Honda EX1000 - Running Wide Open / No Speed Control

A subscriber reached out asking me to take a look at his Honda EX1000 generator. It runs and makes power but the engine just idles and bogs under load. Someone added an extra spring to keep the throttle plate in the idle position. When the extra spring is removed the engine runs wide open. It the governor damaged? Easy fix or engine tear down? Lets find out.
Generator Model: EX1000
Governor Spring: 16561-ZC0-000
Lock Pin: 94251-08000
Washer: 94101-05000
Pilot Light Bulb: 34902-202-000 amzn.to/3wGHkhF
I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors.
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#HondaPower #GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
Alternator, Bent Governor Rod, Bogs Under Load, Damaged Governor Rod, Engine Speed, Fixed, Generator, Governor Linkage Binding, Governor Reset, Governor Spring, Governor, Hertz, How To, How-To, Load Test, Pilot Light, RPM, Repair, Running Fast, Set Engine Speed, Small Engine, Tachometer, Troubleshooting, Wide Open, Z Bender

[@FarmCraft101]

Excellent demonstration/explanation of the governor function. Nice work, Jim.

[@jcondon1]

Thanks Jon. I enjoyed your saw video yesterday. Great job with that tank. Looking forward to the third saw repair. I have 3 Stihl saws in line for repair. Need to get going on them. Quite a contrast between the John Deere engine rebuild and the small engine work. Love it all.

[@thijs3514]

Agree👍

[@Barracuda48082]

During governor calibration, try a sponge wedged in there to hold arm, throttle open..

[@Barracuda48082]

Piano wires..have some spring tension but is quite manageable if annealed with a propane torch to a dull orange and air cool before bending, trimming. Great informative video James, thank you.

[@haugstule]

bicycle rims have lots of carburetor rods. they are often hardened, so heat them glowing red once and they likely won't snap when you bend them.

[@RossReedstrom]

Ah, you mean the spokes! Yeah the center part of double-butted 15/16 gauge spoke should be about 1.5 mm

[@haugstule]

@@RossReedstrom if you've ever seen a bicycle rim without spokes then you got too much money to spend on lonesome hobbies. ps: buuuuu imperial measurments, they suck.

[@goodness-mercy]

Brilliant!!!! A pleasure to watch a Master Detective.

[@buckchase1]

I am a James Condon subscriber. I just had an amazing victory on a Honda eg2200 generator. Cleaned the carb, but rpms were out of control Recalibrated the gov and BAM! proper idle. I give JC all the credit. Thanks, James.

[@jcondon1]

Good stuff

[@derf_the_mule1405]

Those small spring clips are available in hobby shops. They are used in RC cars and planes regularly.

[@jcondon1]

You are right! Could have borrowed one from my sons RC car

[@Conservator.]

I very much like the: “Hey guys, welcome back. Today we’re going to work on this …” Gives me the feeling I’m doing some work too! 🤣

[@danielparsons3995]

His two theme sayings: "Hey guys welcome back" and "I hope this video helps someone, thanks for watching". And he always has that calming voice while saying it just is awesome.👌

[@Conservator.]

@@danielparsons3995 I couldn’t agree more! 😉

[@johncourtneidge]

Learing and cheering on are both work. Enjoyable work, eh!?

[@williamfoote2888]

@@danielparsons3995I wait for the dog’s bark and the chuckle at the end…

[@manofharmonizingstrings]

That's what I love as well about these videos, making you FEEL like your there with him as he works on anything he finds! don't see that with some channel's these day's, it really is enjoyable :)

[@magilla9792]

Hey James, another high quality video. Your explanation of how the governor works was very understandable. I look forward to every Thursday for another relaxing video.

[@T.McGarry]

My mom and dad's closet has a historical progression of coat hangers, from wood to wire to plastic. The ones used by dry cleaners, with the cardboard tube on the bottom, have the right size wire.

[@mylesschlicher965]

Great video. Needle nose pliers might be helpful to help bend & tweak the throttle linkage.

