Generator Backfiring and Won't Start - Fixed

[@barrygrant2907]

I noticed you gave the oil-fill cap a tweak with the pliers. Back in 2004 when hurricanes were slamming Florida, many residents used portable generators to fill in until power came back. A house up the street burned to the ground, the cause being traced to a loose oil cap that backed out and sprayed oil out and starting the generator on fire, and the house. The oil cap is something that needs to be checked for tightness!

[@bertruttan129]

I would ask why was the generator close enough to the house to catch it on fire? Ppl keep gens at least 20 ft away for proper exhaust ventilation.

[@marcheld]

I love how your specimens need to “earn” their oil changes.

[@aarongrabowski3775]

Yeah I laughed at that.

[@FPVForLife]

It's the right way, why waste fresh oil on an engine which is junk. You first find out what's wrong and what's not. Then you start spending money.

[@jesterr7133]

They all have to. There is nothing worse than putting $20 worth of oil in a blown up engine, lol.

[@YohanathanD]

Iv always made things that have been sitting around or brought back earn an oil change. Can't waste good oil

[@KensSmallEngineRepair]

On a woodruff key just tap on one end of the key and it will rotate out. Avoids damaging the key. Another great vid Jim!

[@jcondon1]

Good tip! Thanks Ken.

[@40arpent]

I had one stuck on the drive shaft on my boat for the impeller. Sprayed penetrating oil and kept working both ends back and forth until I was able to drive it out.

[@throttlebottle5906]

I'll add use brass rod or similar to not nick the crank when you hit it. ( yeah I said when, because you always will.) 🤣

[@marktomlinson6714]

I have the exact same unit. It was the first generator I ever bought. I got it new from Home Depot about 20 years ago the day before we were to have a major ice storm. We used it as the primary back up power supply for our home until installing a LP Generac but kept it as a back up to the back up. It still performs flawlessly. It has the normal Subaru puff of smoke on start up after sitting for a couple of months and after watching one of your other videos about the weakness of this model with the high failure rate of the stater windings due to heat from the exhaust I added a heat shield between the muffler and the power head. I just took a piece of sheet steel and put a 90 degree bend in the top of it, pop riveted it to the existing heat shield under the tank and it hangs between the power head and muffler. Thanks for another great video!

[@jcondon1]

All Subaru's have that puff of smoke, but they run well. Good point on the heat shield. Powermate' s of this vintage have poor heat shielding if any at all.

[@4Truth4All]

Another great episode Jim. A good reminder to establish and run through a checklist when diagnosing an engine that you are not familiar with. You never know what may have been done prior to your seeing it.

[@methods-SE]

This is becoming my favorite KZbin feed. So magnificently practical. It makes my long drives go by so much faster

[@jesterr7133]

I am a huge fan as well. I love the care a time he takes to explain what he is doing. I normally watch them as soon as they drop.

[@tristanschaper281]

Well done! at 10:28 you can see the flywheel key notch at about the 9 o'clock position on the shaft. And then we later see the key at about the 1 o'clock position! I've never seen a key so worn down but not sheered off. I've seen plenty of sheered keys on push lawn mowers (from hitting a hard object with the blade) and even a power washer, but never on a generator. I think your synopsis a the end is correct - the flywheel was removed and installed by someone who didn't line it up. Good deal for you - easy fix!!! Another great video!

[@lomni02]

I am liking this channel more and more. the calm methods of James, and learning lots.

[@eugenbaldovin5566]

Helo and thankyou for another great one . Love your content Sir James. On this specific case i will specifically ask you and other viewers that run gensets of this kind to take a moment to do a simple exercise in observing the body and specialy their arms and wrists during the rope pull movement,doo that in slow motion and you will see something very dangerous at the end of the pull. Your left wrist is bent out at max wille trying to help the write fist which is holding the rope end piece. On this particular problem with ignition timing being way of the engine can VERY POWERFULY KICK BACK and hurt your left wrist witch is locked in that moment. That happened to me and broke my wrist (15 hp honda tiller). Since then i got in the habit of never using both hands , especially when using starting fluid. For my if i canot start it one handed then there is a problem that needs adresing . If you understan what i say maybe you can include that in one of your video for folks that are unaware. I have the same hoby in Europe but not with your elegance in explaining things. Looking forward for the next one!!!

