Briggs Engine Rebuild - Another Chance at Life

This Briggs engine blew up after it ran out of oil. The engine had less then 50 hours of runtime from new. There is a little damage in the cylinder. I don't think it will cause an issue, but I guess we will find out.
Part 1: • Briggs Threw a Rod - N...
Part 2: • Briggs Threw a Rod - N...
Part 3: • Briggs Engine Rebuild ... (this video)
Engine Model: 210312-0159-E1 CODE: 090219YD
Connecting Rod: 694691
Crankcase Gasket: 694953
Head Gasket: 697690
Wrist Pin: 696581
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner www.harborfreight.com/1-gallo...
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Micrometer 2-3": amzn.to/3Belam4
Micrometer 3-4": amzn.to/3Bg0fPv
Plastigauge: amzn.to/41qA03E
Ring Compressor: amzn.to/3nKNt8L
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo #BriggsAndStratton #EngineRebuild #BlownEngine
10HP, 210000, 9HP, Alternator, Blown Engine, Bore Gauge, Briggs and Stratton, Briggs, Caliper, Conrod, Cutting Valves, End Gap, Engine Rebuild, Fixed, Generator, Hertz, Horizontal Shaft, How To,
How-To, Load Test, Micrometer, Muriatic Acid, No Oil, OHV, Out of Round, Plastigauge, Polish Journal, Rebuild, Repair, Small Engine, Spring Compressor, Threw a Rod, Timing Mark, Troubleshooting, Valve Lapping, Volts

[@brianwood5220]

I'm not a mechanic and I don't own an engine or a generator. But I can't stop watching your videos, James. They are so addictive. Thanks again for sharing.

[@emylrmm]

agreed!

[@vw4x4]

You guys better try someone else, he is not doing this job correctly or conventionally.

[@brianwood5220]

@@vw4x4 No, he's doing it the way that's always worked for him.

[@thebridge6967]

I am watching to fix but was thinking the same thing

[@lavina58]

Me too 😊👍🍀

[@teedee9903]

I am 76 years old James and even though I have been doing mechanic work since the 60's I still like to learn. You are an excellent teacher. Your voice is so calm and positive. I work in my shop everyday and hope I can for a few more years. Keep those video's coming.

[@robertcochran7103]

I hope all is well with you. I'm getting older myself and understand what you mean.

[@martinflanagan2506]

Great trick of using fine sandpaper and rope to polish the rod journal.

[@thepubliceye]

You know that chunk missing will never stop bugging you, good video though

[@HappilyHomicidalHooligan]

Yup! If that was my engine, I'd have CAREFULLY bored out the cylinder and done a 0.003" interference fit on a sleeve (using liquid nitrogen to shrink it down enough to slip in)... That way, I know the cylinder is now Perfectly round, proper diameter and full length... Still, his way works just fine too...I'm just WAY to CDO* to leave that missing chunk in the bottom of the cylinder bore... 😄😁😆😅😂🤣 *It's OCD but in the proper Alphabetical Order darn it!

[@jasonm6468]

I disagree. I think James will give purchaser a copy of this video, he will have disclosed it and won't give it another thought after that. It will be fine for the needs of the purchaser. Great video!

[@paulravitsky2898]

I was hoping he would show the piston travel before he put the side cover on. Oh well....

[@toofast8706]

I have massive OCD and if any of my engines have something broken on them like in this case then it’ll bother me

[@garygullikson6349]

You have a special talent for making "how to" videos. Great camera work, great description without being annoying or skipping over details or being in a hurry. Appreciate showing of detailed techniques.

[@williambennon7532]

I learn so much from your videos. Thank you for all the effort you put into producing them.

[@johncourtneidge]

Yes!

[@jaygee999]

You're always clear, concise and honest in your presentations ! -- Thanks !

[@Larry-kh7rw]

A Thursday morning treat!! Thanks much.

[@johncourtneidge]

Very good. I recall the comments to the effect that the piston skirt could cope with the damaged section. This was a master-class yet again, thank-you!

[@generessler6282]

Your conscientiousness is amazing. This episode reminded me of a great time with my father, rest is soul. He was a machinist, mechanic, and about four other trades at a high level. Your approach to things reminds me very much of his, except he was able to do things with the simplest tools imaginable. A point of pride for a depression era kid. We worked on an old lawnmower that someone had thrown away. This was over 50 years ago. Briggs and Stratton. Had been run hard. Many things to be fixed as you did here. CS journal was egg-shaped ~7 thou (he guessed; his only micrometer was at work; but even 12 year old me could see the wiggle). He did not want to spend money on it, so hand-worked the rod with a file until it "felt right." Put it back together. That thing cut an acre of grass every week of every spring and summer for four years before I ran it into a big rock and bent the crankshaft. Man was I in trouble 🙂.

