ha! James, I wanted to say that, some of those ignition components looked like a GY6 style, i wonder, if you had total ignition failure, if you could use a GY6 series pickup, CDI, and coil as a standalone? They make 2 types of CDI for the GY6, one that needs a battery and one that doesn't, obviously you would want one that doesn't, or you would need to keep a small 12v battery in there, which may not be feasible- but even so, you could use the 12V output to keep it up.
@@Deveak You know what tripped me out, was looking at the run times of the Sportsman vs Yamaha, the Yamaha is rated at almost twice the output yet uses less fuel... I built a live-in camper van, and I parked it for a weekend, a weekend turned into almost a year because I loved it so much, but the issue was power out there, under a tree n the back 40, I was using a "regular" generator and having to fill it often, when I got the Sportsman, it ended up using just a fraction of the fuel, which made me fall in love with inverter generators. When I got the Yamaha I was super happy, and it is going into another van I am building, except it is going in a metal compartment, without the "skin" as James called it, with the exhaust run outside, CM monitor, and more noise insulation. It is only a backup genny. I am primarily running on solar on this van build, 1,600 watts, plus an alternator tie in, so the batteries are always up.
@ I really like the ones in the 1600-2000 watt range. Large enough to run a 15 amp circuit to full power and run a decent amount of motors and still thrifty on fuel and easy to lug
It would have been dreamed unrepairable for sure. Even if they thought it was just the block, that would be a $500 quote probably where k doubt this thing new was much more than that,
Wow, what an adventure! We got top-end issues, an epic "remove the flywheel" quest, the coil mystery, and of course carb issues. And who could forget our friend, the rusted tank? As always, you tackled everything with your typical big picture analytical approach. This has become one of my favourite videos from you. Great job!
There are so many points in this video I thought for sure would be the end all, but once again, perserverance, patience, and knowledge win the day. Top ten James.
Wonderful finding a new video of yours. This really makes me think an open frame inverter generator will be the way to go. Its really a tight squeeze in these boxed mini generators. Great work, an enjoyable video
Just spent the last two days replacing the recoil rope on a Westinghouse I Gen2200 generator. Had other problems that developed so put the generator together and took it apart three times! Then when I finally got it running and done I went in for dinner and tuned to Utube to see the latest Jame Condon presents. Holy Cow! He’s working on my generator!!! Serendipity. Another great video. I always learn something new from James so now know what to look out for. Thank you James. I have six generators in my garage to tinker with. It’s a great hobby and I have helped quite a number of people in need of a generator. Craig
This would have to be the biggest most frustrating rabbit hole of a rebuild I've seen! How you didn't throw it across the yard is beyond me! But I enjoyed every minute and can fully relate to every one step forward and two steps back aspect to this rebuild! And it reminded me to go out in the garage and kick over my 2500 watt pure sine wave inverter generator that I haven't used for over 3 years!
Hi, James! Well now you've done it. A 2.5 hour video that I could not pull myself away from. Boy is my wife pissed! I started watching with my morning coffee and now it's late morning. I was supposed to finish painting the sunroom. You'd think after 51 years of marriage she'd know better but nooooo. Actually you'd think I would know better. Oh well. I gotta say that's the first time I seen a complete disassembly of one of those small inverter/generators. Pretty amazing how they manage to cram everything in there. My little Westinghouse iGen2200 has a plastic gas tank. Everything is about the same as that Sportsman so you might be able to get away with that replacement you found. Anyway, loved the video as usual. Thanks!
I always enjoy your videos James, but this one was really exceptional. I would have never believed that generator troubleshooting could create this much drama and engagement. Legitimately, I've watched more than one movie/TV show recently that didn't create as much tension and interest as this video. After the first couple of setbacks each subsequent test and new twist had me holding my breath waiting for the outcome. You really do an exceptional job with the presentation.
Idk exactly what's inside the electronics but any kind of transistor loses efficiency with heat maybe that has something to do with it.James makes everything look so easy! I would be cursing and throwing things.He just has a gift IMHO very satisfying to watch.
"Order online, you'll love it" Like you James, I find online and quality of products today are horrible and I've spent, wasted, more gas, time and money returning them than I saved in the first place. As I've said in the past; another great and informative video! Thank you James!
Outstanding Video!! Really helps when chasing down issues even on my generators. I have 2 Yamaha EF1000is generators, a Honda EU1000i and a Honda EU2000i . I purchased the EU1000i in a box totally took apart I rebuilt the engine and we have dry camped on a military base for over 10 years during winter months in Key West. The EU1000i Honda always starts its just incredible and I think I had around $250 dollars in it when it was all said and done. The Yamaha EF1000is generators are pretty cool in the fact that they have inverter technology but when they are not pulling a load or a small load they slow down like a Honda inverter generator but they have like 2 circuits in the generator windings and they slow down again making it capable of running like 9-12 hours on around 1/2 a gallon with just a small load which is incredible especially when your dry camping. The only thing I didn't like about the Yamaha generators was that choke cable like on the generator you repaired especially when you are depending on it like we do for 2-4 months the carbs at some point will need servicing so I modified my choke cable using a piece of stainless wire I make a loop that will slip over the brass circle on the carb for the choke then I attach that stainless wire loop to the choke pull cable with a small cable clamp once its set up like that you can slip the stainless loop off the brass circle on the carb easily too remove the carb and slip it back over the brass circle when putting carb back on. Once I slip the stainless loop over the brass circle I put the the yamaha screw back into the brass circle and that keeps the stainless loop from slipping of the brass circle when you pull choke. It is really a game changer when I need to pull a carb quickly. The Honda generators choke system is simple as you know and no cable needed I wish Yamaha had went that route.
