I repair generators part time for a shop down the street. After a storm like we just had in florida, after people ran their generators for a week or so, many come to the shop with the same running issues. And yes, its that crappy spark arresting screen. I could charge each customer a hundred dollars shop time for the repair and make a fortune. But I tell them to remove the screen and try it before they bring it in. It doesn't help my bank account but I can't rake people over the coals on something that simple to correct. Cheers and Merry Christmas to James and everyone out there.
I tell people that with their chainsaws or weedeaters as well. 2-stroke engines produce a bit of carbon anyways, and then when you put a screen over the exhaust, it starts building up. The more it that builds up, the richer the engine runs, the more carbon it produces, plugging it up even faster. I have a brand new Stihl and after about 6 gallons of gas, the screen was plugged up already. Using non ethanol gas and the new HP Ultra synthetic 2-stroke oil that they recommend. So it's not because I was using junky old two-stroke oil.
Thank goodness that there are still meticulous craftsmen like you who have a passion for repairing mechanical devices. We who are not "handy" salute you! 👍🐻🇺🇲
James, one of the things that sets your channel apart from the others is how you take the time to show exactly what's wrong. For instance, putting us in view of the exhaust to hear what was troubling you. Others would simply say there's a noise and begin to fix it. BTW: Your solution for the spark arrestor was excellent as was the rest of the video!
yep, and once all that carbon blew out of the muffler, it rang great, the carbon was choking out the engine as it looked like that spark arrestor thing james took off was plugged up
Of all the small engine videos I've watched on UA-cam, I believe this is the first one with a 4-cycle engine with a clogged spark arrestor. I've seen it enough times on 2-cycle equipment, including on my better-branded line trimmer. This is a good one to remember...
If you have a generator, and it has an Economy mode. I am NOT 100% sure, but on Yamahas from what i've seen, it just cloggs up the spark arrester, No big deal to clean it, but customers come back with it ect. Anytime i do a service i clean it out. I have NEVER seen one this bad though. Normally its slightly clogged. This was CAKED.
K, so this has literally become one of my fav channels.. I am an Electrician, but have been looking at doing small engine repairs on the side, just to make some extra coin... This channel has been incredibly informative, and I wish I had found this channel several years ago when I got rid of my 1960s Lawnmower that had a crank no start condition, but would happily run on starting fluid..
I'm an Industrial mechanic. This was pretty simple, but when folks just aren't mechanical, this thing was a frustrating nightmare. the seller kicks himself but is glad you got it working I'm sure. The other freak zone is when a new land owners waterwell stops working. Many times it is a simple fault, but it is always, OMG My Pump motor is dead! Not always....
Wow! What a steal for $150 dollars. That machine would run my whole house, no problem. My Gennie didn't come with a spark arrester, but then I don't live in a dry area. Also the decal on the recoil assy. looks to be crooked, someone clocked it to the top position. Nice vid.
I love your inventiveness James. These types of hourmeters come in DC types and AC types, as you said. Yours is obviously one of the AC types, as you also said. The instrument counts up with the presence of an input voltage across the input wires. There are three standard AC supply voltages provided by the manufacturer. Those are 24V AC, 120V AC and 240V AC. The instrument should be marked with that appropriate for that one. I am presuming that they have provided you with one of the 120V types. All you need do is to check that the input voltage for your meter is 120V and remove the broken hourmeter from the panel. You will have to wire the input wires onto the hot side of one of the legs. Seeing as you have already paid for it you may as well use it, This can also be a cheaper solution to paying Generac $40 for one of theirs in future projects.
I saw you using a couple of types of lifts to raise equipment. It pleased me. I wish you had a high table of 3/4" plywood that you could set the machines on. We don't think our backs will go until someday a disk squishes out to the side or to the posterior. Then you are screwed for life. I know this is off-topic but I bet you have hundreds of subscribers who can relate. Great videos.
Just a thought for the tractor lifts… they do make a swivel link for such loads. It’s 2 heavy iron half chain links joined in the middle! Working loads variable . The ones I used were rated over a ton! That means that you can use a spreader bar in between the load & the bucket. You can pull straight to your lift & turn the load any direction you need!
I love watching you work. I know a little about engines, but not enough to do what you are doing. Just watching you troubleshoot and fix multiple problems is very satisfying.😅
I know you posted this awhile back. I want to say thank you. Our Predator 6500 just stopped running. Would start and chug for 15 to 20 seconds and Die. Replaced Carb a d related. Components. Air line on tank. ( it was split). Cleaned tank. Was close to giving up. Came accross your video. We pulled spark arrester/s. Outer only had a few specs. Then seen how a. Inner one came out. Removed. Started generator. Ran great after s few seconds of blowing itself out. Saved me from having to replace generator . I just wanted to give thanks to Jesus for leading me to your video and thank you for it's content.
Its always cool to see the rolling shutter effect from the camera on high speed moving vibrations. At 1:03:20 it looks like all the parts on the generator are moving and wiggling independently. Great video, always fun to watch, and youve inspired me to start my own Red Mango Rebuilds channel since I do alot of small engine rebuilds already, might as well have some fun making youtube videos along with the rush I get from getting a non-running motor to fire up! Thanks again and keep it up man
James the spark gap adjustment will create a more complete combustion! The muffler needs to be really hot to breakdown the carbon build up. 4 hours of 50% load will do.
@@raouliii That is a cool camera effect...the absolute best demonstration of that effect I saw was a video of a flying helicopter and because of the camera's frame rate, the rotor blades seemed to be stationary...
For the future, a good size C-Clamp might be useful to straighten a cross member with the generator still installed above it. Clamped on from the bottom, it could press down on wrinkles and give you leverage to bend it parallel to the floor.
I was thinking more of what body and fender guys use when straightening out body panels. A nice piece of iron on the top and some friendly persuasion with a bfh from the bottom side. 😁
@@AmosBHaven you use a hammer and dolly. When you press the dolly on the metal it's like you're hitting the metal from that side. It's called hammering on. You don't need a big hammer either.
