That thing did great on the load test. Surprised the THD was so low. And able to hold steady with an overload speaks well of the company. Nice work as always, Jim.
Thanks Jon. I was just as surprised with the load test. Pretty good for a single cylinder engine. I have tested this engine before on other generators and they all delivered 8000 watts after a little tuning. Never tried an overload. Ideally all generators would have a larger engine then needed. Unfortunately most portable generators max out on hp at the rated load. The XP8000, XG8000 and XG10000 by generac are all very capable. It would suck though to try and service when the power goes out and you discover it won't start. Still a lot easier then the Honda EX5500 starter replacement I just did or the CASE 170B exhaust manifold you fought with.
@@jcondon1 Haha! Comparing a generator repair to that exhaust manifold made me lol. I would toss any generator off a cliff that required that much headache to fix! ;-)
@jcondon1 what is the wattage draw of the fan in the load bank? Watching the test and pushing the machine to 9000w got me thinking about it, how much extra does it add?
@@1MichaelJones Good question, also does the fan stay constantly on throughout any load. If it does then probably the manufacturer has added in the fan wattage to the total.
I'm old enough that we weren't a throw away world. My dad taught me how to rebuild starters, solenoids, generators and voltage regulators. Later in my school years, I helped set up the auto mechanic shop my Senior year in high school. I love the time I spent with my dad learning and at times arguing a bit. Father son time is precious. I'm 75 now and miss my dad every day. Your channel reminds me of him all the time. Thank you and God bless.
One of the most valuable lessons I learned from my dad was he neglected the maintenance but that didn't give him the right to claim that gasoline engines were a curse. A secondary takeaway was an ounce of prevention beat a pound of cure. ;)
The autopsy of the old solenoid was interesting. I have never seen how a solenoid actually works. Very informative. And the involvement of your son at 1:28:24 was OUTSTANDING.
In a car solenoid it uses the same principle but has a fork that engages the pinion gear to the main flywheel gear. Also the contacts has silver ends to provide less resistance. Silver is also much harder than copper so lasts much longer.
The company when they made this version were really not that bright to hide everything that one would need to do as maintenance. Your patience and calm manner are the reasons so many watch your entire vids 🎉❤⭐🥇
Great job is always James! The Generac XP series was their top-of-the-line models when they were on the market. Well over $2k. This is a 5% or less THD rated machine. They marketed it as TruePower. The older 7K EXL Generac has the same exact governor issue. And like you the corrective action to stop the surging was to adjust the spring location on the governor arm to fix it. Appreciate all you do!!
What a great video. One not only learns how to repair, you also learn about the different machines on the market today and helps to make an informed decision on what machine to buy. Thanks James!
I appreciate your curiosity. As you were replacing the solenoid I was thinking "I wonder why the other one failed." And then a few minutes later I found out! Thanks much for the follow through. Another great educational repair job.
Excellent as always, James. It was nice to see you include your son in the process. He will certainly be a much more capable man thanks to dad. Thank you!
Jim, you break the rule of those that can, do and those that can't, teach. You are a truly gifted teacher. Your videos are beautifully paced, always holding a little suspense to keep the viewer engaged and wondering what will happen next. You are obviously a learning junkie, picking up and using something new and sharing it, almost every episode. The audio and video quality have improved over the years to where it's on a par with the best of any one man channels on UA-cam. Keep 'em coming and don't hesitate to include your son wherever he shows interest in what you're working on. I also enjoy your fun-loving, chill alter ego Mustie. Thanks for all you do!
I've drilled out countless rivets over the years, made from brass, aluminum and stainless. In all cases the one method I've used if the rivet starts to spin in place is to rotate the drill handle in a circle so the drill bit is aiming to the side instead of straight down. Almost always that does the trick. Also, if you only need to remove a hollow rivet which has no solid center, using a countersink bit or a considerably larger bit allows just the outside rolled edge of the rivet to be removed, after which just use a drift to punch out the remainder. That way there is no way the rivet can get jammed onto a drill bit and spin.
In fifty years of engineering experience, the only time I nearly had a tantrum was when repairing a Generac. You have more patience than I had with the geriatric built garbage, even if I managed to get it running nicely again. With the side panel I would have used self-tapping screws rather than disassembling the frame and tack welding it.
Another great video, I’m a true fan now and am obsessed with watching your videos. One thing is clear; avoid the gas and stick with fuel or tri-fuel generators. Use gas as a last resort and be sure to drain and clean before storing.
A weekly highlight is a new video on this channel. Thanks James. Fathers who know 'stuff' and let their kids get their hands dirty(ish) is a gift for life.
I am envious of your ability to understand the electrical components of these machines. I have learned so much by watching you work. Your calmness is impressive and your gentle nature with your son is great. I aspire to be that way with my sons too. You always end your videos by saying I hope you learn something, I did learn something in this video and it wasn’t about generators. Thank you.