[@waffalobill]

Little tech tip. Not sure if you read comments but those spring loaded center punches you just push them, no hammer needed, they work great for removing the pin that holds the float in. Seen so many ppl ruin a carb using a punch and hammer. Bust off those ears. Plus it's hard to hold and tap it out. The pin is pretty hard. It usually doesn't leave a mark even.

[@lot27a]

Another mystery solved. Great content James. I find myself diagnosing these machine problems with you. I love it when class is in. The flywheel being improperly installed and the other little hints that this machine was previously worked on are great diagnostic tips. I'm soaking this stuff in!

[@MadmanJimbo]

James put the The sander in a vice use rags around it to clamp it softly and you will send off a lot more material quicker on the key. If you leave it the way it is the key is vibrating with the sander and takes very little material off. That’s why it took 3 to 4 minutes.

[@idontneedaname85]

I work Sunday - Wednesday. Nothing like a video like this instead of Saturday morning cartoons. Great video good sir.

[@johnlichti4954]

I enjoy your clear, organized explanation of protocol and reasoning of what/why you are doing the procedures.

[@butler386]

Fantastic diagnosis and repairs. If you ever get tired of doing these repairs you should become a detective on a police force somewhere. Thanks for the videos.

[@kenk3102]

...another great DIY video James.....I was on edge every time you pulled that rope...hoping a kickback would not occur... 🙂.... audio and video quality is first class....very enjoyable to watch....keep 'em coming!.... 🙂

[@jcondon1]

Every once in a while they bite kzbin.info/www/bejne/qH2qeYRsgMZpfJI

[@brianwood5220]

Perfect job James. I wonder if that fellow who gave you it as payment, is kicking himself. It didn't take too much fixing. See you next time and thanks for sharing.

[@coaterdave]

Morning coffee with James and another successful repair. What better way to start the day!

[@davyarthurs]

Be wary If James offers you a coffee in an off-white mug 😜

[@coaterdave]

@@davyarthurs Always smell first🤣

[@davyarthurs]

@@coaterdave 😝

[@johncourtneidge]

Genius! As always! It is astonishing, these days, how many tiny, tiny things have to line up for things to work!

[@martyb3783]

Great video as always. I noticed also when you took the flywheel off that the key was not lined up with the slot on the flywheel. Well done!

[@harryminerly4967]

Neat trick for a tight O ring

[@richardthomas9263]

Making small engine repair look easy. I appreciate your videos, I don't get the opportunity to work on them much so having your videos is a great refresher on what I should be doing. Thank you for sharing your expertise with us.

[@bertgrau3934]

I understand not wanting to wait for parts. I have had customers that tell me, you should have those in stock. Whatever it might be. Ignition coil, or carburetor. I tell them I apologize for not having the correct parts in stock. Perhaps you would rather have someone else work on it? They usually say. No, I'll wait. Interestingly enough, they dont want to pay for overnight freight. Great video, as usual sir 😊

[@RiverratGoRVing]

Very good save James, your post always helps those of us that DYI as much as possible.

[@curtdunlap6818]

I've had a few flywheel keys shear on my mowers in the past. Never knew why, but they were old engines, however after replacing them, I never had that problem again. I also never liked hitting the top of the crank to pop the flywheel either for fear of damaging the crank bearings. I've done it, but I don't like it! Thanks for the lesson. Great acquisition there!

