No Power - Broken Rotor Wire Repair

[@gman3109]

I don't know if anyone has acknowledged or even noticed but I'd like to thank you for not putting ads in your videos

[@peterevenhuis2663]

@@gman3109 you can also pay for premium and don't have ads.

[@jcondon1]

Sometimes I do, but never on new releases.

[@kellyscut1761]

I don't notice because I have KZbin premium.

[@kinglangren]

I’ve never noticed.

[@erik_dk842]

It must be browser related, 'cause I never see any ads in any videos, and I'm not paying for Premium

[@robertmorin6495]

Textbook steps to isolate the engine and rotor problems. You're a very good technician. Enjoying these videos and learning a lot.

[@DanKoning777]

It's always good to see a new JC video. No clickbait, cussing, distracting background music, and the annoying AI voiceover-something that's becoming more/more prevalent. And I'll learn something knew just like today re: broken wire issue(s). Great content James-keep em' coming. 👍

[@johncourtneidge]

Yes!

[@jamesalbrecht395]

James, another nice save. The generators with metal fuel tanks always seem to be the weak point. I used to work in a specialty electric motor shop. The winding wire is always a challenge. I used to use, like you did, a sharp exacta knife to scratch up the varnish and the follow by using a fine plumbing sandpaper to get a good surface. Next time for a repair like this you may want to try using some copper winding wire, a little thicker than what was used for the armature winding. Remove the insulation from the middle of this wire and then install the “bracing” wire between the two winding posts. Then wrap and solder the two winding connections to the bracing wire. This should give you a good connection point that is both light and strong to avoid vibration. Finish this off with some high temperature motor varnish, if you have it. Cure the varnish with a heat gun. The motors I built were for applications that required much higher speeds. Adding more mass on one side of an armature would require having to rebalance the armature. 3600 rpm, should not be a problem. A 20,000+ rpm motor would have problems with too much added weight on one side of the armature, even a small mass. Great work! I always enjoy your videos.

[@jcondon1]

Thanks for the tips

[@Yanto-Kun-JP]

why steel fuel tank? not stainless nor plastic? it's a week point,　I think so too

[@jamesalbrecht395]

Steel because it is cheaper that stainless and plastic is probably not used as much because of the engine heat. Generators can run for long durations and possibly in not well cooled environments. Plastic tanks are likely to be more of a liability than steel tanks. It seems that generators with plastic tanks also have a metal shelf that separates the tank from the engine, adding to the cost of manufacturing.

[@johncourtneidge]

Excellent comment thank you. Your point about unbalance had occurred to me.

[@eclectictech]

​@@Yanto-Kun-JPanother consideration is that plastic tanks may not be compliant with evaporative emissions regulations without resorting to a multilayer tank construction, as I believe is the case for automotive tanks (although it's hard to discern the different layers since I believe they're integrally laminated/molded.

[@goofe.washington953]

These videos are always superior. Well worth watching.

[@dw7444]

Back about 30 years ago I was having trouble soldering very fine coated wires using standard fluxed solder so my grandfather walked out back, found a little dried pine resin and showed me how to use it as flux. It worked better than anything else I had tried and I still keep some on hand and use it on tough soldering jobs. You can use it dry but it's a lot easier to use as a liquid IMO. Just add some dried pine resin to just enough alcohol to dissolve it and apply where needed. It works great and costs a few cents at most to make... and it smells great!

[@glennstough7328]

Thanks great idea

[@jcmx0180]

Ok thanks. I’m in Ny and I trust your work. We can’t find good repair people like you.

[@jackkreighbaum783]

I echo other comments about your thoroughness and skill, and I appreciate you not dragging out every task for minutes of extra views.

[@rkins100]

I was telling my wife today how much I've learned from you and your videos. Thank you James.

[@iandennis7836]

Hi Jim, welcome back. Another "fix" for a Thursday evening (been working today), so I'm all set 😁. My favourite phrase...." let me get you set up a little bit better and get going on this".

[@maksimlasunin]

I’ve been watching your content for several years now, and I wanted to take a moment to let you know how much I truly enjoy your videos. I appreciate everything: your meticulous approach to every problem and your incredibly detailed explanations of every action. Thanks to your videos, I feel like I’ve already learned how to diagnose and repair hundreds of types of generators and other motor equipment. You’re doing an amazing job-thank you so much for that. Best wishes, A subscriber from Ukraine.