Besides sharing the views of most other viewers, I find it VERY interesting that Generac calls this their model 8000 rather than using the less important marketing number of 12000, as most manufacturers do these days. Wonder if that's corporate culture and honesty! As to you, I immensely appreciate your matter of fact, no nonsense videos. I'm impressed that your focus is on accurate evaluation, how-to facts and concise demonstration, rather than on time wasting comedy, mugshots or unrelated drivel. Kudos to you! And with so much marketing hype flooding the rapidly expanding generator marketplace, it would be great if a guy with your experience periodically posted Consumer Reports styled videos reflecting your assessment of present day generators. I.E., Overall quality, durability, utility of features & functions, preventative maintenance tips, repairability, and even your brand/model recommendations. Thanks for a job very well done.
I would never have thought that one hole over on the governor arm would make that much of a difference. This is good to know as many people would assume (wrongly) that they have carburetor issues when they don't.
Working on this exact model. We live on solar power and this is a backup for my Honda 8kw generator, which is working great. The last time I started the Generac the engine was working fine but there was no AC out. So because of that and not needing to use it for backup, it has been sitting for a long time with gas in the tank. After watching your videos I decided to clean up the generator and see why no volts. After having so much fun getting the tank off and getting to the carb to clean it up, I'm thinking this generator may need to find a new home.. At any rate, I fount that the generator capacitor measured 10uF and was supposed to be 47uF.... I have replaced it and hope that is the problem with AC generation.... once I get everything back together. Thanks so much for the video.
You make it look too easy mate... I'm glad you took the time to educate us on how the solinoid works. Good to see your young bloke getting in on the action. God bless 👍🏻
A death wheel in the angle grinder works well to remove rivets, albeit overkill. Nice save & tutorial on the solenoid! Good to see the young humans helping.
Hey Jim. We lived through Helene, thanks to my Briggs 4500w generator. I ran ethanol gas through it while I was using it. It ran close to 50 hours of the 108.5 hours that we did not have power. Today, I ran all the ethanol gas through it. I then changed the oil 2 ounces of STP with the remainder Pennzoil Platinum 10 W 30. I the filled the tank with premium non ethanol gas plus one ounce per gallon of Marvel Mystery Oil. The gas had one ounce per gallon of Optimizer PLUS stabilizer. It ran perfectly for the 50 hours that I ran it. People should be careful not to overfill it with oil. I let mine just drain off any extra oil before I put the cap on. I also crank it up and run it for a minute or two and then drain off any excess oil before storing it away. At almost 80 storing away is a chore but it is now back in my shop, awaiting its next use. I did run all the gas out of the carb, first. Tank is full but the carb and fuel lines are empty. Hope HELENE DID NOT BITE YOU IN THE BUT!
Thank you for posting this excellent video! I think your daughter deserves a big mention in dispatches for helping you out. I also think it is really good that you take the time to teach her repair skills.
Thats a monster of a machine to work on. However as you say it has a most excellent performance when calibrated correctly. You do not just repair the machines James you re-engineer them so that they work better and become more reliable than the original designs and implementation. I used to hate working for large manufacturing companies when common faults would occur on a large number of manufactured products. Very simple fixes and component upgrades would solve 99 per cent of them. The accountants would say no in an instant in order to save pennies for each machine. Thank you very much James.
That Generac line of generators are impressive would love to come across one in great shape for myself. I'm currently running an SVP 5000 I've had since almost new it does a great job, but now I'm considering an upgrade to an 8000 version. Great job on this one. The black paint on the tank doesn't look sus either.
Thanks again Jim for another Great How to Video . I learned the hard way about how to fix a GM starter solenoid which works that same as what you have shown just on a larger scale the contacts corrode and Pit from the arcing of the High current draw , a good teaching experience for your son which there's not a lot of today ,well done Jim
Indeed theose starter solenoids are generally pretty easy to fix, the failure is usually corrosion on one terminal that just needs to be wire wheeled off. Even if it's riveted together the rivets can be drilled out and then put back together with small screws and nuts (typically the mounting bolts also clamp it together so the rivets are barely doing much once installed). I've had good success with repairing them, and on my own equipment I've had the repaired /cleaned ones last years with no issue
Thank you, another excellent demonstration, your son already shows a goods abilities. Merci, encore une excellente démonstration, votre fils montre déjà beaucoup de capacité.