[@AW-Services]

Brilliant video James and very clean generator. I was surprised how shallow the crankshaft key was

[@AngelGonzalez-kx1pl]

Thanks bro! I have the same generator , got it from a friend and I have to clean the carb out and got it running. I let it sit for about 2 years and clean the carb again and got it running. I'm a mechanic but I never worked on a generator before. Your video was very helpful and I learned a lot from you. And now I feel more capable on working on my generator. Thanks again bro !

[@boomerdrillman]

Your videos are still and always informative. I really appreciate the diagnostic regimen you use, like a surgeon!

[@declanoshaughnessy7733]

Dear James, you are absolutely brilliant at what you do no doubt about it , giving the head of engine two stroke to put more oil into piston and walls and then changing oil underneath and thus checking fuel system best wishes from Galway Ireland cheers Declan 👍

[@justinvanaulen2478]

Great video Jim. I was really hoping you weren't going to get snapped by the recoil. I think we all have been there once or twice, especially when working on a machine with unknown issues. Glad it worked out and glad you had some spare parts to make this an inexpensive fix. Another one saved from the trash! Nice work.

[@Bent_Wing_Brewer]

James. Your videos are a treasure trove to DIYers everywhere. I’m dealing with two “surging Subaru’s” and getting overly proficient at Mikuni (or cheap knockoffs) carbs…😢

[@bjusticeforever]

James, nice diagnosis! The flywheel had me scratching my head! I simply despise these carbs on the EX30 Subaru. They are DEFINITELY the weak point to an overall good running engine.

[@martinburgess4814]

Great video as allways.I had Honda generator last year running too lean I cut the anti tamper nub off and after full service it ran spot on.All the best to you

[@noweare1]

Wow, great job! That was kind of disheartening when it started surging after reducing the load. Agree with the flywheel theory although why someone would not line up the keyway is puzzeling.

[@user-xb2sh7wn8h]

always enjoy your videos good sir. i like the way you work and attention to detail. after a day of being anxious, i find it relaxing to watch and listen. i love working on anything with an engine and have so since i was 8yrs old. im not very good with crowds,noise and would rather spend all day in the garage. dont think the other half would like that lol.

[@ScottPlude]

I love your videos. I have an older generator with the subaru engine. It sat too long (my fault) and it wouldn't start yesterday. I pulled the spark plug and sanded it slightly. I drained the gas via the shutoff valve and refilled. Still wouldn't start. After watching your video, I pulled the drain plug on the carb with the valve on, still no start. I saw you use a shot of starting fluid and did the same. It fired up on the first pull! I now have a pretty good running generator again. It's a beast to get started but I will keep my can of starting fluid around since I hardly use it. I wish you were closer to service my machine. Thanks!

[@ourpetpekinducks7123]

I just want to comment that I wish that other small engine repair techs were as thorough

[@PaulHigginbothamSr]

I think James needs to use Mustie's, (Darrin's) method of enriching the circuit by drilling the main jet one size larger. Of course ya'll need a full set of jet size drills which may cost more than a carburetor. Mustung 1 seems to find stuff at yard sales but that is really hit or miss.

[@enzofitzhume7320]

Subaru - 1 star out of 5 stars. Hence the Subaru logo!

[@percival23]

James, I would love to see dedicate a video to rating the different brands of Generators based your experience on fixing them and what are the most common problems with each brand. That would be great. Needless to say I really enjoy your channel.

[@throwbo]

Percival, this generator was an older one so it had an American made generator head and a Japanese Subaru engine but nowadays, except for Honda, all generators come from China. There is more than one manufacturer in China but they are all very similar to each other and they all have the same problems. The brands that we get in the US (Champion, Westinghouse, etc.) are just marketing brands and are not the actual manufacturers. They just contract with the Chinese factories to make the gens for them. Often the only difference between brands is the paint scheme.

[@percival23]

@@throwbo I don't thing you realize how this works. Company's all over the world send thier products to be made in China. But the Chinese factories must follow the specs set forth by each company. Some company specs produce a higher end product, some lower. Now when it's a Chinese company making the product they control the specs and that is when you end up with a cheaper quality product. This idea that all products made in China come out the same is completely false.