[@MegaDirtyberty]

My grandfather was like that, my father tells me stories about what my grandfather would fix.

[@onthemudd1]

It's the best rebuild ever. The cord and sandpaper for crankshaft priceless. ❤

[@jsaurman]

26:15 "PTO" for those who don't know, stands for Power Take Off, which means the connection point for whatever the motor is driving. Devices like farm tractors have a PTO connection point so you can hook up a driveshaft to it for powering things on a trailer, like a mower deck. In this case the PTO connection is to the generator power head.

[@mrobi5797]

I ecourage you to continu your videos James. They are very educative which permitted me to do my own repair on small engines. Thanks for your knowledge.

[@TheSoundmanPete]

I've been working on small engines all my life. Your knowledge and videos are exceptional. As mentioned they are addictive and are fascinating to watch. Keep up the great work.

[@ericponta9771]

Ever seen the bolt that holds counterweights to rod and crank broken in 12.5 hp. Slight damage to case and counterweights.

[@butler386]

One of the best video's of rebuilding a small engine. Fantastic job and camera work. Thanks for the videos.

[@YukonHawk1]

Totally agree on the camera work. Outstanding!

[@dougs6460]

Most excellent step-by-step engine rebuild that I have watched, and mostly everyday tools. Absolutely the best use of a Phillips screwdriver ever!!! You make the job look so easy, that even I could do it. Who am I kidding? Thank you James

[@coryheckler2354]

James, I've worked on a number of engines, but I'll tell ya, you have it going on. I'm in the middle of ac724cc Briggs V Twin. Procedures are basically the same! Really good video my friend. Keep sharing, there are those who want to save dollars by DIY. Thanks again! I enjoyed the vid.

[@bertgrau3934]

Doing the valve job, reminds me of working on a Briggs 875, the valve guide had moved. I did a thorough job cleaning. Took it to a machine shop to have the guide fixed, and a valve job. I had a gentleman tell me that IF a machine shop does a valve job, it would ruin the head. I laughed at that. The engine never ran as good. Sometimes people have unusual ideas, that may or may not be correct. The machinest said there was no way lapping the valves on that head would have worked. (Most do) just not that piticular head. You do great work, easy to understand what and why. I always enjoy your videos. I have a 3500 Predator generator/ inverter. I checked the ohms on the outlets so I would have an idea of where it should be in case I ever need to check it. It was 0.019. I learned from you that's where it should be. I changed the oil at 10 hours and I try to use it once a month. It's just a year old. I'm pretty happy with it .

[@jcondon1]

Just note the inverter generator outlets connect to the inverter module and not the stator directly. Still good to have that measurement because it’s usually the inverter that eventually fails.

[@bertgrau3934]

@@jcondon1 Thank you sir.

[@christophermarshall5765]

Good fix. Runs great. Test will be under load. I don't think the piston will suffer.

[@prorityfeed3210]

This is great. Thanks for doing this. I'd like to see the unit put into use. Get it under a load for say 1/4 of it's expected lifetime, then pull it apart and inspect it to see how it does. We can all learn from this as to what can and can't be done.

[@jamesmcmanamy4704]

You could put a swiss watch back together with your skills. Another great job.

[@philliphall5198]

I was waiting for this video It’s a keeper for sure and will run great 👍

[@philliphall5198]

It’s fun to clean up a crank and save a lot of money plus build a good engine Most of the time if rod didn’t come apart it can be saved, might be at limit but will run for years

[@georgehelaine]

I work as diving tech and you have taught me so much! It will be great to give you back in return. Your voice is very soothing and calming and you work with meticulous care wonderful to watch!

[@williamalexander1743]

At 37:00 I would have tapped the end of the valve near the keepers with a plastic hammer. This would settle the position the keepers. If they were in the correct position (locked), that would show that they are locked in. This guy is very smart. He is someone who can teach you the correct way to repair things!

[@eostrike]

This video was pretty darn cool. Loved the rope trick. Thanks for the hard worm you out into making this video.

[@arthurbiringer5676]

Great video! And now I even know the E5 size for the carb studs! 70 inch pounds torque!

[@fourbyfourer]

Great job on the rebuild James. With your meticulous work I have no doubt that engine will last many, many hours. 👍👍

[@2OO_OK]

Great video! Potassium hydroxide or sodium hydroxide dissolve aluminum with no effect on iron.

[@r8118830]

Preparation is everything.