Hi James, I am a 74 yo female, and I am looking to buy a self propelled mower. I am taking the bull by the horns and asking your opinion on which one. I was looking on UA-cam for help, and you popped up. I like how to talk and explain things, your opinion would be greatly respected and appreciated. No pressure. I live in Australia, and love mowing the lawn. I live on my son’s property and hope I will still be mowing into my eighties. Thank you, my son says I am random, explains everything really.❤
I especially appreciate the failure analysis performed on the starter solenoid. I not only want to know how to repair things - I want to know exactly why they failed. Having a clear mental picture of what the internals of sealed units of any kind look like and how they function is absolutely priceless. The only other person I know who does this on a regular basis is Ivan from Pine Hollow Auto Diagnostics. The only detail left unsaid which would have made that segment complete would have been an explanation of what happens on a molecular level to cause that issue. Something about electrons bleeding off or adding onto a surface or something. Can't remember exactly, but that's the actual root cause and is pretty standard for switching mechanisms that make and break contact. Someone who's an electrical engineer probably understands it and can explain much better than I. ;-)
The three hands thing is amazing. I have a watch band pin pusher that might work for pushing the pin that holds the float in the cab. The pin pusher holds both posts & only pushes the pin so the posts won’t break.
James: You have done us all a favor by demonstrating what a PIA the generator is to service. I personally would need to find a VERY cheap model in order to become an owner ! Cheers! from the windswept Prairies of Alberta.
James love your videos I'm a 81year old fan you are so precise in your. Discriptions you make it so easy carry on your good work wish you all the best lol Billy Weir Glasgow Scotland
Another excellent video, many thanks. If you are concerned about flammable fumes, have you considered keeping the air going inside the tank while you were using the other equipment (heat gun and sander). That way the flammable vapour is well diluted and the risk of ignition becomes minimal - just a thought.
It appears the tank was placed on the assembly line first and the generator was built around it. Worn starter ropes and bad solenoids tell a story. I am glad to see Jr. is learning from the best. It not only amazes me that your revive these generators but that you find them so cheap. In my area, they would be asking $200-$300 for it and get it.
Nice reveal on the starter solenoid rebuild. I had one fail in a closed position on my boat's outboard engine. No fun when your on the water and the starter keeps turning. It turned out that this was a replacement part, someone installed a "cheap" version solenoid and there was no return spring installed in it. It probably saved them $30 by avoiding the OEM part. Needless to say I also added a battery disconnect switch for future emergencies like this.
🤫 We are not supposed to know this, but recently, James had a Pan Galactic Gargle Blaster with Zaphod Beeblebrox and had this third arm installed on his recommendation. You know how these things go 😊
I really appreciated the section on solenoid. Please add more of these kind of topics to your videos. Would love to understand how relays and other electronic components.
James. I've had a lot of success on Mikuni carbs getting the float pin out by gripping it with a very sharp pair of side cutting pliers and twisting back and forth whilst pulling back towards myself.
When storing or charging the battery always place a rubber mat or wood between the battery and floor that helps maintaining the battery charge. Hope that helps James.
Hi James, I’m Brad I love watching your videos they’re so informative. This is one of the best generators I’ve seen you work on it really did want to do it from the start. You little TLC but it is a great running generator. Great job love your videos.
When you were disassembling the solenoid, the reason you had difficulty desoldering the wires comes from the solder. They use high(melt) temperature solder. This is because long cranking times would cause the wire to heat and possibly melt the solder. That is the reason for the high temp solder.
For the pin on the float , I’ve seen on another site and they used a spring loaded centre punch on the pin and the stuck pin came right out , might be worth a try next time 2vintage channel
Looks like some 'designer' got their hands on that one, creating an 'artistic' and 'unique' product. It must have had excessive production costs. Old school KISS principals are still the best guide to follow in this type of product. Old style automotive starter solenoids, used a ring of copper for the contactor, that would rotate a little each time to present a fresh surface for the connection.
James.... Practice makes perfect. Nothing wrong with your approach to welding. A slightly higher setting might help. Short bursts are the best advice. If you really want perfection is flap wheel the metal down, mix up a little Bondo and smooth it from there. All good, Keep fixing the generators up. I bought a generator with a bad motor but it is one of those (11HP) Briggs and Stratton 6300 Watt units. Hard to find used Briggs motors. Crank punched the main housing so it is toast... I will keep looking 👍👍👍
James, I have had good luck with carb float pins by using the Dremel and grinding flats on opposite sides of the pin. Then I can grab it with pliers and wiggle it out. If it doesn't move I leave it alone. Cool video.
Just a heads up notice he put the fuel tank cap back on before unscrewing the tank...the possibility of a drill/external spark and fumes are a very real safety consideration. Great work and channel btw.
Another great video. Well done. The new paint was satisfying and the solenoid demo was cool. I’m not a big fan of generacs but I am jealous of those knipex pliers 😊
One year I purchased back to back two generators from Generac. Both of them had hunting issues that the local warranty shop couldn’t fix. Both returned and got a more electronic sensing 10k one. All no charge in the end. Yes they had issues then James. Long story short. FYI they were factory tested! lol
I am thinking of doing the same contacts cleanup on my 96 Hp Excavator, if I can only get at the thing on my machine. Done it before on cars and Mowers, so it is a good method... They are all the same, big or small. Looks like you now have a very good Genny there.