It took me three days to watch this rebuild but it was well worth the wait! You must have an amazing wife who can run the rest of the house & let you indulge in your hobby of small engine repair. I noticed the boo boo bandaid half way through the video. No explanation? Probably not worth mentioning? Another great video! Looking forward to your next. Thanks for producing quality content!
I have 2 of these generators which don’t have the propane option. They both run great. I will keep this video in my archive in case I ever have to tear into them. I’m really glad to see you work on these suitcase generators. They are very popular, but a pain to work on. As always, thanks for your great videos.
This man does not give up ! I wonder if this company that builds these units has any quality control! I have had 2 of the Honda 2200 v units and Never had a single issue! I know there is a major price difference !
Hi James, This is your best video to date. Your diagnostic skills are unsurpassed. You approach every issue with confidence and confidence, you never seem to get flustered or upset. Thanks for sharing your knowledge. Rob
omgosh you are perfect mechanic engineer because I am motor mechanic and I don't give up ... Mann your the best in explaining thank you sooo much bless 🤩💯❣
Hey James, years ago I bought two of the inexpensive Sportsman generators. Both of them ran poorly out of the box. Both of them had carburetors that flooded over. They did make power and I only used them for lighting on my farm so I didn’t care how clean it was. They were such poorly made that it just wasn’t worth using them. So I threw them in the dumpster. It was a good lesson though. I have had a couple of 2kw Hondas that have over 1000 hours on them and they put out clean power reliably. I also have a 1kw Honda that is equally good. Lesson learned, cheap ain’t cheap! I have a Chinese generator to power my house during outages situations. It is such a pile of crap also. If I can get it to start it is as loud as a bull dozer working in a rock pile. I am thinking about building an efficient power unit out of a small automobile engine. I can gear it up so that it will run at about 1200 rpm and not use much fuel. It will also be quiet and reliable. I only wish that I had natural gas at my farm.
Your voice and approach to generator repair is so similar to another channel I view - Wristwatch Revival. Not sure if you are in fact one and the same, but I love your content! Keep up the great work. I’ve learned a ton!
@@mikenonameneeded3485 I’m at the point of comparing his hands between both videos. I’m nearly certain it’s the same guy. If not, then it’s the same narrator. Not trying to create a conspiracy. I’m just curious as I LOVE both channels. The content is wildly effective at relaxing me after a crazy day. Plus, I’m learning a ton. While I’ll never get into watch making, I now have enough confidence to attempt to repair my neighbors’s generator carburetor and my old riding mower carburetor (I’m converting it into a yard gorilla utility cart hauler).
Way to go on persistence James!! Nobody else would have put all the effort in on getting this generator running as you did. I was glad to see you drain the break in oil out of the engine as I did not see where you filled the crankcase up with oil. Only you with your vast array of diagnostic equipment would have discovered the coil problem after all the other testing you had done. I wonder if removing the small fuel filter caused the carburetor to overflow with a small amount of debris in the needle seat? Coating the inside of the tank would have made it a dual fuel machine, but if the new owner is aware of it being a propane only machine, no problem. Plastic is not the total answer to things, especially where heat is present. Good show, and it was very entertaining for the entire 2-1/2 hours. Keep up the good work.
I work on a lot of motorcycles. When putting the stator on through the magnets, it is easier to do it with long studs. Find long screws that fit in the threaded holes and slide it in! You just need two studs. Hope this helps someone too. Love watching your videos!
Nice work! I own two Smarter Tools generator 1600/2000W (similar in design) Your video provided an in-depth knowledge of what's happening behind the plastics. Thank you!
Thank you for this video, what a very pleasant way to spend a couple of hours watching your expertise and gently manner in returning this generator to life. Tony (UK)
My FAVE video... as I have this same generator... and I have no fire on another so same process, I found my coil got smoked thanks to you I found that quickly... and this was a whirlwind of just about anything that can go wrong... glad you took the time to give us the grand tour of inverter gensets.
Your tenacity is nothing short of amazing, I'd have given up on this machine, inverters make clean power but it comes at a cost, complexity and little manufacturer support, great video
Many years ago with my old Honda Motor cycle had a similar problem, was told by a garage mechanic the coils can start to internally short out under heat, most fail when the internal insulation starts to break down and spark track inside the coil itself. It probably got water or moisture inside.
What a monumental task, James. But as usual, you took it in your stride. I can't help but admire you. Oh, and by the way. This was better than watching a movie on TV, I watched it in one sitting. Fabulous. Thanks for making and sharing this.
Hello James: Your Patience and perseverance were put to a Rigid test on this project. The result You Won Another one, not a piece of landfill just yet. One suggestion for your viewers regarding the freyed cable. When I have this issue I usually just heat a candle and carefully wind the cable back into shape. Then dip the last inch of cable into the melted wax. This usually works well. If cable is stiff enough it will not reshape well and wax not strong enough to hold I will mix up a little 5 minute epoxy and do the same with end of cable. You can easily sand the hardend epoxy back to cable dimension and it will hold & stop the end from fraying and being difficult to get through the connection point. As the saying goes Try it you will like it. Have a great day and keep on saving units from the landfill.looking forward to your next project.