[@YukonHawk1]

Another award winning video from Dr. Generator. That engine is just as good as new!! Loved all the tips and tricks as you went along getting this bad boy back in shape. Awesome that is started on the first pull. Thank you for your weekly college lessons!!

[@davidplaster4576]

Good job James!! I am glad that you gave that engine another chance at life. About 90 percent of engines that blew a rod that I rebuilt for people had some sort of minor damage to the cylinder skirting, and the engines held up like nothing happened to it. I have never had a comeback or failure due to minor chunks taken out. I have had cracks in the skirting, and using a air Dremel, ground the crack out of skirt to remove the small crack. As far as pistons go, I have used pistons with scratches in the skirting far in excess of what I saw in the video. I used the wire wheel on the bench grinder to smooth them out, and have never had a comeback. Believe me, these small engines have a lot of tolerance for abuse. While I understand the guilt feeling to use possible substandard parts/components, what should be taken away is it's not the space shuttle, it's not flying to the moon. You would be amazed at what these engines can endure. So long as the piston rings are good, little piston slop in the cylinder, the valves are sealing, the carb is cleaned up, you got good spark, the valve gap is in spec and no slop, the engine is getting its lubrication, you will then have a good running engine. Unlike a multi-cylinder engine where every detail counts, single cylinder engines are tolerable to things not quite being 100%; you will know if something is off due to lack of power or failing to run good or at all. Some times you have to YOLO (You Only Live Once) it, I have saved many people a lot of money rebuilding their engines; where some shops would not touch it.

[@jcondon1]

Good to know. Because I just brought home two more storm responders both run out of oil and both needing an engine. So it looks like I will be putting it back in service.

[@davidplaster4576]

@@jcondon1 Wow, that is crazy!! I have never heard of a line of generators that have had this kind of failure. One note is that it is correct with the piston rings being 180 degrees apart during assembly on some engines, but also take into consideration that the rings will move as the engine runs and takes on hours. It's possible that is why Briggs did not include that spec in the manual, they probably figured it is pointless to do that, as they know the rings will move. Unless the piston has tiny pins to retain the rings in position, they will move. They move during the end travel when the rings are "unloaded" from the travel of the piston, they can slightly turn during opposite travel (my guess is due to the scratches of the hone) This is a good thing, as the wear will never be in the same exact spot over and over again. It becomes a problem if the rings are stuck on the piston, and can not move (due to overheating, and thick oil burn in the ring grooves) I would guess that with the engine being new, it was burning excess oil as the rings seat into the cylinder (or bad hone job from factory, I've seen that) Generators have it hard when new, as they typically run hours at a time, and nobody wants to shut it down to check oil level. I recommend people when buying a new one, to run them for a 24hr break in procedure, where the genset is not needed, so you can check the oil at 4-6hr periods. The other way is to check the oil when new at 4hr periods, until it has racked up 24hrs. It would be interesting to see if it is even remotely possible to add some kind of oil level sensor to these engines. I would take what you just did and repeat that process for the next ones. You did good as far as lightly honing the cylinder (use WD40 as oil when honing), checked clearances with the crankshaft, and other considerations when putting it back together.

[@williampugh6699]

I would have liked to have seen how much piston you could see from the chipped out cylinder.

[@martynbuzzing3327]

It's always a good watch. You detail every move very clearly. As a seasoned mechanic myself, I'm still learning. Thanks

[@PabloDiablo682]

People should really clean the heads thoroughly after lapping the valves. That lapping compound can really eat up the inside of your motor over time if any of it remains. Even a little bit. And or change the oil after warming it up once really well.

[@ron827]

Excellent work as usual. Muriatic acid is hydrochloric acid and needs plenty of ventilation when reacting with aluminum. Secure it well if your kids are allowed to mess around in your shop as it is some VERY nasty stuff. Your lapping method of the journal is pure genius. Removing the sharp points of the broken section of the cylinder wall was good thinking as they could be stress risers and cause cracks to form. The top two rings are compression rings and "should not" have much of an affect on oil consumption. The bottom ring is the oil ring and scrapes oil off the cylinder wall to prevent it from being burned.

[@appasahebpatil9139]

I enjoyed watching this video. The best technical video on any mechanical thing I have ever seen. Very informative with many good practices/methods and practical tricks of the trade. You also knew, mentioned and adhered to all technical specs on the engine components, installation/assembly. This video is head and shoulder above all other videos I have seen. It also reminded me of my brother who taught me about the valve grinding and cleaning and rebuilding a Bosch fuel pump on a diesel engine. Your commentary is very clear. I would give this video a five star rating. THANKS !

[@edmckinley1333]

Excellent and detailed video, thanks for taking the time to show us your rebuild, very educational and precise

[@ScottDube1]

Great video James, Thanks!