My father in law gave me one of these generators and it was in great shape. I bought a new firman tri fuel for myself and gave the generac generator to my uncle. A few years later I’m having to go through it and get it back into shape because he left it out and never maintained it. I don’t understand why people would let such a valuable and useful thing go to waste like that. I can tell you that he’s not getting it back when I get done with it 😂
You can actually extend the length of a rivet gun with a thin tube. You just have to advance the handle maybe four times instead of the two times that are normal. I’ve used brake line, telescoping antenna sections and even butt connectors to extend the reach. Eventually I drilled out each hole size of insert and added a threaded hole to accept various lengths of appropriate tubing.
I disassembled the solenoid that failed on my riding mower... The buss bar was completely melted/burned up. I think it was arcing to the point of deforming the buss bar enough that the return spring couldn't push it back up, so it maintained contact until it melted. That's my story and I'm sticking to it.
That laugh when you initially pulled on the handle and it didn't move... I've said it before: Add several tablespoons of table salt to the old fuel. Shake it up, let it settle, and pour most of the old gasoline off for re use. The moisture will separate itself cleanly from the gasoline and take all the water soluble gunk with it. Those soda bottles would be a good idea to use as your separatory funnel, because you can see where the garbage line is. The salt water and left behind gasoline will be a fraction of the volume and the recovered old gasoline is good to go, mixed with fresh fuel.
Good work James, please check and see if the governor linkage is rubbing on the housing causing some of the sticky surge issue. It appeared to me in the video that the linkage might have been dragging. Thanks for the video.
The orange paint on that generator looks very much like Hemi Orange which is what Chrysler painted its hemi engines back in the day. I also think that taking the defective solenoid apart is good because even if it's not worth fixing, there is always something to be learned that could be of use at another time.
I like to think of it as Kubota/Echo orange. Also, it could be Genesee and Wyoming orange. Unfortunately, Generac and Husqvarna have tainted that orange a bit.
My annual backup generator check is check/replace oil, run a quart of gas through it, make sure it's making power, and AIR UP THE DANGED FLAT TIRES. I really need to put solid tires on it.
That thing did great on the load test. Surprised the THD was so low. And able to hold steady with an overload speaks well of the company. Nice work as always, Jim.
Thanks Jon. I was just as surprised with the load test. Pretty good for a single cylinder engine. I have tested this engine before on other generators and they all delivered 8000 watts after a little tuning. Never tried an overload. Ideally all generators would have a larger engine then needed. Unfortunately most portable generators max out on hp at the rated load. The XP8000, XG8000 and XG10000 by generac are all very capable. It would suck though to try and service when the power goes out and you discover it won't start. Still a lot easier then the Honda EX5500 starter replacement I just did or the CASE 170B exhaust manifold you fought with.
@@jcondon1 Haha! Comparing a generator repair to that exhaust manifold made me lol. I would toss any generator off a cliff that required that much headache to fix! ;-)
@@FarmCraft101 Just wanted to say Hi Jon. Was just getting ready to watch your latest that posted today :)
@jcondon1 what is the wattage draw of the fan in the load bank? Watching the test and pushing the machine to 9000w got me thinking about it, how much extra does it add?
@@1MichaelJones Good question, also does the fan stay constantly on throughout any load. If it does then probably the manufacturer has added in the fan wattage to the total.
3-in-1 today! Generator refurbish, starter solenoid rebuild lesson and Father and Son time! Perfect.
I'm old enough that we weren't a throw away world. My dad taught me how to rebuild starters, solenoids, generators and voltage regulators. Later in my school years, I helped set up the auto mechanic shop my Senior year in high school. I love the time I spent with my dad learning and at times arguing a bit. Father son time is precious. I'm 75 now and miss my dad every day. Your channel reminds me of him all the time. Thank you and God bless.
I am proud of you for teaching your son. My father taught me how to do these things too. Have a blessed day.
His daughter. She’s growing up so fast.
One of the most valuable lessons I learned from my dad was he neglected the maintenance but that didn't give him the right to claim that gasoline engines were a curse.
A secondary takeaway was an ounce of prevention beat a pound of cure. ;)
The autopsy of the old solenoid was interesting. I have never seen how a solenoid actually works. Very informative. And the involvement of your son at 1:28:24 was OUTSTANDING.
Yeah, I was screaming "fix that thing" and you did! Thank you!
A Dremel cut off wheel makes rivet removal a breeze! 👍
In a car solenoid it uses the same principle but has a fork that engages the pinion gear to the main flywheel gear. Also the contacts has silver ends to provide less resistance. Silver is also much harder than copper so lasts much longer.