James, very well done. A very well done instructional video from beginning to end. I personally use a lot of older equipment, machines, lawn tractors, snow blowers, generators and even full size tractors and some old cars and trucks. One thing I have found is if you rebuild one part, another will fail. I always feel jipped when I don't get a huge distance out of something when I put new parts on it. So, IN MY OWN CASE I will do things to get it to run like: connect another device to spin the engine over 2,000 to 3,000 rpm until it starts and runs. Then I run it long enough to get it good and hot. Then cool it down and do it again. After several heat cycles things like valves begin to seal and piston rings come loose and begin to work correctly. I have even done that to car engines and pulled 10,000 Lbs 1,000 miles to see how well it's living back in service. The only thing I ever found that I couldn't fix is when the 3 part Oil Ring gets full of Rust. When that happens it cannot scrape the oil off correctly and leaves too much oil on the cylinder wall, which goes right on over the top and gets burned. I have an engine with rust filled oil rings and it used 1 qt of oil in 35 miles. It had great power, but oil fouled the sparkplugs and created misfires. I purchased those sparkplug extensions sometimes called "Anti Oil Foulers" and had 100% success with them. People have told me to change the motor oil and replace it with ATF instead of motor oil and put the engine into very light duty service and it will clean the oil rings out. I've not tried that yet, but I do have that engine and I want to try it out. OK, JIm, I'm not advocating anyone do what I do, just learn the lesson. But if you look at that rusty residue in the bottom of the old cylinder block, I can tell you it's rust that was on the piston rings and somebody ran it after it rusted. You can see where the rings sat in the bore and the rust deteriorated the aluminum wall. If you ran that engine thru several heat cycles it would have begun to loosen the stuck rings and begun to work, but it may consume too much oil for your liking. I live with that kind of imperfection all the time everyday. I had a GM 350/ 5.7 Liter Old's Diesel that had a blo6wby issue. It used a quart of oil every 2 tanks of Diesel. ( around 1,000 miles) I was able to reduce the oil consumption to 1 quart in 4,000 miles by putting HARLEY DAVIDISON 70 wt oil mixed 50/50 STP oil treatment in it for engine oil. It's obviously not a permanent fix, I could never have used it in the winter, but for one summer I drove that Cutlass 16,000 miles using it. ben/ michigan
Another machine saved from the scrap yard! This one seemed haunted, which is fitting for a Halloween video release. Most people would've given up on this one. Just goes to show what perseverance and analytical thinking can do!
Perfect day for a long format video for me, Jim! Out of state hunting and it's way too windy. So I've been passing the time in the stand with this video which was very helpful in that way AND educational too!
I’ve watched all of your videos and have to admit sometimes im frustrated with your obsession with minute details, ie safety etc, but wow you know small engines! 1:02:38 You definitely know your craft and have my respect.:)
Great patience and skill James!! And all for 1600 watts. I know I would have given up on that machine in the 1st hour. I prefer the open frame inverters because of the larger gas tank, and easier to work on. So much to take apart and later assemble with the enclosed generators, and I hope that people who own that Make/Model of Gen. won't encounter the vast array of problems that you did, especially from the same unit and all at the same time. Very fortunate James to get a new engine block for so cheap... What didn't fail with that Gen??...lol
I have watched almost every one of your videos since finding your channel a few years ago. I have watched you close up the machine then take it apart again so many times I admire your patience. Thank for the inspiration to go back to the two cycle leaf blower I am working on. I have the knowledge, just lack the patience. Thanks also for much of the knowledge.
I have this exact unit that I have only ever run on propane. It works great and I've never had any issues with it pulling 1500W. Always a pleasure watching your videos and seeing you work through difficult problems. I'm sure if mine ever started acting up, I could just reference this video and diagnose some basic items. Happy to see you save one more from the dump, even if it wasn't a profitable adventure.
James, I was watching a previous video where you had 2 generators with melted brushes. As a model railroader, I use a chemical called Rail Zip. It is a highly conductive oil that also cleans and prevents arcing. It's made by Pacer Technology, and it's sold by Amazon. Just make sure you use it sparingly, or it could cause a connection between the slip rings.
Utility power went out due to storms here last night, had power due to repairing my generator a few months back. Thanks James for the info I needed to repair it!
This has been an enjoyable video from time to time today. I've got a Honda G2200 Watt Generator and a Generac 5000 Watt Generator. Both need their (once a year) oil changes. I also check them over. The Generac kept the frig, coffee maker, one cable box and one TV going along with the "can I charge my phone too" (?) for about a day and 1/2 till the house power was restored because of a blown transformer on our street. It was in Aug of 2023, and it was over 100 degrees that day. My wife, her Mom and brother went to our Daughter's house. Her power and A/C worked. I stayed home to monitor the Generac and to be here when Edison got the power restored because of a blown transformer on our street. The Generac never missed a beat over an 8 hour period, didn't use much gas, oil level stayed right up at the full mark, and yes the next day it got a well deserved oil change and a new air filter. Why that maintenance? Oil and the air filter are cheap. GENERAC GENERATORS ARE NOT! Thank you for this video. Can you recommend an A/C Voltage/Frequency meter like you have and is that 1500 Watt load device a space heater? When I do my Generator maintenance, I don't have a way to temporarily load test them. That would be a great load. The Honda might hate it, but the Generac will probably shrug it off. Thanks again.