[@20havenfun08]

Could you have used hot glue? Just asking. Thanks for the videos:)

[@Eckat-y6r]

Just yesterday my friend and I repaired his generator, after watching your videos about methods for checking generator windings, we managed to find and eliminate two breaks in the stator winding, we messed around a little, but it works

[@thomasstewart9368]

That was a good one. Thanks James....I thought for sure you were gonna burn one up before our eyes. As always you found & fixed the smoking problem quickly. You're the best.

[@dapperdave2090]

excellent camera work for the close up photography... awesome narration skills... most impressive....

[@jcondon1]

Thanks

[@NETWizzJbirk]

Saw this yesterday… Truely impressed you found and repaired that broken wire. Superb work.

[@mitucaragea]

The enamel on the wires is very easy to remove by heating them with the soldering iron while touching with acetylsalicylic acid (simple aspirin). The smell is not nice, don't inhale the fumes, but the effect is great :)

[@YukonHawk1]

Wow....this one was an adventure. Excellent work none the less. Thanks for another first rate video.

[@trentofdestiny]

I was pleasantly surprised to see a video from you about this exact problem I had emailed you about in the summer! It's still sitting in pieces and I think it's time I tried to put it back together.😎

[@jcondon1]

You can only make it better. The exacto knife worked well for scraping the enamel off. Next time I would use a better fitting ferrule. The difficulty is most crimping tools do not fit in the small space. Some recommended using the JB weld that is meant for plastic and also putting some JB weld on the other side for balance.

[@trentofdestiny]

@@jcondon1 I seem to remember I had fixed it earlier in the year to the point that I had the correct resistance across the slip rings; however, I don't know how much current goes through the rotor or how much my repair could handle so I probably should resolder it again now.

[@fraydnot]

Great video as always! My Genrac tank was rusted up, I used 4 gallons of vinegar to clean it out removing the rust. My neighbor just fixed his generator using you technique. Thanks for the upload

[@stevetealey2804]

You got lucky with that one well done keep up the great work.

[@russnixon6020]

James, you can use a solvent like Brakleen to remove the enamel insulation from magnet wire and allow you to tin and solder copper plated aluminum wire. Also, a bit of copper or nickel anti-seize on the exhaust manifold studs and any steel bolts threaded into aluminum wull go a long way to ease maintenance,

[@d.shaffer2537]

What a repairman! NICE job!!! 🙂

[@baratono]

Nice fix! It blows me away that folks will drop $1k on a generator, but won't spring for a $10 tarp and a couple of bungee cords to keep it out of the weather...

[@benjamincresswell3713]

OK James, another fine video. Well thought out and well edited. I will share one of my peeves: The way manufacturers use push connectors to make assembly quicker is contrary to good long lasting continuity. I have many times soldered those connections since I have the time to unsolder them if I need to replace the part. I have talked with aged auto repair guys who have come up with remedies like Contact Cleaner to remove the corrosion and silicone grease to keep out the oxygen so the contact doesn't corrode again, all in an effort to improve upon the assembly line method. Because they are selling their work to the public they feel better about a cleaned and greased connection than soldering. I have seen push connectors get so bad on a vehicles that when driven over a railroad crossings, the vibration jiggled the main bulkhead connectors on the firewall loose and the engine stalled. So I have learned that assembly line techniques are not necessarily the best way to go for longevity and durability. It is a pet peeve though as I am not working on the Space Shuttle. ben/ michigan

[@maggotspawn6882]

I learn so much on this channel, the videos do help people!

[@blackhorse11thcav74]

Awesome, Perfect way to start my day. Thank you James.

[@RaymondSmith-h9r]

I really appreciate your taking the time to clean the carburetor with wire wheel and spray prior to soaking. This seems to make things cleaner than just the tank.

[@rickwhitescarver8526]

I appreciate your logical troubleshooting and taking us along for the ride step by step explaining your thought process along the way. Great quality videos

[@haint7709]

Awesome video. I always spray my electical connections on old units-its the elec tech in me🙂. Now you reassured how important those connections can be. If they supply info and then adjustments, its critical that they have a good mating!

[@robertcochran7103]

Thank you for posting this excellent video. I learned a couple of things from you this time, such as how to locate bolt holes on metal tubing. Thank you!

[@richardwalters1803]

Mr. C, glad to see you ve got a nice belt sander. Your building up a pretty nice assortment of shop machines. Great video and workmanship

[@jcmx0180]

I have the same one sitting in the back of my garage. I’m going to watch this video over and over. I also have a snow blower and it won’t start. I need to get that going before it all starts

[@JohnDeUlloa]

Always learning from you Jim. Keep up the great videos.