The company when they made this version were really not that bright to hide everything that one would need to do as maintenance. Your patience and calm manner are the reasons so many watch your entire vids 🎉❤⭐🥇
Awwww....as a child I similarly helped my dad with his Home TV & Radio Repair business. Kudos to you both.
Great job is always James! The Generac XP series was their top-of-the-line models when they were on the market. Well over $2k. This is a 5% or less THD rated machine. They marketed it as TruePower.
The older 7K EXL Generac has the same exact governor issue. And like you the corrective action to stop the surging was to adjust the spring location on the governor arm to fix it.
Appreciate all you do!!
Agreed they command good money small to the large
What a great video. One not only learns how to repair, you also learn about the different machines on the market today and helps to make an informed decision on what machine to buy. Thanks James!
I appreciate your curiosity. As you were replacing the solenoid I was thinking "I wonder why the other one failed." And then a few minutes later I found out! Thanks much for the follow through. Another great educational repair job.
Woke up for work and this is what I see! Happy Thursday y'all!
Excellent as always, James. It was nice to see you include your son in the process. He will certainly be a much more capable man thanks to dad. Thank you!
Jim, you break the rule of those that can, do and those that can't, teach. You are a truly gifted teacher. Your videos are beautifully paced, always holding a little suspense to keep the viewer engaged and wondering what will happen next. You are obviously a learning junkie, picking up and using something new and sharing it, almost every episode. The audio and video quality have improved over the years to where it's on a par with the best of any one man channels on UA-cam. Keep 'em coming and don't hesitate to include your son wherever he shows interest in what you're working on. I also enjoy your fun-loving, chill alter ego Mustie. Thanks for all you do!
I've drilled out countless rivets over the years, made from brass, aluminum and stainless. In all cases the one method I've used if the rivet starts to spin in place is to rotate the drill handle in a circle so the drill bit is aiming to the side instead of straight down. Almost always that does the trick.
Also, if you only need to remove a hollow rivet which has no solid center, using a countersink bit or a considerably larger bit allows just the outside rolled edge of the rivet to be removed, after which just use a drift to punch out the remainder. That way there is no way the rivet can get jammed onto a drill bit and spin.
In fifty years of engineering experience, the only time I nearly had a tantrum was when repairing a Generac. You have more patience than I had with the geriatric built garbage, even if I managed to get it running nicely again.
With the side panel I would have used self-tapping screws rather than disassembling the frame and tack welding it.
Another great video, I’m a true fan now and am obsessed with watching your videos. One thing is clear; avoid the gas and stick with fuel or tri-fuel generators. Use gas as a last resort and be sure to drain and clean before storing.
A weekly highlight is a new video on this channel. Thanks James. Fathers who know 'stuff' and let their kids get their hands dirty(ish) is a gift for life.
I am envious of your ability to understand the electrical components of these machines. I have learned so much by watching you work. Your calmness is impressive and your gentle nature with your son is great. I aspire to be that way with my sons too. You always end your videos by saying I hope you learn something, I did learn something in this video and it wasn’t about generators. Thank you.
Glad you like them!
Besides sharing the views of most other viewers, I find it VERY interesting that Generac calls this their model 8000 rather than using the less important marketing number of 12000, as most manufacturers do these days. Wonder if that's corporate culture and honesty! As to you, I immensely appreciate your matter of fact, no nonsense videos. I'm impressed that your focus is on accurate evaluation, how-to facts and concise demonstration, rather than on time wasting comedy, mugshots or unrelated drivel. Kudos to you!
And with so much marketing hype flooding the rapidly expanding generator marketplace, it would be great if a guy with your experience periodically posted Consumer Reports styled videos reflecting your assessment of present day generators. I.E., Overall quality, durability, utility of features & functions, preventative maintenance tips, repairability, and even your brand/model recommendations. Thanks for a job very well done.
I would never have thought that one hole over on the governor arm would make that much of a difference. This is good to know as many people would assume (wrongly) that they have carburetor issues when they don't.
Working on this exact model. We live on solar power and this is a backup for my Honda 8kw generator, which is working great. The last time I started the Generac the engine was working fine but there was no AC out. So because of that and not needing to use it for backup, it has been sitting for a long time with gas in the tank. After watching your videos I decided to clean up the generator and see why no volts. After having so much fun getting the tank off and getting to the carb to clean it up, I'm thinking this generator may need to find a new home..
At any rate, I fount that the generator capacitor measured 10uF and was supposed to be 47uF.... I have replaced it and hope that is the problem with AC generation.... once I get everything back together.
Thanks so much for the video.
Good quality components with so-so quality control letting them out the door it seems. Good video.
The best segment is repairing the old solenoid. Switches are amazing.
Just like a surgeon and on the solenoid even a surgical assistant. From the surgeon who loves your work
You make it look too easy mate... I'm glad you took the time to educate us on how the solinoid works. Good to see your young bloke getting in on the action. God bless 👍🏻
It is great that you can include your son. Might be absolute skills in a few years, but it will be life long memories.