It's cursed! The inverter from hell! In all seriousness though, I really enjoy watching your videos. It's always a great feeling when you fix something yourself. Who would ever have thought that watching someone else could give you that same "job well done feeling". Great job as always!
James, I'm assuming that this is a labor of love, and not a going commercial concern. Can you touch on the economics of a repair this deep? How can you tell that you aren't going to have a generator or inverter problem, once you get to a "better than new" engine? Thank you for taking your time to show us what CAN be done. It is a joy to watch a skilled mechanic at work. The word "mechanic" I use with great admiration and respect.
Grrrrrr8 video. Many wins + challenges to overcome with this generator. You are an inspiration to struggle through to victory on this Onan microquite 4000 giving me fits.
ONE THING ABOUT JAMES HE DOES NOT GIVE UP .
That thing would have been in the dumpster if it was me
@@howardnielsen6220 Yes, about 1 hour into it! Congrats on getting it going and your succinct explanations of each of the issues. Tons of knowledge!
I would have probably refused to work on it just because the previous owner said he "lapped the valves". The only thing worse is when it's brought to you in a basket.
That was a struggle. But you won the battle. Congratulations!!!
@@kensam684 yeah I throw tools and curse. My video would be half me looking for tools I misplaced and half my cursing about it.
No matter how stressed I am, I know a vid from James will calm me right down.
LOL. same. so glad to see this vid just show up. I use these vids to help me relax before bed time.
100% i get the same with rainman rays repairs as well. i said it's mindful wrenching
He's great. Very calm manner.
Me Too! It's good therapy.
Valium James huh?
Wow. This one had it all! It has definitely earned a place near the center of the speakers' table at the Condon Hall of Fame annual dinner.
It was a full movie plot:
Exposition: The introduction of the characters, setting, and conflict
Rising action: The characters grow and change in response to the conflict
Climax: The conflict escalates to its peak
Falling action: The story moves toward resolution
Resolution: The conflict is resolved and the story ends
One of the best videos he’s done to date.
@@MrZZeroG yes!
Perfect engine learning video. So nice to see what happens when ignoring the phrase “You could but I wouldn’t recommend it”. You overcame so many obstacles. Truly the journey was the value. You touched every bit of that machine. Thank you for an amazing demonstration of what is possible.
Absolutely favorite UA-cam channel!
1) your calm voice and approach
2) thoroughness and tenacity
3) intelligence and ability
4) how you teach as
you fix
Thank you for an awesome video!
Agreed. A humble man.. I would say this is only a 'hobby' judging by his house and yard - we are lucky
What amazes me is that the generator sat for a long time disassemble and you still remember how it all went back together.
He has the video.
Your patience and resilience never cease to amaze me. When you broke the aluminium starter cup trying to take the engine apart made me think that was it, end of video. But no, not James. Instead you just got the right part to fix it and got it working like new, despite all the setbacks. Thanks, James. I really look forward to your videos. They make my week.
The broken one probably would have worked fine, but luckily there was a used OEM Yamaha one on eBay
It may smoke until the rings seat.@@jcondon1
@@lestergillis8171It likely had oil and carbon in the exhaust from running with the stuck piston rings before it finally failed.
An EPIC struggle between man and machine! Will James successfully save an inverter generator from the parts bin? Drama, mystery, and intrigue awaits... Better than most movies these days, GREAT JOB James!
Wow. This one had everything. What a battle. Really great work, Jim.
This is more than a regular presentation. This is like a full training course in engine repair.
This is a basic engine rebuild. You crack me up.
This is a basic engine rebuild. You guys crack me up.
Nobody except James fights for such a long time with a small generator and win . My respect.
My favorite UA-camr! I’d watch him restore a wheel barrow!
and I went one step further by adding a second wheel from harbor freight and an axle to mine, now it does no longer tip over
Same
I especially want to thank yyou for refraining from playing background music. We can all deal with silence, but we don't all like the same music, besides most of those who do play it play the most motonous crap they can find, and usually too loud.
@@jimdavis6833 Just hit mute and cc to solve that problem.
It is good that you got it running. But, the original owner was sold a bill of goods. Unless it was damn near given to him. It is highly unlikely that the average backyard mechanic could have solved the multitude of problems. Very few would have thought of reversing those two wires. I might have said it before, but; you have an extremely high level of patience. Another nice job.
How cool. I had a Sportsman 1000 that changed my life with how efficient it was. I am presently working on a Yamaha EF2000IS that was given to me, because it has low compression, due to the user using it without an air cleaner. (Turns out rings are stuck. Valves and bore actually look fine! Even the piston looks clean) I used to consider myself an small engine expert, but i found myself, when tearing down the Yamaha, comparing everything I did, "Would James Condon do it this way? Would he be in such a hurry? Would he, etc, etc..." LOL.
So, to see this drop today, as I have been ill, is like a little light in my day
I have one of those. It’s fuel efficient but there are models that are larger that use even less fuel per hour and it’s larger. Check generator bible.
Great for the price though, I got it shipped from tractor supply for 180 bucks. Ran an inverter window AC all summer.
Very handy for charging dead batteries while I’m out in the field or small loads like fans or computers.
100% run it out of gas, the fuel shut off leaks through.