@@1pcfred IMHO, and something I would do. In this particular case? The bigger the better. Is not like your trying to finesse the curve in a fender yanno? 😜
Great tip regarding the handle grips and the air. When I worked at a repair shop ages ago we were instructed to coat the metal with rubber cement and slide the grips on. I like your way much better, easier and less messy.
James.....Great video as always. Whoever worked on that genny prior to you had not one clue as to what they were doing. Nice job to get it up and running again. A lot to be said for those older genies still kicking around.
Jim, Next time you have an awkward access 'blown out hole' like this in sheet metal -- a fine thread bolt (aprox same diameter as the original bored hole with threads fully along the shank), 2 heavy washers and a bolt. Lube everything with grease or heavy oil (not WD40). Sandwich the washers on either side of the ragged hole and put the bolt through washer, hole & other washer then thread the nut on the shank as snuggly as fingers will do. Then with a box end wrench on one end of the bolt and an impact wrench socket holding the other end, MIGHTLY tighten the nut / bolt and pressure squeeze that sheet metal "blow out" flat. Joe S
Great job, James, as usual. One suggestion for the replacement grips. I've seen folks use soapy water, which adds lubrication, then dries. It may help sliding on, although your solution worked well
I hve always just used a little WD-40 they slide right on an it evaporates in no time. Same thing for removing them, just slide the tip under the grip and give it a shot and they slide right off.........
51:10 If you use a C-Clamp on the bad hole on the frame rail, you might be able to flatten the ridge and straighten the frame to the point it the foot sits straight. Then a long steel plate with matching holes can be placed under the frame rail to reinforce it and the foot would then sit against the plate and everything is then bolted together... So what I'm thinking is from top to bottom: Frame Rail Steel Plate that runs from round frame rail to round frame rail (instead of the washers you used) Foot Piece With 4 bolts going through all 3 pieces to tie them together and hold everything on...
Great video as always. Learned that those spark arrestors can and do fail. Also learned that nifty trick with the air compressor and the handle grip. Nicely done. Merry Christmas!
Mr. James, You could get under that frame rail with an air hammer and a flat bit in it and straighten out that frame rail without disassembling everything. Back up the opposite side with a 3lb sledge hammer... you'll have it back into proper shape in no time.
James I have learned a lot from you your approach to your repair and assessment is a great role model. Thanks for all the education as a result I am now "that guy" in our neighborhood that people bring power equipment to when they have issues, I like to help my neighbors.
James Condon has the Midas Touch! Everything he touches turns to gold! Especially generator repair videos and brilliant troubleshooting. Gentron generator repair and how to troubleshoot a generator that wont start is much better when you can learn from watching. And besides, this is the best of UA-cam right here! 😊Thank you!
Is it weird that I go down more youtube rabbit holes watching James fix generators than any of the other 'viral' stuff out there?? haha its just fun to watch the diagnosis and trial/error and he does a great job bringing you along the journey
A good trick for grips is to spray the inside with rattle can paint and then slide them on. The paint dries, it's non greasy, and they remain in position.
It is most interesting watching your generator repair videos. I was thinking that if you ever need a gasket -- you might be able to 3-D print the exact gasket design you need. You might even be able to decide what material the gasket should be. I don't know, I am not a 3-D printing person, but there are plenty of folks on Thingiverse and I'm sure some can provide what you need.
Hello James: I love your videos. I entertain myself and learn a lot watching them. As I told you in another comment, I maintain two generators that my brothers-in-law own and I have been able to apply techniques and knowledge that I have learned from you all these years. Thank you for your dedication to filming, editing and uploading them to UA-cam. Ramon Jimenez From Hialeah, Fl.
Hi James love your videos!!! I find them so satisfying watching someone out there actually fix stuff properly! I do have a suggestion for that cross brace for the foot. You could use a ball joint press to flatten it out and use the rings as positive/negatives to get it in the shape you need. Most parts stores will loan them out.
Jim, old motorcycle hand-grip tick. Spray the bar and the inside of the grip with Windex, just a little. Grip slides right on and the Windex will completely evaporate in a few minutes leaving you with a nice tight hand-grip.
50:45 Get the largest nut and bolt that will fit through that hole, and the largest impact driver you have. Put the bolt through the hole with a huge stack of beefy washers on each side and then use the impact driver to tighten it down as hard as you can, which will have the same effect as putting that rail in a vise. It should flatten out the blown out hole and eliminate most of the ridge. It's not 100%, but it should get you to 90%.
And another generator is ready to serve. Sorry to hear about your back James, it's pain that I know very well. Prayers for a speedy recovery. Thanks again for another great video. Merry Christmas to you and your family. Rev. D.
It’s always a pleasure watching your videos, I always come away with something new to learn about. I like the way you fully analyze the problem and your explanation of what you’re doing is always clear and precise. Thanks for sharing your expertise! 👍👍
England- thank you so much for all the work you put into your channel. As an old wrinkly I don't sleep that well and your videos are always worth watching. As an old fasioned engineer though there are times when I think you are trying to repair planned solescence. I wonder what you would make of an 80 year old Lister generator that needed it's brushes changing after 40 years.
About the air on the grips. Don't slide the air nozzle under the grip as the air blows out both sides. No just aim the air at where the grip meets the bar which lifts the whole grip up. If it doesn't have a hole in the end.