A death wheel in the angle grinder works well to remove rivets, albeit overkill. Nice save & tutorial on the solenoid! Good to see the young humans helping.
Hey Jim. We lived through Helene, thanks to my Briggs 4500w generator. I ran ethanol gas through it while I was using it. It ran close to 50 hours of the 108.5 hours that we did not have power. Today, I ran all the ethanol gas through it. I then changed the oil 2 ounces of STP with the remainder Pennzoil Platinum 10 W 30. I the filled the tank with premium non ethanol gas plus one ounce per gallon of Marvel Mystery Oil. The gas had one ounce per gallon of Optimizer PLUS stabilizer. It ran perfectly for the 50 hours that I ran it. People should be careful not to overfill it with oil. I let mine just drain off any extra oil before I put the cap on. I also crank it up and run it for a minute or two and then drain off any excess oil before storing it away. At almost 80 storing away is a chore but it is now back in my shop, awaiting its next use. I did run all the gas out of the carb, first. Tank is full but the carb and fuel lines are empty. Hope HELENE DID NOT BITE YOU IN THE BUT!
Thank you for posting this excellent video! I think your daughter deserves a big mention in dispatches for helping you out. I also think it is really good that you take the time to teach her repair skills.
Thank you!
I was watching another channel and the guy used the automatic punch to pop the pen out and it worked really well. Thanks for the content James.
Thats a monster of a machine to work on. However as you say it has a most excellent performance when calibrated correctly. You do not just repair the machines James you re-engineer them so that they work better and become more reliable than the original designs and implementation. I used to hate working for large manufacturing companies when common faults would occur on a large number of manufactured products. Very simple fixes and component upgrades would solve 99 per cent of them. The accountants would say no in an instant in order to save pennies for each machine. Thank you very much James.
That Generac line of generators are impressive would love to come across one in great shape for myself. I'm currently running an SVP 5000 I've had since almost new it does a great job, but now I'm considering an upgrade to an 8000 version. Great job on this one. The black paint on the tank doesn't look sus either.
The tear-down of the solenoid that wasn't working was very interesting, thanks for that.
Thanks again Jim for another Great How to Video . I learned the hard way about how to fix a GM starter solenoid which works that same as what you have shown just on a larger scale the contacts corrode and Pit from the arcing of the High current draw , a good teaching experience for your son which there's not a lot of today ,well done Jim
I like the color change on the tank. I enjoyed watching you teach your son and having a good time doing it. Continued success!
Indeed theose starter solenoids are generally pretty easy to fix, the failure is usually corrosion on one terminal that just needs to be wire wheeled off. Even if it's riveted together the rivets can be drilled out and then put back together with small screws and nuts (typically the mounting bolts also clamp it together so the rivets are barely doing much once installed). I've had good success with repairing them, and on my own equipment I've had the repaired /cleaned ones last years with no issue
Thank you, another excellent demonstration, your son already shows a goods abilities.
Merci, encore une excellente démonstration, votre fils montre déjà beaucoup de capacité.
Hi James, I am a 74 yo female, and I am looking to buy a self propelled mower. I am taking the bull by the horns and asking your opinion on which one. I was looking on UA-cam for help, and you popped up. I like how to talk and explain things, your opinion would be greatly respected and appreciated. No pressure. I live in Australia, and love mowing the lawn. I live on my son’s property and hope I will still be mowing into my eighties. Thank you, my son says I am random, explains everything really.❤
I especially appreciate the failure analysis performed on the starter solenoid. I not only want to know how to repair things - I want to know exactly why they failed. Having a clear mental picture of what the internals of sealed units of any kind look like and how they function is absolutely priceless. The only other person I know who does this on a regular basis is Ivan from Pine Hollow Auto Diagnostics.
The only detail left unsaid which would have made that segment complete would have been an explanation of what happens on a molecular level to cause that issue. Something about electrons bleeding off or adding onto a surface or something. Can't remember exactly, but that's the actual root cause and is pretty standard for switching mechanisms that make and break contact. Someone who's an electrical engineer probably understands it and can explain much better than I. ;-)
With the clean-up and adjustments, everything seems pretty healthy. Nice to get something that's not blown to bits.
Brilliant yet again James and great to see your son involved.👍Thanks for keeping me entertained on a thunder and wet day here.
Another great vid James. With the starter, put the rope through the grip before installing on the recoil. Less waste at the end! 👍
the disassembly of old solenoid was very nice, appreciated
You know he's a true handy-man when he's got 3 hands!! Nice work.
The three hands thing is amazing. I have a watch band pin pusher that might work for pushing the pin that holds the float in the cab. The pin pusher holds both posts & only pushes the pin so the posts won’t break.
James: You have done us all a favor by demonstrating what a PIA the generator is to service.