[@justinvanaulen2478]

Nice rebuild video Jim, these are a nice change of pace outside of the normal genset stuff. Looks like you saved another one from the scrap pile.

[@swallowinn4410]

Hello James I am glad to see that you took the time to repair the engine. I have repaired many with similar damage and they all worked well. 2 of about 10 🎉did e entirely fail again but only after many hours of heavy work.(I expect they were run low on oil again.) Most were snowblower use engines.Your investment in quality measuring equipment & tools is impressive, Micrometers and Bore guages are not inexpensive. Great video keep them coming.

[@emylrmm]

Superb work again James, and thanks for yet another high quality presentation.

[@hectorarroyo2285]

Great video Mr. James!!! I enjoy watching your videos and I learn a lot from your experience... thanks for your time!!! 😊😊😊😊😊

[@grahamlack3302]

Great video James as always, amazing view of honing from inside the crank case, never seen that before it has to be a first.

[@robertmorin6495]

Nice going James. I enjoyed watching it and your explanation of the ring clocking and the plastic cover function.

[@aerotro]

Good job James, yeah I think it makes a good bench test engine to test with until your happy it's not going to self destruct.

[@williambrandenburg1196]

Thank you for your very informative content! Love the way you showed every detail measuring the crank, cam, bore, valve lapping, and most importantly...... torqueing all the fasteners! Great Job and keep the videos coming!

[@andrewrussack8647]

Really appreciate your methodical measured approach. Also makes for relaxing viewing.

[@AW-Services]

Nice rebuild James. Sweet sounding engine and a big hello from your UK viewers 🇬🇧

[@woody95124]

Your defiantly top notch on all the work & details you do....Enjoy your vids

[@johndawson2122]

Thank you for a very interesting video. I like your detailed views of the progress and attention to cleanliness. Great!

[@anthonyhawkins3576]

You had me worried. You've said before that you have to remind yourself to fill with oil. Since we didn't see you fill it, I wondered if you had. Obviously you did, but you had me thinking 🙂

[@jcondon1]

Somehow missed adding that video clip into the final cut. But rest assured it was done. Just found the missing clip kzbin.info/www/bejne/pmfQl5SXftyHrs0

[@dennistennyson8856]

I liked your method of polishing the rod journal, it keeps it in round.

[@tonygriffiths2485]

That was terrific. The engine should last for years after that excellent work, thanks, very interesting. I have done that kind of work myself, but its always nice to see it done properly and skillfully :)

[@PeterDurrant]

Brilliant as usual. Thank you for an informative and meticulous procedure. -Cheers 👍

[@waynec3121]

Was wondering if this engine was going to make a comeback. Great video James

[@stevendufresne9994]

Thanks for the Great Video James always pickup new things!!👍👍

[@texascottonfarmer]

👌👌👍👍 Nice work James, as always. Thanks for the video.

[@WADS-rr9wy]

Great video. I’m learning about Small engines and doing repairs on lawn equipment. Vids like this really help my understanding of all the mechanical relationships within the engine. Great stuff thanks!

[@martyb3783]

I think that engine will run as well and as long as any new one. Great job. I learned allot!

[@somerandomguy3868]

It's looking pretty good, excellent video James

[@hubertwhitlock9968]

Carburetor cleaner works for getting that carbon out of the head

[@thepoopsoup]

Couple table spoons of gum out in the gas every now and then keeps carbon from happening.

[@shatnersufolanded7785]

Actually wd 40 or PB blaster a piece of Scotch Brite works better and is less harmful.

[@mjg263]

Great resurrection video, really enjoyed that! I don’t think that little missing piece is going to matter one bit; it’s not in a critical mechanical area, doesn’t have any structural function and doesn’t have any influence on the piston travel. Runs beautifully!

[@richardkimrey]

Most people will tell you it is too expensive to repair one. You just proved to me that it is feasible. Thanks.

[@jcondon1]

Definitely too expensive to pay a shop, but usually looks a lot better if you do the work.

[@josekuster803]

Amazing Work, Congratulations, here in Brazil we have almost no technical content about brigs engines....

[@johnnybgoode6466]

Another runner, well done yet again James. Great to see 112k subscribers - roll on 150k.... its increasing quite steadily now...

[@workaholic5318]

Run the engine for a time then use your borescope to inspect the wear. There is no need to disassemble unless you are going to mic the clearances after use. The borescope will show you the damaged cylinder area in the sump and will allow you to see the cylinder wear inside the area of piston travel through the spark plug hole.