I like the video and really appreciate some of the things that you shared with us. I like how you correctly and quickly identified the spark arrestor as a potential problem for why the engine would be shutting down; I would not have thought of that. I know this is unsolicited, but I noticed a few things that some other best practices would have helped. Here are a few best practices that have worked for me in the past. When putting on the hand grips, use a water bottle with a little dish soap and mist the bars and the inside of the grips; you will find that they will easily slip right on and when they dry they will not move. I learned this from a bike shop that used to replace the foam grips on handle bars. One thing I would mention, running the engine indoors is more dangerous than it may seem. It does not take a great deal of carbon monoxide to kill someone and by the time a person begins to feel the effects it is most likely too late to do something about it. While you may have had enough ventilation, other people watching your video may not realize the danger and assume it is ok to do the same since they saw it done in a UA-cam video. There was a man around here that was working on his lawnmower in his garage and they found him by the door trying to get fresh air, unfortunately it was too late. I like the video, but maybe a little disclaimer warning people to have proper ventilation when running an engine in a confined space. On a separate note, could you have reused the wheel hub that you removed to cut down to the spacers that you needed? It seemed like a good potential reuse, especially if you had no option on hand. My favorite part of the video was the carburetor teardown. I especially like the use of the tea ball for the small parts in the ultrasonic cleaner. I also loved the "form a funnel," I have not seen that before, I usually just use aluminum foil to make custom funnels, but I really like that product. Another great pointer was when you explained the difference between the types of fuel filters, i.e. paper vs. screen, as it relates to pumped fuel vs. gravity fed. This is a big help in troubleshooting if someone makes the mistake of using the wrong filter. Great video for anyone looking to work on a small engine system. Thanks for sharing.
Jim, I recently bought a similar battery to the one you took off this generator. I bought a Peak brand battery charger that is called a "Teligent" type that is a smart charger. It can refurbish a battery under certain conditions, and while this or other chargers is a low amperage type, it doesn't cook a battery.
The usual problem with small lead acid batteries in a genset is that they are flattened by repeated fail to start cycles, then just left flat til they cannot be recharged. Also there is no knowing how clever the on board charger is while the generator is running.
@@seymourpro6097 the cycling of the battery is always a problem. I wouldn't use the charge while the generator is running as the charge voltage most likely would be perceived as battery charge, and the battery would probably just be dead. The refurbishing is not always a guarantee. For me, so far I've not had the need for a battery to be refurbished yet.
Great video as always... I like the way you go into detail and, as someone else commented, how you actually take the time to show us your fix, etc... thanks again.
Nice work James. I never understand how people that don't do small engine repair can screw up expensive machines so much. Can you check the choke plate screws, they looked loose, but may have been a reflection that I was seeing. Thanks for a great video.
Jim, that threaded cap is different from the one for my generator. On mine, I opted for a used gas tank, which, is from a Harbor Freight, and a larger capacity. It's as close as I could find for a direct replacement. What was left of the old wheels has what are likely good bearings, which can be removed with a hammer and screwdriver.
On my Honda EU 20 I fitted an hour meter that picks up off the high tension lead. No wiring needed. The simplest way to clean that spark arrestor in future is to hit it with a propane torch until the mesh is red hot. That burns off the carbon without even removing it. Cheers Stuart 🇦🇺
Merry Christmas Jim. To fix the dented rail I would fashion a small 1/4" plate top and bottom and squeeze the rail between them with a nut and bolt - essentially using the plates as large, strong flat washers.
I just had a generac RS550 I got off of Facebook Marketplace with the same symptoms - initially thought it was the low oil switch (no light) but I also heard the hiss and it turns out the entire exhaust was packed with Georgia clay- a little creative augering to get it out and Bob’s your uncle! She runs like new
I was hanging for my fix so I started a 1 year old video, then you released this. Now I have 2 hours of Condon to catch up on. Which is totally fine. Happy holidays to you and yours.
I just bought a Gentron like this. Having issues with it right after getting it home. Quit running after 2 minutes. Oil was so dirty wasn't letting the sensor work correctly. Change oil. Started to adjust the valves and the valve guide plate was missing the plastic/rubber guides. Had been gone so long that the intake had almost rubbed thru the plate. The valves were out of adjustment really bad. Replaced the plate and adjusted the valves. The engine was running hot. In checking the cooling fan was in pieces in the shroud, replaced that also. So now it will run and make power. My concern is the compression is on 58 hot/38 cold. I'm not sure if I am up to going farther. Your video's have helped so much already, was glad to find this one on the same unit that I have. Thanks
Old trick from BMX days when I used to ride freestyle bikes and want to get a grip on the handlebars so it’ll stay on and it won’t come off hairspray they go on so easily and when they dry, they never want to come off. I usually have to take a razor blade to cut them off. And spark arrester’s I do everything I can to remove them as soon as I find one absolute garbage always a headache always a problem just get rid of them and no more problems.
Excellent, as always. Thanx. I might have done the spark arrestor just a bit differently. I would have cut the new screen maybe 3/8" long and folded it back over the exhaust tube, then inserted the end cap. That would prevent the screen from ever falling into the muffler.
A suggestion, put the rubber hand grip on before you mount it to the frame. That way you can use a mallet to get it on the handle. Also I would have used some talc power to make it go on smoothly.
Another excellent video and great deal getting get the generator back up and running. James you should add a cable tie gun too your inventory of shop tools, I use one in the electronics field and they work great for dressing up cable harnesses, you can adjust the tension and they make a nice clean cut on the cable (zip) tie. Love watching and learning from your videos. 👍
you should point out the three ports just inside the carb by the choke plate; idle, mid speed and high speed. you have to bend a wire at 90 deg to reach in. also check the fuel shut of sol. with 12v
Bob Ross of Generator repair! HAHA! That's a compliment I know. I see the similarities. You just had to see the running generator in there it's hiding! I loved Bob Ross.
I watched him all the time back in the day. Maybe a little rubbed off. "Talent is a pursued interest. Anything that you’re willing to practice, you can do." “There are no mistakes, just happy accidents.”
I'm wondering if the clogged spark arrestor caused the engine to backfire at some point, and the impact of the exhaust gasses during the backfire caused the damage to the spark arrestor?
Great job James! I would run a 50% or greater load for an hour to really heat up the engine/muffler in an effort to burn off all that carbon. Guy probably was running at half choke most of the time. Other instances the improper high altitude jet is installed but thats rare.
Absolutely! Most folks don't stretch their machines legs like they should and they seldom get put under a heavy enough load for an extended period of time.