[@christophermarshall5765]

Good fix!! It worked out well in the end. You think like I do in a lot of ways. Putting the spacer bars between the fuel tank and the frame is exactly what I thought you would do.

[@JohnSmith-qi9qs]

Funny you let the BAD smoke out but kept the GOOD smoke in. Never seen that before!😮👍

[@Mr_Meowingtons]

lol just burning off the spider eggs

[@sammaze2103]

I am a retired Electrician. ! You did the best you could do with that connection! In the old days the wire was copper but aluminum is tough to repair! Hopefully that repair will last ? Good Luck !

[@bradwren9924]

Thank you very much James for your videos. Very educational. I love them. Keep up the good work every machine is different. Great job.

[@luissimmons654]

good day mr James as you may know i look for new videos each and everyday from you because i love watching and learning from them

[@Rein_Ciarfella]

He posts regularly on Thursdays.

[@billwhite4414]

You might consider turning the rotor 180 and placing a glob of jb weld on the other side for balance.

[@markeasterwood1187]

I was thinking the same. Centrifuges in the lab would not tolerate that much of an unbalanced load, I was expecting the worst when I saw that. I think what it had going for it was that it was so close to the center of axis.

[@philliphall5198]

Balance is very important and good ideal

[@DonnieThomas-m2y]

My favorite thing about Thursday’s a new video from James

[@KensSmallEngineRepair]

it's like Deja-Vu!!! I'm hoping to do the same repair this weekend and maybe head up next weekend for breakfast and testing!!

[@jcondon1]

I am hoping for some good suggestions in the comments on how to do it better.

[@KensSmallEngineRepair]

@@jcondon1 That expensive flux and solder for aluminum was not something I was planning on doing

[@Thib2003]

It would be great if you guys split the cost of the aluminum solder & flux for experimental repair work

[@gerardrusso9642]

one of the best channels on youtube

[@PilotMcbride]

G’day. Back in the early 70s part of my job was repairing small motors. My employing body was very fiscally tight. Sometimes it was cheaper for us to simply replace a single coil rewind the entire motor. To reconnect we would do similar to what you have done, but we would basically ‘whip’ the twisted ends with a very fine wire for mechanical strength then solder the joint. Cheap and nasty, but kept me in a job. Way too old these days to try it again 😂, whipping wire was taken from destranding old extension cord, about 0.002”. And for the record, the repair would cost more than a replacement 😂, but who were we to argue 😂 Hopefully this all made sense. Cheers and best of the season to you.

[@arthurbiringer5676]

Great resuscitation! Strange where the magic smoke came from.

[@mikechiodetti4482]

Thank you for this video. I have a 5000 Watt generator thats over 20 years old. I change the oil every year and check the air filter. It should have a fuel filter and I will install one. Never adjusted the valves. It still works great, but I will check them. I also have 2 other B&S OHV engines on other equipment that I'll check their valve adjustments and one Honda 2000 Watt Generator with an OHV engine that needs a valve adjustment check. Thank you for your tips and I think my Fluke Digital Multimeter has the Hertz setting on the control for testing. Gotta do that test to the two Generators.

[@ItsABoatThing]

Thanks for sharing this, very interesting, specially that it doesn't quite work.

[@deere3321]

I'm betting that connection will never go bad. Nice save.

[@terryscruggs5876]

New subscriber recently. Awesome to watch your work/troubleshooting and such attention to detail !!! Take care and stay safe !!! 😁🇺🇸😁🇺🇸

[@MrRmh3481]

Say what you want, this machine will make 2500-3000 volts for 25 years. Your an excellent tech James, my hat is off to you.

[@ДмитрийВелобос]

И Вам Джеймс здравствуйте из Сибири! Любовь к искусству объединяет людей, также как и любовь к технике 😊

[@patmadix172]

Excellent detective work

[@northidahodreaming5657]

amazing attention to detail....Thanks for this video....I use generators a lot, off grid charging solar batteries in window cloudy weather....I've learned a lot from you!

[@dmaverick2396]

First time I saw a wire repair. This was really a great vid….thanks for the excellent details.

[@jcondon1]

I usually do not bother, but hoping to find an easy way to do it that anyone can do.