I personally would need to find a VERY cheap model in order to become an owner ! Cheers! from the windswept Prairies of Alberta.
Great load test!! 1kW over rated capacity is awesome. Nice fix.
James love your videos I'm a 81year old fan you are so precise in your. Discriptions you make it so easy carry on your good work wish you all the best lol Billy Weir Glasgow Scotland
Thanks
Another excellent video, many thanks. If you are concerned about flammable fumes, have you considered keeping the air going inside the tank while you were using the other equipment (heat gun and sander). That way the flammable vapour is well diluted and the risk of ignition becomes minimal - just a thought.
Very nice work generator looks better than new. Awesome to see your son participating.
Very impressive, when it comes to generators you are the man.🐞
Hey, James! At 1:41:53 (and elsewhere), what are the two unconnected wires hanging down on the right side?
I was going to ask the same question.
They are probably leads from the 12 volt charging coil behind the flywheel.
@@s.koerner6486 You're probably right. I wonder why he didn't connect them? Did I miss something in the video?
@Tom-In-Ga the person that was working on it before, probably removed the leads in an attempt to troubleshoot the starter issue...
Just a guess.
The solenoid piece was a super value-add. Thanks for yet another awesome post.
It appears the tank was placed on the assembly line first and the generator was built around it.
Worn starter ropes and bad solenoids tell a story. I am glad to see Jr. is learning from the best. It not only amazes me that your revive these generators but that you find them so cheap. In my area, they would be asking $200-$300 for it and get it.
The good deals like this are far and few, but I have a lot of local subscribers keeping an eye out for me.
what a great save James. Interesting autopsy on the solenoid. Thank you for posting
Nice reveal on the starter solenoid rebuild. I had one fail in a closed position on my boat's outboard engine. No fun when your on the water and the starter keeps turning. It turned out that this was a replacement part, someone installed a "cheap" version solenoid and there was no return spring installed in it. It probably saved them $30 by avoiding the OEM part. Needless to say I also added a battery disconnect switch for future emergencies like this.
1:35:38 Wait a minute! BUSTED, you got 3 hands! that's why everything goes so well when you work! :) Great video James!
🤫 We are not supposed to know this, but recently, James had a Pan Galactic Gargle Blaster with Zaphod Beeblebrox and had this third arm installed on his recommendation. You know how these things go 😊
James is a handy man. 😉😏
@@Plons0Nardah. Someone else that's gotten hooked on the sci-fi stories.
@@brianmcaskill6215 👍🏻🤝🏻
You read my mind on that solenoid. Your tooling is very impressive. Thanks for another great video!
The solenoid deep dive helped me out, I have one just like it that needs attention. Thanks James.
I really appreciated the section on solenoid. Please add more of these kind of topics to your videos. Would love to understand how relays and other electronic components.
Very nice find James, great troubleshooting 🐈🐕 and kudos to Son of James for his Input 😊
James. I've had a lot of success on Mikuni carbs getting the float pin out by gripping it with a very sharp pair of side cutting pliers and twisting back and forth whilst pulling back towards myself.
James, you are a Master Educator. Thank you! Most enjoyable!
Been watching you for years. Love the way you bring them back to life!
Great job taming that governor. We cant have it "freaking out" again. Great video as always James!
Guys unbelievable video. Great great great I love this channel ❤️❤️❤️
Another award winner! Great resuscitation!
This video is a great lesson in. Leaving well enough along. Another masterpiece. Great job.😊
As usual, very educational and informative. I have seen all your videos and watched a few twice. They just keep getting better. Thank you for sharing.
Good morning James, great to be here.
I love it when your videos come out, thanks for all you do. The narration is perfect.
Thanks for the video James. Really enjoyed it although I watched across several evenings. Looking forward to this weeks now!
When storing or charging the battery always place a rubber mat or wood between the battery and floor that helps maintaining the battery charge. Hope that helps James.
Great video, thanks! Look forward to these each week. Always fantastic workmanship and attention to detail. Quality job!
As always a Master Class! I loved the Solenoid part!!! Thanks. Saludos from Mexico 🇲🇽
Glad you enjoyed it!
Hi James, I’m Brad I love watching your videos they’re so informative. This is one of the best generators I’ve seen you work on it really did want to do it from the start. You little TLC but it is a great running generator. Great job love your videos.
I love it when the fuel coming out of the gas tank is the same color as the gas tank.
When you were disassembling the solenoid, the reason you had difficulty desoldering the wires comes from the solder. They use high(melt) temperature solder. This is because long cranking times would cause the wire to heat and possibly melt the solder. That is the reason for the high temp solder.
For the pin on the float , I’ve seen on another site and they used a spring loaded centre punch on the pin and the stuck pin came right out , might be worth a try next time
2vintage channel
I saw the same. Will try it next time.