@@giggiddy exactly a buildup of carbon in a gasoline engine is the equivalent to wet stacking in a diesel engine. Run them with a heavy load for at least an hour and you'll see that exhaust clear up very quickly
Well James, if you hear a chirping while you're working on the genny or another engine, I saw a cricket run under your bench behind you while you were mounting the first wheel spacer. LOL
Merry Christmas Jim! You might try a Old School Carbon Removal Method. Remove the spark arrestor. and air filter. With the engine running squirt water down the throat of the carburetor from a spray bottle. The water will flash to steam in the combustion cylinder and clean out much of the soot and carbon. Best of Luck.......................
The exhaust is typically not considered as the culprit if one has a non-starter, because it hardly ever gives you trouble. I am an experienced automotive engineer, and I once struggled a whole saturday with a stupid 50cc 2-stroke moped which would not start, although it had spark, compression, fresh fuel amd whatnot. After hours I glimpsed into the exhaus tailpipe (10mm diameter) and saw "something", which turned out to be soft when I was poking it with a screwdriver. It was the cocoon of an insect. After it had been easily removed, the motor started upon the first kick. Lesson learned. If you have someone who deserves it, spray construction foam into the exhaust tailpipe of his car. He and his repair shop will have a lot of fun.
Great post. I have a running 5kW diesel unit with no power output in my in tray, but it will prolly have to wait to fix due to impending house move. We're looking at blackouts coming in the deep UK winter due to continued complacency & foolishness over certain 'belief systems' of the government here, so maybe I'm doing ok here with my 2KW backup petrol unit I acquired as an unwanted return from Screwfix at discount. However, I'm still puzzled why manufacturers can't design effective mufflers for these units when they seem to have done so on cars, it's one of the most off putting features of these crucial bits of kit. Your dedication is commendable.
I live in UK too Ruth. Living in a fairly populous area means we do not get many power cuts. I have never owned a generator for myself because it never seemed like a good investment. I repaired loads of them when I was still of working age. I am just hopeful that we will not get these winter power cuts that people are talking of. My back up plan consists of a calor gas bottle heater, an oil lamp and lots of candles. Gas, or petrol as we say, generators are just too noisy. If I am forced into it I would buy a battery powered inverter generator with a good set of batteries and a good charger for when we do have power.
Again, learning even on the engine side!! I would not have caught the plug! Spark arrestor, In some locals I am sure they are highly recommended. But your solution looks even better than original, so good call there. Coming in after others worked on these generators is hard on your brain trying to figure out what they were thinking to get it into the condition you found...
You too? I hurt mine carrying 24 30Kg 2V cells out to my car to take to the recyclers. Car was about 40M away, can't get it closer, I was praying really hard on the last one, spent the past 2 days licking my wounds so to speak, take care James, merry Christmas to you and yours.
The blown out rail might be fixed by putting the biggest bolt you can through the hole and 2 thick washers, one on each side and then use the bolt and nut to squeeze the blown out hole in the rail. It might work. You have great videos and I am a car mechanic, so watching you work is very interesting to me. But I'm retired now,,,,,,,,,,,,,,,,,
I repair generators part time for a shop down the street. After a storm like we just had in florida, after people ran their generators for a week or so, many come to the shop with the same running issues. And yes, its that crappy spark arresting screen. I could charge each customer a hundred dollars shop time for the repair and make a fortune. But I tell them to remove the screen and try it before they bring it in. It doesn't help my bank account but I can't rake people over the coals on something that simple to correct. Cheers and Merry Christmas to James and everyone out there.
I tell people that with their chainsaws or weedeaters as well. 2-stroke engines produce a bit of carbon anyways, and then when you put a screen over the exhaust, it starts building up. The more it that builds up, the richer the engine runs, the more carbon it produces, plugging it up even faster. I have a brand new Stihl and after about 6 gallons of gas, the screen was plugged up already. Using non ethanol gas and the new HP Ultra synthetic 2-stroke oil that they recommend. So it's not because I was using junky old two-stroke oil.
Maybe show them how to do it for themselves and charge 25 bucks for the lesson. You deserve something for your expertise.
You're a good man.
@@iamthemiracle81 I agree.
Good man!
Thank goodness that there are still meticulous craftsmen like you who have a passion for repairing mechanical devices. We who are not "handy" salute you! 👍🐻🇺🇲
James, one of the things that sets your channel apart from the others is how you take the time to show exactly what's wrong. For instance, putting us in view of the exhaust to hear what was troubling you. Others would simply say there's a noise and begin to fix it. BTW: Your solution for the spark arrestor was excellent as was the rest of the video!
yep, and once all that carbon blew out of the muffler, it rang great, the carbon was choking out the engine as it looked like that spark arrestor thing james took off was plugged up
Most would say it was clogged and now its fixed without actually showing any of the work.
@@jcondon1 i agree james
Never had that issue to resolved before.
Good comment Tom, and not a lot of ego talking as well😅
Clearly this generator needed someone with attention to detail, luckily you found it and gave it another chance to make power for someone, nice job
As our temperature is headed to the negative (F°) it was great to see a warm video.
Predator gennys are notorious for clogging their spark arrestors, sweet find on this generator. Congrats!
Of all the small engine videos I've watched on UA-cam, I believe this is the first one with a 4-cycle engine with a clogged spark arrestor. I've seen it enough times on 2-cycle equipment, including on my better-branded line trimmer. This is a good one to remember...
It’s rare, but it does happen
Fairly common on high use chainsaws, can usually remove, burn carbon off with a torch and reinstall
Same here. First for me but great lesson.
If you have a generator, and it has an Economy mode. I am NOT 100% sure, but on Yamahas from what i've seen, it just cloggs up the spark arrester, No big deal to clean it, but customers come back with it ect. Anytime i do a service i clean it out. I have NEVER seen one this bad though. Normally its slightly clogged. This was CAKED.
I had one this year but I think we will see alot of them this spring after heavy use this winter
K, so this has literally become one of my fav channels.. I am an Electrician, but have been looking at doing small engine repairs on the side, just to make some extra coin... This channel has been incredibly informative, and I wish I had found this channel several years ago when I got rid of my 1960s Lawnmower that had a crank no start condition, but would happily run on starting fluid..