[@blainedalby8634]

@@throwbo😊

[@wildefox1478]

Very simple fix with this one, just ignition timing, very nice work James!

[@PabloDiablo682]

Let it earn it's oil change.......Brings back great memories of me and my dad and brother working on something , and that is the EXACT same thing my dad would say.

[@joemc111]

Great show, a few years ago after watching your videos I bought a generator, for $100.00, put a new carb on and it’s good. So I just bought one that looks like this one except it’s got a GFCI OUTLET, it’s starts but no power. Thanks James for the great videos you make.

[@michaelcherp2280]

Epic testing and repair. Just bought a Firman T07573 and wouldn't run out of the box. Going to clean carburetor, fun fun fun!

[@jameshedrick605]

That's one reason why i save some used oil. If work on a generator that needs an oil change but don't know if it runs and it's low on oil i put use oil in it and if it starts and runs good i'll change. How often do you recommend cleaning and reoiling foam air filters ?

[@g1jee]

Interesting they didn't reinstall the flywheel correctly. Nice catch. BTWay... In virtually all of your videos, the carburetor needs cleaned - mostly because neglect and improper storage. How about a video on how to properly prepare a generator for long term storage? Your thoughts?

[@ShaamoneHeeHee]

How nice does that engine run once the timing was sorted. Excellent diagnosis.

[@louislectric]

I have a miniature 900w 230v gennie that I use twice a day for 2 hours. Watching this I'm convinced the pilot jet up top must be somwhat clogged. Perhaps I can find a metal hair somewhere! Thanks for sharing!

[@jcondon1]

A wire from a wire brush or a small guitar string.

[@arsinoeivlostprincess4228]

Interesting video about the key. I just by passed auto spark advance module on a Kohler cv 16s. Took a while to figure that one out. I used the stock flywheel and a non auto spark adv coil. Running for now. The kohler manual helped a lot. In the process I I turned the gov shaft the wrong way and dumped the gov gear into the bottom of the pan so I had to split the case. Not a lot of fun but it runs. Kohler sells a new kind of adv unit but at $180 I'll try he work around first. The plug wire was too short on the other coil and had a 90 where the old one was straight. It kept popping off while I was cutting the lawn. Out of frustration I cut the old coil wire off for the extra length. I joined the two with a 3/8 inch length piece of paper clip with the coating rubbed off pushed down the center of the plug wire. I held the two together with what else a wrap of duct tape. Went on to cut an acre of grass.

[@MrTonyPiscatelle]

The original generator whisperer ! Nice job james

[@Kuzzzzman]

Thanks again James for another awesome video. It's always great watching your next project being diagnosed and come to life. Thanks for taking the time to video each step along the way, always really helpful.

[@richardphelan8414]

Another one solved James ,way to get it done love your trouble shooting skills

[@markyoung7470]

Looks like you got a charming generator for your previous work, hoping you come out ahead very helpful video Thanks for sharing all of your knowledge.

[@larrykelly2838]

Great diagnostic procedure, ye have a good generator Doc.

[@jcondon1]

Thanks

[@jeffreylord8172]

Great videos always ,you should get together with Mustie1, and do a video

[@smarthome2660]

We have all heard of fake it till you make it. I think some previous owner faked it till they broke it. Nice thorough repair. When I have the coil off or the flywheel exposed, I always clean them, also checking the coil gap. You might have done so but did not show this step.

[@zodzod9378]

Very strange James dont think i have ever come across a key way fail on bikes clutch and staters ? good job mate ! Little john from the UK

[@ron827]

When you pulled the flywheel, the key slot in the flywheel was at about 9 o'clock and the key on the crankshaft was at about 12 o'clock which was roughly 90º off.

[@tubemember21]

I really enjoyed the tour of your storage unit! Keep em coming.