What a wild ride this video was! Like a 2 part movie almost, but the climax is a while in, then keeps going. Ha! James, I wanted to say that, some of those ignition components looked like a GY6 style, i wonder, if you had total ignition failure, if you could use a GY6 series pickup, CDI, and coil as a standalone? They make 2 types of CDI for the GY6, one that needs a battery and one that doesn't, obviously you would want one that doesn't, or you would need to keep a small 12v battery in there, which may not be feasible- but even so, you could use the 12V output to keep it up.
@@Deveak You know what tripped me out, was looking at the run times of the Sportsman vs Yamaha, the Yamaha is rated at almost twice the output yet uses less fuel... I built a live-in camper van, and I parked it for a weekend, a weekend turned into almost a year because I loved it so much, but the issue was power out there, under a tree n the back 40, I was using a "regular" generator and having to fill it often, when I got the Sportsman, it ended up using just a fraction of the fuel, which made me fall in love with inverter generators. When I got the Yamaha I was super happy, and it is going into another van I am building, except it is going in a metal compartment, without the "skin" as James called it, with the exhaust run outside, CM monitor, and more noise insulation. It is only a backup genny. I am primarily running on solar on this van build, 1,600 watts, plus an alternator tie in, so the batteries are always up.
@ I really like the ones in the 1600-2000 watt range. Large enough to run a 15 amp circuit to full power and run a decent amount of motors and still thrifty on fuel and easy to lug
James , you are a persistent bear .
You don't give up
You troubleshoot brilliantly 👏
Hars off to you, sir 🎉🎉🎉🎉
I like reading the comments to see how other viewers opinions are! Like myself your fans are so impressed with your work.
Thanks for spending the time to repair this generator. I’m not sure any repair shop would have spent the time to fix it.
It would have been dreamed unrepairable for sure. Even if they thought it was just the block, that would be a $500 quote probably where k doubt this thing new was much more than that,
Jesus, I would have trashed that thing way earlier. You’re a persistent man
Wow, what an adventure! We got top-end issues, an epic "remove the flywheel" quest, the coil mystery, and of course carb issues. And who could forget our friend, the rusted tank?
As always, you tackled everything with your typical big picture analytical approach. This has become one of my favourite videos from you. Great job!
On the bright side James, you now have a good selection of pullers. Great video. 😁
There are so many points in this video I thought for sure would be the end all, but once again, perserverance, patience, and knowledge win the day. Top ten James.
Wonderful finding a new video of yours. This really makes me think an open frame inverter generator will be the way to go. Its really a tight squeeze in these boxed mini generators. Great work, an enjoyable video
Just spent the last two days replacing the recoil rope on a Westinghouse I Gen2200 generator. Had other problems that developed so put the generator together and took it apart three times! Then when I finally got it running and done I went in for dinner and tuned to Utube to see the latest Jame Condon presents. Holy Cow! He’s working on my generator!!! Serendipity. Another great video. I always learn something new from James so now know what
to look out for. Thank you James. I have six generators in my garage to tinker with. It’s a great hobby and I have helped quite a number of people in need of a generator. Craig
This would have to be the biggest most frustrating rabbit hole of a rebuild I've seen! How you didn't throw it across the yard is beyond me!
But I enjoyed every minute and can fully relate to every one step forward and two steps back aspect to this rebuild!
And it reminded me to go out in the garage and kick over my 2500 watt pure sine wave inverter generator that I haven't used for over 3 years!
"it's amazing how the right tool makes a job so much easier" Words to live by, my friend. 😃
Hi, James! Well now you've done it. A 2.5 hour video that I could not pull myself away from. Boy is my wife pissed! I started watching with my morning coffee and now it's late morning. I was supposed to finish painting the sunroom. You'd think after 51 years of marriage she'd know better but nooooo. Actually you'd think I would know better. Oh well. I gotta say that's the first time I seen a complete disassembly of one of those small inverter/generators. Pretty amazing how they manage to cram everything in there. My little Westinghouse iGen2200 has a plastic gas tank. Everything is about the same as that Sportsman so you might be able to get away with that replacement you found. Anyway, loved the video as usual. Thanks!
😂
I’m married for 54 years and they never change the demands lololo
James' long videos have a lot of content and are worth watching. His voice is so easy to understand, I can watch at 2X speed!
Your perseverance on this machine was amazing.
Any kid out there want to start a side or main hustle? Watch this channel get some tool, and get to work! This is a great wealth of knowledge!!!!
Thanks for hanging in there just like I am once I know I'am to deep I will not give up even if its not cost effective or its of vintage quality!
This one is better than new. Your patience and persistence always amazes me. Nice job!
I always enjoy your videos James, but this one was really exceptional. I would have never believed that generator troubleshooting could create this much drama and engagement. Legitimately, I've watched more than one movie/TV show recently that didn't create as much tension and interest as this video. After the first couple of setbacks each subsequent test and new twist had me holding my breath waiting for the outcome. You really do an exceptional job with the presentation.
Talk about going down the rabbit hole.... 6X over! WOw. Impressed is hardly an accurate word. Great job James!
Nothing like a challenge to make life interesting. I was thinking that this one would never run. Thanks for your time and expertise. Great job.
Idk exactly what's inside the electronics but any kind of transistor loses efficiency with heat maybe that has something to do with it.James makes everything look so easy! I would be cursing and throwing things.He just has a gift IMHO very satisfying to watch.
James, I believe what you are trying to tell us is that working on generators and UA-cam funds your tool addiction! I’m with you!!!!!
So much engineering in those suitcase units. Amazing!