[@brianallen9810]

I love anything made by Honda, I like that air filter. Great troubleshooting finding that missing pin, I never would have caught that.

[@gerryj8839]

James is my small engine spirit animal!

[@jamesfitzgerald2361]

Nice work James .Attention to detail makes the difference sometimes.

[@billyscott922]

Absolutely love your content….in depth repair ….

[@rodneymiddleton9624]

Another awesome repair!!! Thanks Jim!!

[@gregb76]

Great job James.

[@paulravitsky2898]

Me thinks the binding was a combination of the ill formed governor rod and the missing washer/clip on the governor shaft. When the governor shaft/arm was "pushed" in the rod hit the head causing the binding.Good work on the "replacement" governor rod. Bill would need to get his new rod as close as possible to your sample and then would recalibrate his governor as you showed. Another great video!

[@tiredoldmechanic1791]

My observation has been that the flat on the governor shaft usually lines up with the slot on the arm. They have to have some indicator to assemble them because they didn't appear to ever have been run when purchased new.

[@Joserocha-wm9de]

I love your videos , very detailed and very well explained and the best of all is they're long videos 👌

[@papawheelie5835]

Great video as always, James. That said, I'm guessing that the steel rod-stock you need to affect the duplication of the governor connecting rod might be found easily in the surplus door of just about any Honda Civic.

[@johnmolnar2957]

You found a good reason to keep some junk governor rods... and probably never have a use for them. LOL. You could make the rod a tad longer & give it a twist in the mid section to shorten it to length . thanks for sharing!

[@MrTonyPiscatelle]

I saw you pour that carb cleaner in the floor, How dare you ! in my best Greta voice.....LOL Good work James

[@cliff56b]

That was nice of you to make an obsolete part for a subscriber

[@williamfoote2888]

At 34 minutes, with 36 minutes to go, I was sure the governor shaft was going to fall into the engine. When I work on something like this, ‘going haywire’ is likely outcome. Smooth. For a generator sent in that’s in a bad way, it’s a real testament to ‘somebody’s been here before’ syndrome. A reversed spring, a twisted linkage, a missing washer and clevis pin. Should all generators be this, in the end, so simple.

[@larrykelly2838]

Great diagnostic video Doc.

[@adnacraigo6590]

You are the master blaster.

[@raywood8187]

Thank you guvnah! I learned something.

[@YukonHawk1]

'Zee' best video yet. Thank you professor James😅😅😅😅

[@clutchSA]

Great video as usual. Its a shame that they have degraded the quality of the mini bulb they are using. American bulbs like that used to last 20+ years before they burned out. But what can we do.

[@novaln]

very detailed. excellent vid. fixed my issue, learned more. thanks

[@anthonymarino4260]

THANKS FOR THE EDUCATION LEARNED A LOT

[@moseskioko1299]

Beautiful work Indeeed

[@Supertech-86]

I gotta say it was a bit excruciating watching you fumble trough wire bending bit, dang Canucks, lol

[@angusshapland2273]

Another substitute may be made from the “piano wire” inner from a rigid throttle control cable.

[@21gioni]

Because the rod you’re using to make the new governor rod is of a small diameter it needs to be slightly shorter and bent over ninety degrees to function properly.

[@liljoeii6091]

THANK YOU FOR THE VIDEO

[@MrJmattr3]

Another great video! Thanks

[@JC-li2xo]

James, I don’t know if this is just the audio, but I seem to hear a chirp that sounds to me like a leaky valve. At one point when the engine was winding down it even puffed out of the intake as it stopped. Just curious if you noticed that and thought about checking the valve clearances off-line. Enjoyed the video, Thx J

[@tmwinegar]

I use copper wire for missing throttle rods. 14 gauge or 12 gauge depending on my needs

[@brianmontgomery8268]

First, thanks for the videos. Second, what are you using to read the rpm’s? I have a generator that someone had thrown out and it is running and producing power but it needs to be set correctly.