I'm an Industrial mechanic. This was pretty simple, but when folks just aren't mechanical, this thing was a frustrating nightmare. the seller kicks himself but is glad you got it working I'm sure. The other freak zone is when a new land owners waterwell stops working. Many times it is a simple fault, but it is always, OMG My Pump motor is dead! Not always....
Wow! What a steal for $150 dollars. That machine would run my whole house, no problem. My Gennie didn't come with a spark arrester, but then I don't live in a dry area.
Also the decal on the recoil assy. looks to be crooked, someone clocked it to the top position. Nice vid.
I love your inventiveness James. These types of hourmeters come in DC types and AC types, as you said. Yours is obviously one of the AC types, as you also said. The instrument counts up with the presence of an input voltage across the input wires. There are three standard AC supply voltages provided by the manufacturer. Those are 24V AC, 120V AC and 240V AC. The instrument should be marked with that appropriate for that one. I am presuming that they have provided you with one of the 120V types. All you need do is to check that the input voltage for your meter is 120V and remove the broken hourmeter from the panel. You will have to wire the input wires onto the hot side of one of the legs. Seeing as you have already paid for it you may as well use it, This can also be a cheaper solution to paying Generac $40 for one of theirs in future projects.
I saw you using a couple of types of lifts to raise equipment. It pleased me. I wish you had a high table of 3/4" plywood that you could set the machines on. We don't think our backs will go until someday a disk squishes out to the side or to the posterior. Then you are screwed for life. I know this is off-topic but I bet you have hundreds of subscribers who can relate. Great videos.
I certainly can. I used to have 5 lumbar discs in my spine. Now I have 4.
I learned something!! Great way to put rubber or plastic handles on!
Just a thought for the tractor lifts… they do make a swivel link for such loads. It’s 2 heavy iron half chain links joined in the middle! Working loads variable . The ones I used were rated over a ton!
That means that you can use a spreader bar in between the load & the bucket. You can pull straight to your lift & turn the load any direction you need!
I love watching you work. I know a little about engines, but not enough to do what you are doing. Just watching you troubleshoot and fix multiple problems is very satisfying.😅
I know you posted this awhile back. I want to say thank you.
Our Predator 6500 just stopped running.
Would start and chug for 15 to 20 seconds and Die.
Replaced Carb a d related. Components. Air line on tank. ( it was split). Cleaned tank.
Was close to giving up.
Came accross your video.
We pulled spark arrester/s. Outer only had a few specs. Then seen how a. Inner one came out.
Removed. Started generator.
Ran great after s few seconds of blowing itself out.
Saved me from having to replace generator .
I just wanted to give thanks to Jesus for leading me to your video and thank you for it's content.
Good videos like this one never get "old".
I like the way you fix and repair generators, and your knowledge about these things is phenomenal.
Its always cool to see the rolling shutter effect from the camera on high speed moving vibrations. At 1:03:20 it looks like all the parts on the generator are moving and wiggling independently.
Great video, always fun to watch, and youve inspired me to start my own Red Mango Rebuilds channel since I do alot of small engine rebuilds already, might as well have some fun making youtube videos along with the rush I get from getting a non-running motor to fire up! Thanks again and keep it up man
I find it mesmerizing.
@@raouliii Me too! its almost calming, to see the chaos that is in each vibration and how well the dampening works
James the spark gap adjustment will create a more complete combustion! The muffler needs to be really hot to breakdown the carbon build up. 4 hours of 50% load will do.
I was thinking the same thing about the camera shot adjusting the carb! I wondered if the frame was made of jelly!
@@raouliii That is a cool camera effect...the absolute best demonstration of that effect I saw was a video of a flying helicopter and because of the camera's frame rate, the rotor blades seemed to be stationary...
I use to use those generators on job sites and their pretty tough! Glad you restored it! If properly maintained, they should last a very long time!
For the future, a good size C-Clamp might be useful to straighten a cross member with the generator still installed above it. Clamped on from the bottom, it could press down on wrinkles and give you leverage to bend it parallel to the floor.
My thoughts exactly. I was thinking of using a large C clamp to flatten out the bumps on both faces at the same time.
I was thinking more of what body and fender guys use when straightening out body panels. A nice piece of iron on the top and some friendly persuasion with a bfh from the bottom side. 😁
Bolt with two thick washers and then crank it down. Would have flattened it out no problem
@@AmosBHaven you use a hammer and dolly. When you press the dolly on the metal it's like you're hitting the metal from that side. It's called hammering on. You don't need a big hammer either.
@@1pcfred IMHO, and something I would do. In this particular case? The bigger the better. Is not like your trying to finesse the curve in a fender yanno? 😜
You're like the Bob Ross of generator repair :)
😆
Just "Happy Little Faults".😏
Great tip regarding the handle grips and the air. When I worked at a repair shop ages ago we were instructed to coat the metal with rubber cement and slide the grips on. I like your way much better, easier and less messy.
James.....Great video as always. Whoever worked on that genny prior to you had not one clue as to what they were doing. Nice job to get it up and running again. A lot to be said for those older genies still kicking around.
Hey Jim, I use rubbing alcohol to install those grips on bikes…. Goes on and evaporates quickly… easier to slide those handles on!
Jim,
Next time you have an awkward access 'blown out hole' like this in sheet metal -- a fine thread bolt (aprox same diameter as the original bored hole with threads fully along the shank), 2 heavy washers and a bolt. Lube everything with grease or heavy oil (not WD40). Sandwich the washers on either side of the ragged hole and put the bolt through washer, hole & other washer then thread the nut on the shank as snuggly as fingers will do. Then with a box end wrench on one end of the bolt and an impact wrench socket holding the other end, MIGHTLY tighten the nut / bolt and pressure squeeze that sheet metal "blow out" flat.
Joe S
Thank you James! I'm always learning from you. So nice to watch a guy who can't be stumped on the unknown.