That was a LOT of work! Always good to see a not working gen brought back to life.
"Order online, you'll love it"
Like you James, I find online and quality of products today are horrible and I've spent, wasted, more gas, time and money returning them than I saved in the first place.
As I've said in the past; another great and informative video!
Thank you James!
James, I pray we would have people in government with your ferocity and diligence to correct problems -- I'm dreaming, I know 😞😞😞
James Condon for President, with mustie1 as his running mate!
@@neilmorten6416 They would make an "Electrifying Combo". (sorry for that one)
Genuinely one of my favorite channels! High quality content, clear/concise information, and a good relaxing environment. I'm proud to be a subscriber.
Outstanding Video!! Really helps when chasing down issues even on my generators. I have 2 Yamaha EF1000is generators, a Honda EU1000i and a Honda EU2000i . I purchased the EU1000i in a box totally took apart I rebuilt the engine and we have dry camped on a military base for over 10 years during winter months in Key West. The EU1000i Honda always starts its just incredible and I think I had around $250 dollars in it when it was all said and done. The Yamaha EF1000is generators are pretty cool in the fact that they have inverter technology but when they are not pulling a load or a small load they slow down like a Honda inverter generator but they have like 2 circuits in the generator windings and they slow down again making it capable of running like 9-12 hours on around 1/2 a gallon with just a small load which is incredible especially when your dry camping. The only thing I didn't like about the Yamaha generators was that choke cable like on the generator you repaired especially when you are depending on it like we do for 2-4 months the carbs at some point will need servicing so I modified my choke cable using a piece of stainless wire I make a loop that will slip over the brass circle on the carb for the choke then I attach that stainless wire loop to the choke pull cable with a small cable clamp once its set up like that you can slip the stainless loop off the brass circle on the carb easily too remove the carb and slip it back over the brass circle when putting carb back on. Once I slip the stainless loop over the brass circle I put the the yamaha screw back into the brass circle and that keeps the stainless loop from slipping of the brass circle when you pull choke. It is really a game changer when I need to pull a carb quickly. The Honda generators choke system is simple as you know and no cable needed I wish Yamaha had went that route.
It took me three days to watch this rebuild but it was well worth the wait!
You must have an amazing wife who can run the rest of the house & let you indulge in your hobby of small engine repair.
I noticed the boo boo bandaid half way through the video. No explanation? Probably not worth mentioning?
Another great video! Looking forward to your next.
Thanks for producing quality content!
Wow, that is a test of patience right there! Great job once again. I would of given up long ago but this turned out to be a great learning experience.
Probably the best video you’ve ever done. I wouldn’t have done it but it made an award worthy video 😀
Wow James, that was quite the enigma, your tenacity in the project is what really solved the issue! Very nicely done. Cheers
I have 2 of these generators which don’t have the propane option. They both run great. I will keep this video in my archive in case I ever have to tear into them. I’m really glad to see you work on these suitcase generators. They are very popular, but a pain to work on. As always, thanks for your great videos.
This man does not give up ! I wonder if this company that builds these units has any quality control! I have had 2 of the Honda 2200 v units and Never had a single issue! I know there is a major price difference !
You outdid yourself on this one James. Over 2.5-hour long video!
Hi James, This is your best video to date. Your diagnostic skills are unsurpassed. You approach every issue with confidence and confidence, you never seem to get flustered or upset. Thanks for sharing your knowledge.
Rob
Thanks
omgosh you are perfect mechanic engineer because I am motor mechanic and I don't give up ... Mann your the best in explaining thank you sooo much bless 🤩💯❣
Hey James, years ago I bought two of the inexpensive Sportsman generators. Both of them ran poorly out of the box. Both of them had carburetors that flooded over. They did make power and I only used them for lighting on my farm so I didn’t care how clean it was. They were such poorly made that it just wasn’t worth using them. So I threw them in the dumpster. It was a good lesson though. I have had a couple of 2kw Hondas that have over 1000 hours on them and they put out clean power reliably. I also have a 1kw Honda that is equally good. Lesson learned, cheap ain’t cheap! I have a Chinese generator to power my house during outages situations. It is such a pile of crap also. If I can get it to start it is as loud as a bull dozer working in a rock pile. I am thinking about building an efficient power unit out of a small automobile engine. I can gear it up so that it will run at about 1200 rpm and not use much fuel. It will also be quiet and reliable. I only wish that I had natural gas at my farm.
You are the most patient man I have ever seen. I would have taken a sledgehammer to that piece of crap a long time ago but you made it work
This the longest video I've ever watched on UA-cam. However, I watched the entire thing and it kept my interest throughout. Well done James.
The usb tester. That’s awesome. Never would have thought it was possible to check usb performance.
Your voice and approach to generator repair is so similar to another channel I view - Wristwatch Revival. Not sure if you are in fact one and the same, but I love your content! Keep up the great work. I’ve learned a ton!
I watch and enjoy both....for the same reason.
@@helicartIs it the same guy? They appear to go by different names.
I thought the same thing.
@@mikenonameneeded3485 I’m at the point of comparing his hands between both videos. I’m nearly certain it’s the same guy. If not, then it’s the same narrator. Not trying to create a conspiracy. I’m just curious as I LOVE both channels. The content is wildly effective at relaxing me after a crazy day. Plus, I’m learning a ton. While I’ll never get into watch making, I now have enough confidence to attempt to repair my neighbors’s generator carburetor and my old riding mower carburetor (I’m converting it into a yard gorilla utility cart hauler).