[@Runco990]

"User inflicted problems" I wonder what made someone tinker around with that in the first place??? Looking at the THD at the end makes me glad I got an Inverter Generator. Today's stuff just does not like that amount of noise. 😬

[@northidahodreaming5657]

well done...many thanks

[@alext8828]

Here in NY, we have issues with the governor too.

[@T.McGarry]

Horse Tooth Hochul....

[@PaulHigginbothamSr]

James did NOT PUT A LITTLE OIL ON THIS FOAM FILTER. His abundance will raise the richness level two points on the needle valve. May be enough for these new lean burn engines however.

[@philliphall5198]

Only wish you would have more videos for us to watch 😊

[@patricklucki5368]

Tig wire works great

[@Roy_Tellason]

I have to wonder how that governor rod got bent, what they were thinking when they added that extra spring, and where that clip and washer went...

[@richardharmon4112]

i seem to remember music wire being an acceptable material to make governor linkages,

[@jimdavis6833]

I just measured 3 of my coat hangers, and all 3 measured 2.39 MM. You got one fat one.

[@2010stoof]

I have one I'd like to send you but I'm sure you're swamped. It's a dual fuel ai power 2700/2200 dual fuel inverter gen. Got it almost 2 years ago. I bought 2. Both ran great. Then all of a sudden #2 needs chock to run. If it wasn't for all the electronic stuff on the carb and the dual fuel stuff it would be easy to fix. They sent me a full carb kit but I'm sure there's a way to just fix it. Only ever ran ethanol free gas so I don't know how there could be an issue. Yes I could just put the new carb on but I'd like to know what went wrong. Honestly I'm thinking I need to check valve timing. Sounds "snappy" if that makes sense when I have the side cover off. It's a Chinese built generator and I'm in warranty for parts so they sent the carb with no issues but makes me think something else going on. It's only got 11 hours. All from my break in. .5 on break in oil, 5 hours on dino oil, changed to synthetic at 10. Replaced China plug with NGK at first oil change. Always had a bit of a "blip" (both of them) during break in when running. Like stiffled misfire. Not sure if was a backfire. #2 got worse and worse. But #1 became fine. #2 went bad fast. I can still run great at 1/4 or so choke They said when I sent video "it's the carb" with nothing about fixing. Just sent a carb lol. Lots of disassembly to get that done. Maybe should have just got Honda. I'm sad. I was so happy with both of them.

[@merrillquintrell8133]

Hi Jim, Just curious, how come you don’t show torque values anymore on the screen when tightening fasteners? Thank, Merrill

[@Conservator.]

0:45 The governor has no control over the engine speed. That should be an easy fix but the considering the video is 1:11 it’s probably not that simple.

[@bradfader691]

Im surprised they dont push a hash mark on the governor shaft

[@74quo]

Hi James,I have this generator. Do you have a part number for the signal bulb? I'm in the uk. Many thanks. 👍

[@hmedwards3]

James, where did you get the blue carburetor screwdrivers?

[@JustAnAverageBrad]

careful with that choke slide plastic piece...if i remember right they are unobtainium ....that old honda is in excellent shape ...ive had a few ex650 that are very similar but never came across a decent priced ex1000 yet

[@marionboucher3155]

good job

[@tarstarkusz]

He shouldn't have any problem finding a closer match with welding rod.

[@davidcraven277]

Bicycle spokes mite be the correct size for the rod ?

[@tomservice1404]

Thankyou

[@johns.4708]

Helping his subscribers just for the sake of helping and demonstration... James Condon is a class act.

[@donprater2754]

Great job James.

[@Justicesdad]

Hour and 11 minutes with jimmy oh ok..

[@Justicesdad]

Good stuff Kevin also thank you for the gift to us all

[@glennschlorf1285]

Nothing wrong with that well spent time

[@russ9740]

These are so relaxing to watch and listen to. Calm voice. Gives Bob Ross vibes.