[@bertgrau3934]

Maybe he wants to check for wear on the bottom of the piston, so he would need to remove the sump to check the piston. I'm sure it won't be a problem, just my opinion.

[@jcondon1]

Good point

[@markae0]

39:45 IMO when placing the rings on the piston, sure put them 180 degrees out, but when the engine runs, the rings will move to where they want to go. It is out of someones control where the gaps end up.

[@ricdenali4213]

I enjoy watching you work and the narration give the details. Nicely none.

[@jim96r]

Your content is so appealing and easy to watch. Thank you,😊

[@wildefox1478]

Great video, that engine runs and sounds great after rebuilding it despite that damage to the bottom of the cylinder, nice work James! Muriatic acid also works great to remove rust from metal gas tanks, I used it to remove the rust from inside the tank on my 1980 Honda XL500 dirt bike then sealed it with tank sealer.

[@totaljunk7508]

I enjoyed watching the whole rebuild and stayed to the end!

[@seansysig]

James after repair and with good maintenance practices that engine could run for 10+ years easily.

[@johnoconnor9331]

GREAT job

[@skynjaydensdaddy]

As thorough of a job as you did, it'll last. I bought a 2018 YZ250X June 11th 2018 and the bottom end went out November 11th 2018. I did a complete rebuild February 2019 and it is still going to this day, I've done a couple piston kits since the overhaul as preventative maintenance, but nothing more.

[@TopCat2021]

Great job on the rebuild; if you're not sure of the longevity of the engine in a critical application it can be adapted for use as a go cart engine for the children.

[@jcondon1]

It would be a fast go cart

[@stevetealey2804]

Great job james well done.

[@patrickthomas6170]

E torx also for water pump studs on Lexus timing belt job

[@AntonioClaudioMichael]

Definitely only time will tell if the piston will become damaged from the damaged skirt sleeve good video @James Condon

[@MrTonyPiscatelle]

Great job James

[@sgtbrown4273]

I'm so glad you fixed the little guy! 😊

[@patrickthomas6170]

I also use those E torx sockets on Toyota Rav valve cover gasket job for stud removal

[@gerardrusso9642]

great as usual high quality content

[@ramtek2702]

You're very competent & thorough. I don't see how you can make a living doing this.

[@KensSmallEngineRepair]

Another great save Jim. We need to plan a Day to get that Tecumseh going. Also, the Generac is still waiting for you here lol!

[@jcondon1]

Trying to find a time to grab the Generac. The Tecumseh is on the back burner for now. Too many projects in the works. Thinking July I can circle back on the Tecumseh.

[@jcondon1]

I actually was working on another gp7500 yesterday. Found the cam to be worn out. Very common problem.

[@ericvaughn1126]

Exceptional quality in terms of the video and audio and meticulous mechanical work which we've come to expect and always value, Jim. Hope it lasts and gets an additional long and useful life. I couldn't help but hear the voice of Todd from Project Farm say "We're gonna test that!" at the end when you were talking about more testing, presumably under load, and then further inspection for damage. Wish you were closer. I've got 2 more I'd donate to the channel that I don't have the time to mess with or the space to keep. Garage sale here tomorrow so maybe they will sell there. If not, maybe I'll reach out to Joey to see if he ever gets back up by you to visit.

[@thesilentonevictor]

Great work on this rebuild engine

[@waynebrundidge206]

I greatly enjoyed the rebuild of this engine I was curious when the engine originally failed if it was gonna be possible to rebuild it at the time you did not so I’m very glad to see that you rebuild this engine

[@jessiedaizx1611]

Am generator technician in kenya and am always inspired by the way you handles those machines ❤❤❤❤

[@DanKoning777]

The plastic piece at 59:15 should be addressed by Briggs engineering. There should be a means to adjust the amount of hot air it's able to contain via a sliding or adjustable opening-one position for hot weather and one for cold to allow the heat to either escape or stay circulating. Just a thought. Great content as always. God bless.

[@BenMitro]

Bravo!

[@michaelkennedy2528]

A follow up bore scope would be interesting, even after just this short run. If there is going to be piston/cylinder wall issues, they will or should already be showing I would think to the point where they can be seen with the scope

[@MrGaby47]

Love your video! Learning a lot watching!

[@dalitohana6979]

Great Informative Video. Thanks!!

[@annierenard5954]

very educational, thank you

[@thomasstewart9368]

Thanks - enjoyed watching 👍

[@stonebruze1499]

WOW.... U r so detailed n u work clean

[@matticus6339]

Great videos!! I just recently found your channel. Hate it took me so long, the positive is I got alot to watch to catch up.

[@loucinci3922]

Well done. Thanks for sharing

[@pc5569]

Great job 👍