[@kirkb2286]

Because of you I have started repairing generators.I have not sold one of them I find people in need mainly single mothers and give them to these moms. They come in handy after a hurricane = no electricity for days if not weeks. It’s all your fault.🤣🤣🤷‍♂️🤷‍♂️ thanks for the motivation and the videos.

[@tombonn9586]

I've got 3 college degrees - - you've beaten hands down all of my old professors for amount learned per time invested!

[@mjg263]

Boy, that was a weird one! I cringe whenever I have to work on something that someone else has tried to fix, you just never know where they’ve been or what you’ll find. Nice generator (now)!

[@robertagner]

On that oil sensor module: You are correct. It is not "original" to that engine. That was a "heavy duty" module (and bracket) that was sent out by the service department of Subaru Industrial. A few of the owners of this generator had complaints where the original module shut down the engine while the engine oil level was actually up. This replacement part seemed to eliminate this problem. Also, I seem to recall that the emulsion tube is, indeed, removable on those Mikuni carbs. I believe they are slotted at the bottom and unscrew.

[@ayozhek1898]

Thank you for another great video James, takes me back to my time working on small engines. Must admit i have never seen anyone get a flywheel on without lining up the key, takes all sorts to make the world go around i guess 🙂

[@seansysig]

James good catch on the flywheel! Did you hear me yelling the flywheel isn’t seated properly.

[@nigelfenlon9035]

Thank you brother for your help and information I can easily understand. I'm a Newby to all this generator stuff as we've been made homeless and so I had to buy a trailer and so needed a generator. So thank you

[@grahammctygue724]

James I kind of sorta remember you found different brand off smeared a hundred or so to one side great job in all cases Peace

[@jesterr7133]

That machine is 20 years old?!? It has been really well cared for. I thought it was much newer than that.

[@HansCSchellenberg]

A long time ago my brother was working on an old 50 HP Evinrude outboard motor. He had just put it back together and wanted to see if the motor would run, before torquing down the flywheel. Every time he started it, as soon as it fired for the first time the key would shear and it would lose timing and stop. Turned out that flywheel needs to be torqued properly, even when testing!

[@deangentles4966]

Hi James great sitting in your class today mate Great content as always thank for sharing

[@sgtmudflaps7942]

ok i have watched over 5 hours of your videos and I have learned so much. still trying to repair mine but learning more and more... it will get there

[@arthurbiringer5676]

Another award winning resuscitation! I’ve learned a lot from your videos!

[@reggaeone]

Thanks for your great video. I have the same unit.

[@daboomer2277]

I love your storage unit. I has a yard machines lawn mower that i put oil in just to have it leak out the bottom. Also, that engine had rod knock.

[@radimkolar2270]

I love your videos, they are absolutely useless to me since i am in Europe but i watch them anyway, who knows, might be handy someday

[@hugh007]

Did the key sit as far into the crank as it looked to me? I was thinking that's why the first one allowed the f-wheel to slip. Thanks for the unusual repair video.

[@jcondon1]

It was sitting very low

[@VincentMartens93]

I don't have a gen, I don't need a gen, the grid here is uberstable, I don't care about generators.. Oooh a new video from James Condon!! Must watch!!

[@stiggywatts4258]

A most informative video. I have to say, I find your videos quite addictive Thank you. 🙂

[@hikerJohn]

This generator looks like someone cleaned it up to look newer than it really is. The flywheel and the shaft look old while the covers look new including the valve cover. Had to go back and look at when you took the flywheel off so I could see that the key was not in the keyway if the flywheel but I don't recall you pointing that out which is why I had to go back and look at the part you pulled the flywheel off. You spent a LOT of time videoing the measuring and sanding a new key and driving to your storage locker and looking through a box of parts that was a wast of video time Still a very useful video that reminded me that I need that strap wrench to put my Honda 5hp pressure washer motor back together (it broke a valve stem but did no damage otherwise)

[@benkanobe7500]

James, do you think the flywheel was forced on with the groove not aligned with the key? What else could it be? EDIT: You confirmed my belief at the very end!