[@Runco990]

Today, we are going to fix a beautiful little Generator.... 😄 Yeah, James is easy listening while he works.

[@haneyoakie14]

We want happy generators. Happy generators. If you want sad things, watch the news.

[@grahameida7163]

invest into some stock of piano wire, always handy ;-)

[@brianwood5220]

Fantastic, James. Another one ready for sale. Your storage unit must be getting full? Thanks for sharing with us.

[@KaldekBoch]

Right on time.

[@johnnybgoode6466]

Hi James , these Honda's are beautifully engineered. I have used bike spokes and welding wire ( in the metre lengths ) to make linkages - the welding wire rods were better than the spokes. Just on another matter check out the rugby league being played in Las Vegas this weekend - something a bit different to grid iron. Hello again from New Zealand.

[@robinbeckford]

Paper clips are easy to bend templates / patterns with. Vibration will cause their metal to quickly weaken in use, though.

[@phatmhan69]

James, Ive been following your channel for a few months now. great work! you may get asked this a lot, but i have failed to find the question in other video comments. from YOUR experience, what brands of portable generators do you find most reliable. and would fair well with running home appliances. keep up the good work!

[@jcondon1]

Gen-pro and Honda

[@EvaderGuy]

Master class! What an education! Thank you very much for the time, effort and expertise you put onto your videos.

[@Amy_McFarland]

I truly love your mindset when working on machines. You dig into it to find the true cause of an issue!

[@stephenhaslam680]

Another educational video from James. More detailed discussion on how things actually work and some parts fabrication for those of us who get bitten by the obsolete parts scenario. Don't need to be scrapping a working machine because of an unavailable part. Another good one James.

[@loucinci3922]

Enjoyed the video. Thanks for sharing

[@rodh2168]

Instead of just a video of watching a guy fix something your videos are, as planned I'm sure, very well done with the goal of being instructional. Over the years I feel I've gained so much from your tutorials that there should be some sort of certificate. I love to hear the purr of those little Hondas.

[@billgeorge7804]

James, Amazon has a selection of wire gauges in stock that are quite reasonably priced. Sizes run from 0.9mm through to 1.8mm. It might be worthwhile getting one or two for just jobs like this. Great video as always.

[@PaulMack1249]

Jim, you may want to consider installing a dropping resistor in series with the hot leg of the pilot light, especially if this is a common problem. With a device that produces variable voltages and has no regulation it might be worth it to sacrifice some bulb brightness for longevity. Love the paper clip solution. We’re going to start calling you MacGyver. 😂

[@jimmyupson1959]

Thanks Jim for another excellent video. Concerning THD, have you tried cleaning up the THD with a voltage converter. I bought a Vevor 3000 watt and it certainly cleaned up the THD on my 5500 W Generator with a capacitor. I tried the capacitor by itself, but didn't see a significant change until I added the voltage converter on the 120 V in and 120 V out setting. It works just like coil choke holding the voltage steady. Just like in our old steel mill drives.

[@jcondon1]

Have not tried that, but sending through a large transformer like that should help clean it up.

[@DYLANTRIES]

Dude jim bud... You are a freaking genius!!! To notice a tiny little clip behind a governer arm!? Who notices that kinda stuff!?

[@georgemartinezjr]

Good point

[@Conservator.]

Note that this generator has started on the first pull every time! 👌

[@PeterDurrant]

Great video as usual Jim. Regards from the UK. I tried to leave a link as I found the part no problem but it seems I can't. The part No. is Honda 16555ZG0000 ROD, GOVERNOR Part#: 16555ZG0000 This is available at Jacks Small Engines. Hope that saves some time. 👍

[@rbedwar12]

Nice looking honda

[@DanKoning777]

James I'd love to see how many volts are generated as your "views/thumbs up" numbers rapidly roll over while I'm watching one of your new videos. Based on the comments here and in past videos, I'd say you could steadily power your house with a THD level of about 3.7% 😂 You never disappoint. God bless.