Ha, I saw the same video and was going to say something too.
Plus, on any pin/rod, if you can’t twist it, you can’t pull it.
Looks like some 'designer' got their hands on that one, creating an 'artistic' and 'unique' product. It must have had excessive production costs. Old school KISS principals are still the best guide to follow in this type of product. Old style automotive starter solenoids, used a ring of copper for the contactor, that would rotate a little each time to present a fresh surface for the connection.
KISS was imprinted in my mind.
James.... Practice makes perfect. Nothing wrong with your approach to welding. A slightly higher setting might help. Short bursts are the best advice. If you really want perfection is flap wheel the metal down, mix up a little Bondo and smooth it from there. All good, Keep fixing the generators up.
I bought a generator with a bad motor but it is one of those (11HP) Briggs and Stratton 6300 Watt units. Hard to find used Briggs motors. Crank punched the main housing so it is toast... I will keep looking 👍👍👍
James, I have had good luck with carb float pins by using the Dremel and grinding flats on opposite sides of the pin. Then I can grab it with pliers and wiggle it out. If it doesn't move I leave it alone. Cool video.
Your driveway looks amazing.
Just a heads up notice he put the fuel tank cap back on before unscrewing the tank...the possibility of a drill/external spark and fumes are a very real safety consideration. Great work and channel btw.
Recently I discovered your channel, cannot stop watching it! Relax voice and well explained! Nice work, greetings from the Netherlands.
The best photographer on UA-cam bar nun 😊😊😊
Another great video. Well done. The new paint was satisfying and the solenoid demo was cool. I’m not a big fan of generacs but I am jealous of those knipex pliers 😊
One year I purchased back to back two generators from Generac. Both of them had hunting issues that the local warranty shop couldn’t fix. Both returned and got a more electronic sensing 10k one. All no charge in the end. Yes they had issues then James. Long story short. FYI they were factory tested! lol
I am thinking of doing the same contacts cleanup on my 96 Hp Excavator, if I can only get at the thing on my machine. Done it before on cars and Mowers, so it is a good method... They are all the same, big or small. Looks like you now have a very good Genny there.
My father in law gave me one of these generators and it was in great shape. I bought a new firman tri fuel for myself and gave the generac generator to my uncle. A few years later I’m having to go through it and get it back into shape because he left it out and never maintained it. I don’t understand why people would let such a valuable and useful thing go to waste like that. I can tell you that he’s not getting it back when I get done with it 😂
You can actually extend the length of a rivet gun with a thin tube. You just have to advance the handle maybe four times instead of the two times that are normal. I’ve used brake line, telescoping antenna sections and even butt connectors to extend the reach. Eventually I drilled out each hole size of insert and added a threaded hole to accept various lengths of appropriate tubing.
Great suggestion.
@@robertheim352 Why thank you. Works so well for me!
I appreciate your videos I was able to bring back an old ETQ 8250 that hasn’t ran since 2016 from watching your videos 👍
Nice
I've never seen ANYONE spray paint wiithout releasing the trigger. I guess it works for you, James. Thanks for the video.
I actually like the black tank better, works well. Another awesome video! I look forward to each of them.
I disassembled the solenoid that failed on my riding mower... The buss bar was completely melted/burned up. I think it was arcing to the point of deforming the buss bar enough that the return spring couldn't push it back up, so it maintained contact until it melted. That's my story and I'm sticking to it.
That laugh when you initially pulled on the handle and it didn't move...
I've said it before: Add several tablespoons of table salt to the old fuel. Shake it up, let it settle, and pour most of the old gasoline off for re use. The moisture will separate itself cleanly from the gasoline and take all the water soluble gunk with it. Those soda bottles would be a good idea to use as your separatory funnel, because you can see where the garbage line is.
The salt water and left behind gasoline will be a fraction of the volume and the recovered old gasoline is good to go, mixed with fresh fuel.
Good work James, please check and see if the governor linkage is rubbing on the housing causing some of the sticky surge issue. It appeared to me in the video that the linkage might have been dragging. Thanks for the video.
That is another problem with these engines. The governor rod tends to get bent with the way it is run through the blower housing.
Wow looks brand new
The orange paint on that generator looks very much like Hemi Orange which is what Chrysler painted its hemi engines back in the day. I also think that taking the defective solenoid apart is good because even if it's not worth fixing, there is always something to be learned that could be of use at another time.
I like to think of it as Kubota/Echo orange. Also, it could be Genesee and Wyoming orange. Unfortunately, Generac and Husqvarna have tainted that orange a bit.
@@WJCTechyman That'll work too.
Wheels from harbor freight r 10 each. Great quality. I quit trying to use air tires. Love these. No problems
My annual backup generator check is check/replace oil, run a quart of gas through it, make sure it's making power, and AIR UP THE DANGED FLAT TIRES. I really need to put solid tires on it.