@@mikenonameneeded3485 Well maybe I’m wrong. I went ahead and googled enough to see the face behind the hands. They sound and act so similar. Weird.
Way to go on persistence James!! Nobody else would have put all the effort in on getting this generator running as you did. I was glad to see you drain the break in oil out of the engine as I did not see where you filled the crankcase up with oil. Only you with your vast array of diagnostic equipment would have discovered the coil problem after all the other testing you had done. I wonder if removing the small fuel filter caused the carburetor to overflow with a small amount of debris in the needle seat? Coating the inside of the tank would have made it a dual fuel machine, but if the new owner is aware of it being a propane only machine, no problem. Plastic is not the total answer to things, especially where heat is present. Good show, and it was very entertaining for the entire 2-1/2 hours. Keep up the good work.
I work on a lot of motorcycles. When putting the stator on through the magnets, it is easier to do it with long studs. Find long screws that fit in the threaded holes and slide it in! You just need two studs. Hope this helps someone too. Love watching your videos!
Nice work! I own two Smarter Tools generator 1600/2000W (similar in design) Your video provided an in-depth knowledge of what's happening behind the plastics. Thank you!
That one went all 9 rounds but the winner is James Condon!
Thank you for this video, what a very pleasant way to spend a couple of hours watching your expertise and gently manner in returning this generator to life. Tony (UK)
A very meticulous man/ mechanic..Such a calm person...Very good work James...
My FAVE video... as I have this same generator... and I have no fire on another so same process, I found my coil got smoked thanks to you I found that quickly... and this was a whirlwind of just about anything that can go wrong... glad you took the time to give us the grand tour of inverter gensets.
Super lovely and beautiful, James, thank-you!
99.99 recurring % of us would have thrown that thijng in the creek away's back . . . You didn't. Wow!
Your attention to detail is impressive.
Well done, James. I can see why someone less experienced would have given up on that one. Problems ran ramped.
Your tenacity is nothing short of amazing, I'd have given up on this machine, inverters make clean power but it comes at a cost, complexity and little manufacturer support, great video
I enjoyed that one, working on small engines can be very enjoyable, and some times it can bring a lot of challenges, glad you stuck with it as always.
Many years ago with my old Honda Motor cycle had a similar problem, was told by a garage mechanic the coils can start to internally short out under heat, most fail when the internal insulation starts to break down and spark track inside the coil itself. It probably got water or moisture inside.
Super cool series of complex/intertwined problems & educational diagnostics. Superb content and the filming and editing are on point as well.
What a monumental task, James. But as usual, you took it in your stride. I can't help but admire you. Oh, and by the way. This was better than watching a movie on TV, I watched it in one sitting. Fabulous. Thanks for making and sharing this.
You have a lot of patience. I would have given up on this, but you didn't. Nice inverter once you killed the demons. Great video.
My heavens, what patience! Superb job, James.
Hello James: Your Patience and perseverance were put to a Rigid test on this project. The result You Won Another one, not a piece of landfill just yet. One suggestion for your viewers regarding the freyed cable. When I have this issue I usually just heat a candle and carefully wind the cable back into shape. Then dip the last inch of cable into the melted wax. This usually works well. If cable is stiff enough it will not reshape well and wax not strong enough to hold I will mix up a little 5 minute epoxy and do the same with end of cable. You can easily sand the hardend epoxy back to cable dimension and it will hold & stop the end from fraying and being difficult to get through the connection point. As the saying goes Try it you will like it. Have a great day and keep on saving units from the landfill.looking forward to your next project.
The patience this man has is unbelievable!
James never fails to entertain in the most educational manner. Also a lesson/teacher of patience and tenacity/"sticktuitiveness". Thank you, brother.
James, very well done. A very well done instructional video from beginning to end. I personally use a lot of older equipment, machines, lawn tractors, snow blowers, generators and even full size tractors and some old cars and trucks. One thing I have found is if you rebuild one part, another will fail. I always feel jipped when I don't get a huge distance out of something when I put new parts on it. So, IN MY OWN CASE I will do things to get it to run like: connect another device to spin the engine over 2,000 to 3,000 rpm until it starts and runs. Then I run it long enough to get it good and hot. Then cool it down and do it again. After several heat cycles things like valves begin to seal and piston rings come loose and begin to work correctly. I have even done that to car engines and pulled 10,000 Lbs 1,000 miles to see how well it's living back in service. The only thing I ever found that I couldn't fix is when the 3 part Oil Ring gets full of Rust. When that happens it cannot scrape the oil off correctly and leaves too much oil on the cylinder wall, which goes right on over the top and gets burned. I have an engine with rust filled oil rings and it used 1 qt of oil in 35 miles. It had great power, but oil fouled the sparkplugs and created misfires. I purchased those sparkplug extensions sometimes called "Anti Oil Foulers" and had 100% success with them. People have told me to change the motor oil and replace it with ATF instead of motor oil and put the engine into very light duty service and it will clean the oil rings out. I've not tried that yet, but I do have that engine and I want to try it out. OK, JIm, I'm not advocating anyone do what I do, just learn the lesson. But if you look at that rusty residue in the bottom of the old cylinder block, I can tell you it's rust that was on the piston rings and somebody ran it after it rusted. You can see where the rings sat in the bore and the rust deteriorated the aluminum wall. If you ran that engine thru several heat cycles it would have begun to loosen the stuck rings and begun to work, but it may consume too much oil for your liking. I live with that kind of imperfection all the time everyday. I had a GM 350/ 5.7 Liter Old's Diesel that had a blo6wby issue. It used a quart of oil every 2 tanks of Diesel. ( around 1,000 miles) I was able to reduce the oil consumption to 1 quart in 4,000 miles by putting HARLEY DAVIDISON 70 wt oil mixed 50/50 STP oil treatment in it for engine oil. It's obviously not a permanent fix, I could never have used it in the winter, but for one summer I drove that Cutlass 16,000 miles using it. ben/ michigan
Whew...a tough ride, but really nice in the end. Good job 👍👍
Another machine saved from the scrap yard! This one seemed haunted, which is fitting for a Halloween video release. Most people would've given up on this one. Just goes to show what perseverance and analytical thinking can do!