Bad Co2 sensor
Great job, James, as usual. One suggestion for the replacement grips. I've seen folks use soapy water, which adds lubrication, then dries. It may help sliding on, although your solution worked well
I hve always just used a little WD-40 they slide right on an it evaporates in no time. Same thing for removing them, just slide the tip under the grip and give it a shot and they slide right off.........
51:10 If you use a C-Clamp on the bad hole on the frame rail, you might be able to flatten the ridge and straighten the frame to the point it the foot sits straight. Then a long steel plate with matching holes can be placed under the frame rail to reinforce it and the foot would then sit against the plate and everything is then bolted together...
So what I'm thinking is from top to bottom:
Frame Rail
Steel Plate that runs from round frame rail to round frame rail (instead of the washers you used)
Foot Piece
With 4 bolts going through all 3 pieces to tie them together and hold everything on...
Great video as always. Learned that those spark arrestors can and do fail. Also learned that nifty trick with the air compressor and the handle grip.
Nicely done. Merry Christmas!
Mr. James, You could get under that frame rail with an air hammer and a flat bit in it and straighten out that frame rail without disassembling everything. Back up the opposite side with a 3lb sledge hammer... you'll have it back into proper shape in no time.
James I have learned a lot from you your approach to your repair and assessment is a great role model. Thanks for all the education as a result I am now "that guy" in our neighborhood that people bring power equipment to when they have issues, I like to help my neighbors.
James Condon has the Midas Touch! Everything he touches turns to gold! Especially generator repair videos and brilliant troubleshooting. Gentron generator repair and how to troubleshoot a generator that wont start is much better when you can learn from watching. And besides, this is the best of UA-cam right here! 😊Thank you!
Thanks. It’s one of yours. I have respect for companies that sell parts. Was happy to find the jdna.com website.
Another very good video James. You have covered every generator problem I have come across so far. Your videos are a big help. I really enjoy them.
Is it weird that I go down more youtube rabbit holes watching James fix generators than any of the other 'viral' stuff out there?? haha its just fun to watch the diagnosis and trial/error and he does a great job bringing you along the journey
I know that I’m repeating myself…. Another award winning job! Great purchase!
A good trick for grips is to spray the inside with rattle can paint and then slide them on. The paint dries, it's non greasy, and they remain in position.
Hair spray...slips on and acts as an adhesive when dries.
Hairspray works great, using paint be a pain when you want to replace or remove down road
A shit of silicone spray lube or PTFE line will work fine as well. Even a small amount of liquid dish soap.
Dish washing detergent like Dawn is what a lot of bicycle shops use, slides right on and dries tight!
Or drop the grips into hot water for a few minutes, they'll stretch over the handle, then shrink to fit. Great video as always, btw.
It is most interesting watching your generator repair videos. I was thinking that if you ever need a gasket -- you might be able to 3-D print the exact gasket design you need. You might even be able to decide what material the gasket should be. I don't know, I am not a 3-D printing person, but there are plenty of folks on Thingiverse and I'm sure some can provide what you need.
Thanks for producing this video. I would like to see a test added to verify the generator does actually shut down from low oil.
Hello James:
I love your videos. I entertain myself and learn a lot watching them.
As I told you in another comment, I maintain two generators that my brothers-in-law own and I have been able to apply techniques and knowledge that I have learned from you all these years.
Thank you for your dedication to filming, editing and uploading them to UA-cam.
Ramon Jimenez
From Hialeah, Fl.
Hi James love your videos!!! I find them so satisfying watching someone out there actually fix stuff properly! I do have a suggestion for that cross brace for the foot. You could use a ball joint press to flatten it out and use the rings as positive/negatives to get it in the shape you need. Most parts stores will loan them out.
Shockingly simple repair on this one. What an excellent find.
Jim, old motorcycle hand-grip tick. Spray the bar and the inside of the grip with Windex, just a little. Grip slides right on and the Windex will completely evaporate in a few minutes leaving you with a nice tight hand-grip.
50:45 Get the largest nut and bolt that will fit through that hole, and the largest impact driver you have. Put the bolt through the hole with a huge stack of beefy washers on each side and then use the impact driver to tighten it down as hard as you can, which will have the same effect as putting that rail in a vise. It should flatten out the blown out hole and eliminate most of the ridge. It's not 100%, but it should get you to 90%.
And another generator is ready to serve. Sorry to hear about your back James, it's pain that I know very well. Prayers for a speedy recovery. Thanks again for another great video. Merry Christmas to you and your family. Rev. D.
Thanks and Merry Christmas!
It’s always a pleasure watching your videos, I always come away with something new to learn about. I like the way you fully analyze the problem and your explanation of what you’re doing is always clear and precise. Thanks for sharing your expertise! 👍👍
England- thank you so much for all the work you put into your channel. As an old wrinkly I don't sleep that well and your videos are always worth watching. As an old fasioned engineer though there are times when I think you are trying to repair planned solescence. I wonder what you would make of an 80 year old Lister generator that needed it's brushes changing after 40 years.
I am sure that 80 year old generator was built to a much higher standard and will last another 80 years if taken care of.
About the air on the grips. Don't slide the air nozzle under the grip as the air blows out both sides. No just aim the air at where the grip meets the bar which lifts the whole grip up. If it doesn't have a hole in the end.