[@andrewgrace4410]

Thanks James for another great troubleshooting video. Hopefully we will see that engine power a different generator 👍🏾🐶😸

[@rogercollins2653]

Whatever came out of that gas tank looks more like a stain or paint. Fuel not engaged I think the next part it's so cool how you measure and monitor what this machine is putting out as far as power and you can tell the person who is purchasing this is exactly what it does that's the cool part and I just want to thank you for all of your hard work and making this content for us seriously genuine thank you

[@johncourtneidge]

Very nice James, as always. Offering it now for sale on an open -ended warranty would seem fair.

[@CrimeVid]

I dunno I've never had much luck with plain solder and even clean aluminium, years ago we were taught to do it at school but it often failed, you don't seem to get a good bond between materials. In that circumstance I would normally take a single double screwed connection from a choc block and use that , both wires through in the same direction, epoxied or not. I like your giving stickums enough time to cure properly,that helps, more than most people seem to realise.

[@joelpauls9437]

I have always used CLR to clean my metal tanks. Works great and removes all rust and varnish

[@dmaverick2396]

The rotor wire repair was awesome!

[@davidbarr1579]

Thanks for the video James excellent work

[@fayiznalu8411]

Very nice work 👍

[@kerrygleeson4409]

Brilliant as always James thanks for sharing 🦘

[@Rorschach1024]

@James, I think I would have made two suggestions on the repair method. I would have used JB Plasi-weld instead of convetional JB Weld. Second, I would have slathered it also around the two staking posts that the wires were wrapped around to give the epoxy something to hold onto since nylon is famously difficult to get glue to stick to. Those posts are there to help hold the joint stable, might as well use them. Especially since you are adding more mass to the joint.

[@JDLarge]

The only way to know for sure is to go at it full bore and then you’ll KNOW if something is above your knowledge base or your “pay grade.” Never underestimate your abilities brother, you are definitely one of the best around and even if you doubt yourself you’d better believe we’re all cheering for you because you’ve got what it takes…PERIOD! Nice work troubleshooting and repairing that unit. If we could win them all then no one would be playing right?! Keep on keeping on, you the man!😉✌🏼

[@GGigabiteM]

An old stained glass guy told me if you cut the flux with muriatic acid (HCL), it will burn the oxide coating away long enough to solder the connection. It is a bit hazardous, but it usually works. The downside is that it's really hard on soldering iron tips, so you'll want a few tips that are expendable to do it with.

[@richardcook9738]

James, getting the rotor wire coating can be done with acetone. the acetone should just melt the wire coating off with say a Q-tip. Be carefully not to get acetone on the windings which will cause a short

[@rogercollins2653]

James I think this is a fairly new machine, thank you for the content thank you for all your hard work

[@davecasey1582]

Excellent video, I appreciate you sharing your knowledge!

[@mraaron12341]

Thanks for the video! Enjoyed this one as always. I envisioned you using those rubber anti-vibration mounts to raise the fuel tank up. Like those used to mount the engines on some gens. They come in various sizes. Looking forward to next weeks project already.

[@jcondon1]

That would have been easier, but worried about the weight of a full tank. Full support down the rail is safer.

[@mraaron12341]

@ you’re right. And potential side to side movement causing rubbing on the frame/ tank.

[@helmsajr]

Great job James has always. Love your videos.

[@notprovided2823]

Throughout the whole video I was imagining the original owner watching, thinking all potential kinds of thoughts. "Oh, I never looked at THAT as the problem!" "Shoot--I never knew the fuel gauge could leak all that water into my (formerly) nice generator--what a design flaw!" And more. By the end, the previous owner might have had a few different thoughts upon seeing it work well: 1. Well, It's OK I gave it away--I couldn't have found that broken wire in the stator, nor fixed it permanently. And I didn't have a spare carburetor for parts or complete replacement. Heck, I don't have the skills or space or tools to have done what James Condon did. Or 2. Shoot! If only I'd watched more of James' videos--I might have been able to find and correct most, or all, of these problems. I learned more about troubleshooting stator malfunction in this video. And it's always a pleasure to hear your calm voice of reason--you make my Thursdays good ones, James! Please keep up the great work.

[@markeasterwood1187]

Something tells me the previous owner was not a DIYer.

[@ernie7804]

I am a subscriber and enjoy your videos very much watching from Thailand

[@krg038]

Thanks for your video. I have used acetone on a Q tip to remove varnish from Wire

[@alext8828]

James! Excellent explanations.