[@randykeech3557]

Old throttle cable works good to make governor linkage too

[@stephenvale2624]

FYI - 1.4mm is one of the standard sizes of TIG welding rod. Probably too late for this project, but you could check around and see if you could find a welding shop and bribe them out of an aluminum, steel, or stainless piece for future needs. They cost only a few pennies each, and they would probably just give you some.

[@MikeMcAuliffe-g2f]

Mighty nice of you to make that rod for Bill.

[@eikaiwajapan]

I had a Rupp mini bike back in ‘78. I always hated the governor and I always wondered why in Birmingham, they love the governor.

[@haneyoakie14]

Boo! Boo! Boo!

[@eikaiwajapan]

@@haneyoakie14 lol 😝

[@JohnSmith-yv6eq]

Governor stops young people from blowing up their Mini bike by over revving it... Still as you can see.. a length of wire on the governor arm, give it a pull... what governor limiter?

[@eikaiwajapan]

John Smith was the Proprietary Governor of Virginia 1608-1609 but was limited by a lack of arms. @@JohnSmith-yv6eq

[@andrewwalsh531]

another masterclass in generator troubleshooting & repair!

[@ronsafreed2400]

im glad you explained the Gov,,and how it works,,,nice info....i was going to get one of these gens..but there so high in price,,i may still get a used one...not to hurt...great video James,,i learned something..

[@markyoung7470]

Instead of Painting a beautiful scene like Bob Ross, you are repairing a Generator with the same soothing voice as Bob Ross well done love your videos. Did you add the vent tube that was missing?

[@gumbykevbo]

If it turns out that the paperclip wire is too soft and fails, you can get musicwire at any hobby shop or hardwzare store that has a K&S rack. If it is a hobby shop they will also have Z-bend pliers to do a perfect job shaping the ends. As much of this work as you do it might be well worth the $10 or so never to have to wait for another rod...you can probably make one in less time than it would take to research the part number. Also, if you put a light Z bend in the middle of the rod then it gives you a way to fine tune the overall length.

[@DennisDeSautel-du8gq]

Hi James, I enjoy your channel just thought of an FYI, on that governor linkage by using the thicker one you could’ve ground the end down that fits in the hole

[@fiero32v]

Great video. One of my hobbies is rc cars and planes. For control linkages, we use music wire . It is hardened and available in many diameters. To make the Z bends, i have a set of Zbend pliers. Both are available at hobby stores onr sites reasonable price. Using the pliers allows you to measure rod leanth and marrk for accurate bends.

[@justinvanaulen2478]

This was a great overview Jim. I have several of these Honda EX1000's and they are GREAT machines, durable, quiet, efficient and still priced reasonable. Nice work! P.S. I see one of the covers for the EM650 in the background towards the end. Looking forward to that video!

[@jcondon1]

The EM650 was another sent in the mail. Working on it now.

[@garyruark9506]

I may have tried a silver wire coat hanger for that rod. I'm looking at one and It looks about the same thickness. Hey but the paperclip worked. See how it holds up to heat. Very interesting video.

[@TJK3173]

So I was just watching this video, I found a coat hanger that has a plastic coating and trimmed a small portion off of it and it measures 1.6mm. If I had the measurements for the throttle linkage I could make a couple of them for you and whom ever else may need one

[@arthurbiringer5676]

Great job! That rod being perfect could start a cottage industry, custom made rods. Price? To be determined!

[@dougjones9493]

23:34 that should fix the speed problem with the governor spring adjustment im sure the original screw would have worked because the rod being nent wouldn't push the throttle plate far enough. grind down the ends of the coat hanger to the correct size middle diameter shouldn't matter

[@sweetlou5902]

James i go to my local hobby shop and buy some various diameter music wire to fabricate rods. Modelers use them for RC control rods.

[@almclean4835]

Another great video James. You explain things very well👏👏

[@steze48]

The little aluminum nub stand on case has flared out from gov arm constantly rubbing on it from missing clip not allowing washer to slide up on the shaft.