[@rlferv]

Hey James. We didn't see your wife's Coffey mug but who was the Cat that made the cameo appearance ? Great as always.

[@tiredoldmechanic1791]

That was a strange case. It obviously ran for some time to get the oil dirty and to show some wear on the spark plug. Someone must have removed the flywheel or possibly the nut came loose so the pull start slipped and they just tightened the nut without removing the pull start adapter and checking the alignment of the key. Tightening the nut without the keyways lined up would force the key deeper in the keyway making it difficult to remove.

[@muztbnutz4306]

I saw a lot of problems with what you did but Cary on it’s your story.

[@David-mz3or]

Thanks!

[@jcondon1]

Thanks!

[@CapnBubbaa]

Another well done video, very instructional, as well as informative. Great Job!!

[@towguy9557]

I had a similar problem in an outboard boat engine. It would run but randomly lose a little power and eventually die. The plugs would foul out and not restart. The problem turned out to be a worn key which would cause the flywheel to spin on the shaft slightly causing the timing to go out of adjustment and foul out. Replacing the key fixed the issue.

[@gonzo_the_great1675]

I had a cheap 2stroke pressure washer with a timing issue. It got slowly more difficult to stat over time and down on power. Found that the key was actually cast into the alloy flywheel. Sheered and the timing had slowly drifted. Reasonable degree of smugness to find and fix it.

[@merlepatterson]

9:51 note the gap between the flywheel and the shaft. 16:58 Note the gap is gone and the key and shaft shoulder can be seen. My guess would be that someone had the flywheel off and just put it back on any old way and tightened it down.

[@jcondon1]

I agree, good eye

[@bertruttan129]

Powermate gens are great. I have a bigger unit and for 20yrs. now first pull every time, maybe 2 pulls in all that time. I run the gas out of the carb by shutting off fuel and run it dry after use. Change oil once in a while based on how dirty it is. Ran an auxiliary fuel tank during a hurricane and than had to run all week long during power outage and did not miss a beat. 24hrs a day for 9 days straight. Was running my entire home. I'm a believer. Won't live without one.

[@PaulHigginbothamSr]

I think Sabaru cut the woodruff key too deep. What happens is even if the owner puts the key in correctly and does not miss the keyway into the flywheel slot like the person did in this case, flattening the key into the slot as this one was, the key does not protrude as necessary to make non-alignment not correct. It also has a larger surface to be cut in two and will probably break the crank instead. This would mostly occur in a lawnmower blade strike which has a softer metal key to shear to keep engine damage lower. Subaru needs chastised for incorrect machining. Briggs engines seem better.

[@johngrein3325]

Great video James. Excellent narrating.

[@TimClaridge]

Why work in imperial when obviously Subaru is METRIC? Surely you could have used rope over piston crown to lock engine when replacing Flywheel? I am always suspicious when finding machinery previously been got at! You fixed it well done.

[@JoeJoe-yp4xz]

Such a great walk through and trouble shooting. Thank you for taking your time. Such a great video.

[@andymann9861]

Fantastic, James! Another victory!

[@us2tohell]

Another epic video, thanks I really just enjoy watching these like it's a movie.

[@phillipdavis4507]

I am so glad to see that somebody else plays hell getting their keys out

[@TheLawnmowerLady]

Nice! Only a few hoops to jump through on this one. If only they all were that easy. 😺

[@jcondon1]

It’s nice to get an easy one once in a while.

[@dj5752]

Great video. Question: Will this method of checking the coil just coming off the magnet at TDC apply to all generators and other 4 stroke small engines? If so, that's a great little piece of knowledge that saves time. Thanks.

[@leepowelldrones7103]

Please put a link to the small wires and brushes you use to clean the carbs. I love your channel and have followed you for quite a while and have learned a ton from you. Great videos and extremely good troubleshooting steps.

[@stevenmchenry9276]

You are a great mechanic. Keep the great work.