[@stephenvale2624]

FYI. Evaporust, by design, leaves a thin film behind on the metal as a protective layer. But to avoid future fuel contamination, it is good practice to rinse well with plain water after draining the Evaporust from your tank. Your idea of using alcohol after to dry the tank is one I plan to adopt.

[@daviniusb6798]

Why are generators such a big business in your area? I'm 35 and have seen just one of those in action. I love your videos, it's like watching a thriller but without all the screaming and crying of modern tv

[@nsayer]

I’m a tiny bit surprised there wasn’t an effort to save the tank. After draining it looked to me better than some others that have been rehabilitated. Of course, that’s just me watching the video JC is the expert. Is it that this style of tank is just easier to come by so the effort isn’t worthwhile?

[@BruceBoschek]

Excellent repair, as always. Sometime, when you have a bad rotor or stator, try different solvents on the wire. Perhaps acetone or better isopropyl acetone ore even paint stripper will dissolve the varnish. I have made repairs on thin wire by wrapping with litze (the fine copper wire from stranded - flexible - wire) and then using flux and solder. Just some thoughts on this kind of repair. Thanks for the video.

[@najeebullah1155]

I always wait for james confon videos to be uploaded to watch it.

[@RiverratGoRVing]

James saw the smoke and said the magic smoke out loudly, and my wife says, "Where" and I said the video I was watching just bit the bust. Great save though it was done for.

[@faml13]

The smoke fixed the issues 😂. Just kidding best regards. Keep up the good work!!! Thanks for teaching us all 👍!!!

[@larrykelly2838]

Great fix

[@m9ovich785]

Thanks James. Like others have stated to put a glob of JB Weld on the other side for what little out of Balance it might effect..

[@robertmorrison886]

Great work 👍

[@danielparsons3995]

Another great video thanks jim!!! And i really enjoyed the live stream with you and ken! You give such great information and education on this stuff thanks for being able to help us learn this great stuff 💯❤️✌️

[@jcondon1]

Thanks

[@iposttube]

Great content! Thanks for all the info

[@AlfOfAllTrades]

Get a small, suitable batch of splice connectors and a suitable crimping plier for the wire repairs. Makes life easy (Well... easier.) I buy them from RS Components, they have multiple variations, one is stock. no 373-178 as an example. With regards to the "hack" repair... It's not a "hack" if it 1. works, 2. stays working and 3. keeps an otherwise perfectly functional piece of machinery out of the land fills. As far as I am concerned, this is now a fullworthy repair. Definitely worth a shot, and I wouldn't have a problem buying this machine if I needed one if the price was right.

[@jimyeske8498]

Hey James, Great video! In tight spaces, I sometimes use needle nose vise grips to do crimps. Also, perhaps you could have used the Dremel to clean the wires. Keep up the good work!

[@sreekumarUSA]

Thanks!

[@ericvaughn1126]

Very interesting fix and odd testing at rhe end. Glad the stator didn't get fried.

[@jrosa111]

Excellent job sir. I really love it.

[@justinmandoeng3238]

I find it a nice repair to the armature . My aluminum wire repair are usually like that. Dont really like working with aluminum wire for windings cause if you bent it too much it will break.

[@jonhodges5344]

I repaired a rotor on an identical GP5500 the same way only I used liquid electrical tape then epoxied it in place. I did not have confidence in the repair also so that unit stays in my inventory for my family to use when they need it. 😊

[@bunnylove273]

hey well done on the repair big thumb's up

[@TheDamowalshe]

This was a very interesting episode James.

[@TimHancock-h6e]

This is the part where I would stand up, and start clapping. We almost had a fire. And I've never seen one act the way this one did. It was very odd. And your right, i would not sell this to anyone.

[@jimw7916]

ridiculous perfectionism.

[@jimthesoundman8641]

A far cry from the average homeowner who tries to just half-ass every repair. James knows that his repairs will probably outlast him.

[@ANeigh-bor]

ive done this before, great idea on the epoxy to hold it in place!

[@sfrahm1]

That one certainly was a real adventure. That was the first time I've ever seen magic smoke appear and then see a fault clear. Corrosion on the sense leads would indeed explain it. I've bought some aluminum solder for some antenna projects with aluminium elements, no idea whether to trust it much or not at this point. I would have applied a bit of NoAlOx to aluminum wires in a crimp connector. Dust to dust when it comes to aluminum wiring.

[@Maurice1151]

Nice job mate 👍👍