This one was a marathon, but you did get over the line.
Perfect day for a long format video for me, Jim! Out of state hunting and it's way too windy. So I've been passing the time in the stand with this video which was very helpful in that way AND educational too!
I’ve watched all of your videos and have to admit sometimes im frustrated with your obsession with minute details, ie safety etc, but wow you know small engines! 1:02:38 You definitely know your craft and have my respect.:)
Great patience and skill James!! And all for 1600 watts. I know I would have given up on that machine in the 1st hour. I prefer the open frame inverters because of the larger gas tank, and easier to work on. So much to take apart and later assemble with the enclosed generators, and I hope that people who own that Make/Model of Gen. won't encounter the vast array of problems that you did, especially from the same unit and all at the same time. Very fortunate James to get a new engine block for so cheap... What didn't fail with that Gen??...lol
I would have tossed that one. For sure you got 12-15 hours or more into that. More than it’s worth . Your determination amazes me
The best photographer on UA-cam bar nun 👍👍👍🥰🥰🥰🥰
I have watched almost every one of your videos since finding your channel a few years ago. I have watched you close up the machine then take it apart again so many times I admire your patience. Thank for the inspiration to go back to the two cycle leaf blower I am working on. I have the knowledge, just lack the patience. Thanks also for much of the knowledge.
I have this exact unit that I have only ever run on propane. It works great and I've never had any issues with it pulling 1500W. Always a pleasure watching your videos and seeing you work through difficult problems. I'm sure if mine ever started acting up, I could just reference this video and diagnose some basic items. Happy to see you save one more from the dump, even if it wasn't a profitable adventure.
Thanks to James I can fumble my way through talking about carbs that ive never ever worked on.
300 MINUTES! That is a deep dive.
James, I was watching a previous video where you had 2 generators with melted brushes. As a model railroader, I use a chemical called Rail Zip. It is a highly conductive oil that also cleans and prevents arcing. It's made by Pacer Technology, and it's sold by Amazon. Just make sure you use it sparingly, or it could cause a connection between the slip rings.
Utility power went out due to storms here last night, had power due to repairing my generator a few months back. Thanks James for the info I needed to repair it!
Two + hours of quality entertainment.
Thanks!
Pretty tough job for this one, but for James, it's just a walk in the park!!!! 😁😁😁
Another award winning resuscitation! Not an easy one but you prevailed!
Thanks!
I have always thought that having the right tools is half the job. They sure do make a difference!
I love working on small engines but never worked on any inverter generators before. You made it look easy
This has been an enjoyable video from time to time today.
I've got a Honda G2200 Watt Generator and a Generac 5000 Watt Generator. Both need their (once a year) oil changes. I also check them over.
The Generac kept the frig, coffee maker, one cable box and one TV going along with the "can I charge my phone too" (?) for about a day and 1/2 till the house power was restored because of a blown transformer on our street.
It was in Aug of 2023, and it was over 100 degrees that day. My wife, her Mom and brother went to our Daughter's house. Her power and A/C worked. I stayed home to monitor the Generac and to be here when Edison got the power restored because of a blown transformer on our street.
The Generac never missed a beat over an 8 hour period, didn't use much gas, oil level stayed right up at the full mark, and yes the next day it got a well deserved oil change and a new air filter.
Why that maintenance? Oil and the air filter are cheap. GENERAC GENERATORS ARE NOT!
Thank you for this video.
Can you recommend an A/C Voltage/Frequency meter like you have and is that 1500 Watt load device a space heater?
When I do my Generator maintenance, I don't have a way to temporarily load test them. That would be a great load. The Honda might hate it, but the Generac will probably shrug it off.
Thanks again.
It's cursed! The inverter from hell! In all seriousness though, I really enjoy watching your videos. It's always a great feeling when you fix something yourself. Who would ever have thought that watching someone else could give you that same "job well done feeling". Great job as always!
James, I'm assuming that this is a labor of love, and not a going commercial concern.
Can you touch on the economics of a repair this deep?
How can you tell that you aren't going to have a generator or inverter problem, once you get to a "better than new" engine?
Thank you for taking your time to show us what CAN be done. It is a joy to watch a skilled mechanic at work. The word "mechanic" I use with great admiration and respect.
Grrrrrr8 video. Many wins + challenges to overcome with this generator. You are an inspiration to struggle through to victory on this Onan microquite 4000 giving me fits.
Fantastic episode James. A lot of effort went into that machine but it made very good entertainment. Really appreciate your channel. Thanks.