I like the video and really appreciate some of the things that you shared with us. I like how you correctly and quickly identified the spark arrestor as a potential problem for why the engine would be shutting down; I would not have thought of that. I know this is unsolicited, but I noticed a few things that some other best practices would have helped. Here are a few best practices that have worked for me in the past. When putting on the hand grips, use a water bottle with a little dish soap and mist the bars and the inside of the grips; you will find that they will easily slip right on and when they dry they will not move. I learned this from a bike shop that used to replace the foam grips on handle bars. One thing I would mention, running the engine indoors is more dangerous than it may seem. It does not take a great deal of carbon monoxide to kill someone and by the time a person begins to feel the effects it is most likely too late to do something about it. While you may have had enough ventilation, other people watching your video may not realize the danger and assume it is ok to do the same since they saw it done in a UA-cam video. There was a man around here that was working on his lawnmower in his garage and they found him by the door trying to get fresh air, unfortunately it was too late. I like the video, but maybe a little disclaimer warning people to have proper ventilation when running an engine in a confined space. On a separate note, could you have reused the wheel hub that you removed to cut down to the spacers that you needed? It seemed like a good potential reuse, especially if you had no option on hand. My favorite part of the video was the carburetor teardown. I especially like the use of the tea ball for the small parts in the ultrasonic cleaner. I also loved the "form a funnel," I have not seen that before, I usually just use aluminum foil to make custom funnels, but I really like that product. Another great pointer was when you explained the difference between the types of fuel filters, i.e. paper vs. screen, as it relates to pumped fuel vs. gravity fed. This is a big help in troubleshooting if someone makes the mistake of using the wrong filter. Great video for anyone looking to work on a small engine system. Thanks for sharing.
Jim, I recently bought a similar battery to the one you took off this generator. I bought a Peak brand battery charger that is called a "Teligent" type that is a smart charger. It can refurbish a battery under certain conditions, and while this or other chargers is a low amperage type, it doesn't cook a battery.
The usual problem with small lead acid batteries in a genset is that they are flattened by repeated fail to start cycles, then just left flat til they cannot be recharged. Also there is no knowing how clever the on board charger is while the generator is running.
@@seymourpro6097 the cycling of the battery is always a problem. I wouldn't use the charge while the generator is running as the charge voltage most likely would be perceived as battery charge, and the battery would probably just be dead. The refurbishing is not always a guarantee. For me, so far I've not had the need for a battery to be refurbished yet.
Desulfation is worth a try before discarding the battery. But that one sure seemed to be too far gone.
Nice work on all the issues, including that spark plug. Sometimes all you have to do is fix what the person who went before you tried to fix.
I want to thank you for many hours of entertainment.Merry Christmas from my family to yours
Great video as always... I like the way you go into detail and, as someone else commented, how you actually take the time to show us your fix, etc... thanks again.
Well done. I never remember to check the spark arrester. Great video as always.
hi, James. Happy Holidays. I hope you and your family are happy and healthy. Thanks for another smart video.
And now I know a little bit more about my generator! Thanks for sharing!
Another great vid Jim! For grips I always use lighter fluid. It’s something we’ve used on golf club grips for years!
Good to know. Thanks Ken,
Agreed. Rubbing alcohol works well too.
Nice work James. I never understand how people that don't do small engine repair can screw up expensive machines so much. Can you check the choke plate screws, they looked loose, but may have been a reflection that I was seeing. Thanks for a great video.
Jim, that threaded cap is different from the one for my generator. On mine, I opted for a used gas tank, which, is from a Harbor Freight, and a larger capacity. It's as close as I could find for a direct replacement.
What was left of the old wheels has what are likely good bearings, which can be removed with a hammer and screwdriver.
im glad you are using your airlift makes working on these machines much easier and saves your back!
On my Honda EU 20 I fitted an hour meter that picks up off the high tension lead. No wiring needed. The simplest way to clean that spark arrestor in future is to hit it with a propane torch until the mesh is red hot. That burns off the carbon without even removing it. Cheers Stuart 🇦🇺
Merry Christmas Jim. To fix the dented rail I would fashion a small 1/4" plate top and bottom and squeeze the rail between them with a nut and bolt - essentially using the plates as large, strong flat washers.
I just had a generac RS550 I got off of Facebook Marketplace with the same symptoms - initially thought it was the low oil switch (no light) but I also heard the hiss and it turns out the entire exhaust was packed with Georgia clay- a little creative augering to get it out and Bob’s your uncle! She runs like new
really enjoy watching your repairs have learned alot from you and appreciate it
Thanks 👍
Nearly forgot. Happy Christmas James to you and your family. Take care and best regards.
You too, thanks
I was hanging for my fix so I started a 1 year old video, then you released this. Now I have 2 hours of Condon to catch up on. Which is totally fine.
Happy holidays to you and yours.
Thanks, you too
Nice! I was wondering when/if you’d come back to weak spark. Lol.
Well done! Amazing how much carbon was in that arrestor/muffler.
I just bought a Gentron like this. Having issues with it right after getting it home. Quit running after 2 minutes. Oil was so dirty wasn't letting the sensor work correctly. Change oil. Started to adjust the valves and the valve guide plate was missing the plastic/rubber guides. Had been gone so long that the intake had almost rubbed thru the plate. The valves were out of adjustment really bad. Replaced the plate and adjusted the valves. The engine was running hot. In checking the cooling fan was in pieces in the shroud, replaced that also. So now it will run and make power. My concern is the compression is on 58 hot/38 cold. I'm not sure if I am up to going farther. Your video's have helped so much already, was glad to find this one on the same unit that I have. Thanks
Spark, arrester‘s are nothing but trouble. 😊 I would leave it out or clean it when possible nothing less.
thankyou James for showing the things in detail I repair small for the last 40 years and your never to old to add to what you know already 😉
You could cut the old wheel "hub" to make spacers, the size you want ;)
Old trick from BMX days when I used to ride freestyle bikes and want to get a grip on the handlebars so it’ll stay on and it won’t come off hairspray they go on so easily and when they dry, they never want to come off. I usually have to take a razor blade to cut them off. And spark arrester’s I do everything I can to remove them as soon as I find one absolute garbage always a headache always a problem just get rid of them and no more problems.
thank you James, the lift looks like a back saver!
Sometime run a generator to rated capacity and then beyond to see if the circuit breakers work. Great entertaining and learning videos James.
Take care of that back, do your therapy! God bless you. Thanks for your good work.
Excellent, as always. Thanx. I might have done the spark arrestor just a bit differently. I would have cut the new screen maybe 3/8" long and folded it back over the exhaust tube, then inserted the end cap. That would prevent the screen from ever falling into the muffler.
That would have worked better.
A suggestion, put the rubber hand grip on before you mount it to the frame. That way you can use a mallet to get it on the handle.
Also I would have used some talc power to make it go on smoothly.
Really enjoyed this one but I am curious why you didn't check valve clearances on this engine of unknown hours.
Another excellent video and great deal getting get the generator back up and running. James you should add a cable tie gun too your inventory of shop tools, I use one in the electronics field and they work great for dressing up cable harnesses, you can adjust the tension and they make a nice clean cut on the cable (zip) tie. Love watching and learning from your videos. 👍
I recently got one. Its in the tools category in my store. I love it. Unfortunately so do my kids. Its always missing from my toolbox.
you should point out the three ports just inside the carb by the choke plate; idle, mid speed and high speed. you have to bend a wire at 90 deg to reach in. also check the fuel shut of sol. with 12v
Good stuff James - I have never seen a clogged arrestor on a four-stroke before. You get the good ones 🙂 Thanks for sharing this.
HF has it to on there generators and 02 sensor also
It’s all fun and games until you put it in the wrong hole.
Great job James!
Bob Ross of Generator repair! HAHA! That's a compliment I know. I see the similarities. You just had to see the running generator in there it's hiding! I loved Bob Ross.
I watched him all the time back in the day. Maybe a little rubbed off. "Talent is a pursued interest. Anything that you’re willing to practice, you can do." “There are no mistakes, just happy accidents.”
Learned things about my older 8hp 4000 watt generator
Hi James, hair spray is great to get those grips on.? gets sticky when dry.?
Merry Christmas from Derrick Congdon 😎
Thanks for another great video. Hope you're back gets better soon.
I'm wondering if the clogged spark arrestor caused the engine to backfire at some point, and the impact of the exhaust gasses during the backfire caused the damage to the spark arrestor?
Great job James! I would run a 50% or greater load for an hour to really heat up the engine/muffler in an effort to burn off all that carbon. Guy probably was running at half choke most of the time. Other instances the improper high altitude jet is installed but thats rare.
Absolutely! Most folks don't stretch their machines legs like they should and they seldom get put under a heavy enough load for an extended period of time.
@@giggiddy exactly a buildup of carbon in a gasoline engine is the equivalent to wet stacking in a diesel engine. Run them with a heavy load for at least an hour and you'll see that exhaust clear up very quickly
I was thinking the same.
Nice work! I replaced the small paper gas filter, and it fixed my DeWalt 7000. Sincere thanks!
Well James, if you hear a chirping while you're working on the genny or another engine, I saw a cricket run under your bench behind you while you were mounting the first wheel spacer. LOL
Hi James, great detail and content again. You are always patient with the work you do. Merry Christmas to you and your family - from New Zealand
Merry Christmas Jim! You might try a Old School Carbon Removal Method. Remove the spark arrestor. and air filter. With the engine running squirt water down the throat of the carburetor from a spray bottle. The water will flash to steam in the combustion cylinder and clean out much of the soot and carbon. Best of Luck.......................
Use fine windows screen and then spray bottle is what I do
Seen my mechanic Dad do it a thousand times
The exhaust is typically not considered as the culprit if one has a non-starter, because it hardly ever gives you trouble. I am an experienced automotive engineer, and I once struggled a whole saturday with a stupid 50cc 2-stroke moped which would not start, although it had spark, compression, fresh fuel amd whatnot. After hours I glimpsed into the exhaus tailpipe (10mm diameter) and saw "something", which turned out to be soft when I was poking it with a screwdriver. It was the cocoon of an insect. After it had been easily removed, the motor started upon the first kick. Lesson learned. If you have someone who deserves it, spray construction foam into the exhaust tailpipe of his car. He and his repair shop will have a lot of fun.
Great again. You're ready for NASCAR with the wheel changes! Man you do an awesome job fixing and explaining.
Another great video James, liquid dish soap works great for hand grips .
Happy Holidays.
First time I’ve ever seen a spark arrestor cause such a problem. Good video and the spark plug gap whether they did not know or did not check it
Great post. I have a running 5kW diesel unit with no power output in my in tray, but it will prolly have to wait to fix due to impending house move. We're looking at blackouts coming in the deep UK winter due to continued complacency & foolishness over certain 'belief systems' of the government here, so maybe I'm doing ok here with my 2KW backup petrol unit I acquired as an unwanted return from Screwfix at discount. However, I'm still puzzled why manufacturers can't design effective mufflers for these units when they seem to have done so on cars, it's one of the most off putting features of these crucial bits of kit. Your dedication is commendable.
I live in UK too Ruth. Living in a fairly populous area means we do not get many power cuts. I have never owned a generator for myself because it never seemed like a good investment. I repaired loads of them when I was still of working age. I am just hopeful that we will not get these winter power cuts that people are talking of. My back up plan consists of a calor gas bottle heater, an oil lamp and lots of candles. Gas, or petrol as we say, generators are just too noisy. If I am forced into it I would buy a battery powered inverter generator with a good set of batteries and a good charger for when we do have power.
Again, learning even on the engine side!! I would not have caught the plug! Spark arrestor, In some locals I am sure they are highly recommended. But your solution looks even better than original, so good call there. Coming in after others worked on these generators is hard on your brain trying to figure out what they were thinking to get it into the condition you found...
You too? I hurt mine carrying 24 30Kg 2V cells out to my car to take to the recyclers. Car was about 40M away, can't get it closer, I was praying really hard on the last one, spent the past 2 days licking my wounds so to speak, take care James, merry Christmas to you and yours.
Awesome video. At the end the dog was trying to tell ya.
Excellent video and deduction skills. Your Dad certainly taught you well. Have a great Christmas and all the best to you and your family for 2023. 🎅
The blown out rail might be fixed by putting the biggest bolt you can through the hole and 2 thick washers, one on each side and then use the bolt and nut to squeeze the blown out hole in the rail. It might work. You have great videos and I am a car mechanic, so watching you work is very interesting to me. But I'm retired now,,,,,,,,,,,,,,,,,