No Power Output From Generator - Fixed

[@KensSmallEngineRepair]

That hunting got me from $100 to 80 bucks! Another great vid Jim!

[@jcondon1]

Thanks Ken for picking up this generator and talking him down to $80. A new Mikuni carb alone would cost $120+

[@russellbonesteel1115]

Mr. Ken I Vaguely recall reconditioning Rotors for Alternators in a Shop Class??? Can THAT be done?

[@joesinakandid528]

@@russellbonesteel1115 If something can be made it can be repaired. The amount of effort sometimes needed to repair something can easily force a "Just replace it" answer. A drop of solder COULD have resolved the immediate problem and after testing COULD have been the simple, easy fix.

[@kingdommusic5456]

The rapture will happen without a doubt. The rapture will happen much sooner than many believe (much less than 10 years according to all the environmental, weather signs , israel timelines, astronomical etc showings: luke 21:11 . It will happen without any warning , not one , in an instant , catching masses of people off guard just like God always does, ie the flood , sodom and gomorrah ~ a rude awakening . Matt. 24:44 jesus said Therefore be ye also ready: for in such an hour as ye think not the Son of man cometh. luke 12:40 Be ye therefore ready also: for the Son of man cometh at an hour when ye think not. No one knows the exact day or hour the rapture will happen is a certainty . THE RAPTURE CAN HAPPEN NOW at ANY TIME make no mistake !! . Please awake to Christ Jesus which is the ONLY hope NOW and dont let yourself find out it IS all true later when its too late and you have been left behind in the most terrible times the earth Has Ever experienced Before and ever will...for anyone who sees this and doesnt know what to do please If you havent given your life and heart to Christ Jesus you will have REAL BIG problems way bigger than any problems you have Ever had If you are left here on earth after the Rapture . After the Rapture The USA , Worldwide , will face More evils , Inner city chaos, firearm wars etc etc ,power and water , food shortages , military invasions,mass executions (yes much blood will be required by antichrist ) etctec than it Has EVER been seen Before and you surely dont want to be Here then . We Have Time NOW to change , please seek Christ Jesus while there is still time to save ! no one knows the day or hour of the rapture ,But the rapture will start out just like any other day .....The Rapture will Take Place In the day In Broad daylight, sunny day , In an Instant FLASH without ANY warning , and there will be peoples Driver Ids, cell phones ,wallets found in various parking lots , Purses bill folds Found at work etc etc with NO explanation , and People VANISHING so No One can refute it has taken place. . romans 10:9-10 That if thou shalt confess with thy mouth the Lord Jesus, and shalt believe in thine heart that God hath raised him from the dead, thou shalt be saved.For with the heart man believeth unto righteousness; and with the mouth confession is made unto salvation. Many of those that are left behind were seen in deep regret and many hung themselves on fences on interstates , and roadways and different places, their cars left by the roadside and many others also used their cars to kill them selves wrecking into things . It will be a horrible time , and regret will cause many to commit suicide . NOW is the time, dont wait until its too late seek Please Christ Jesus NOW. Those not going in the rapture and left behind , who rejected Christ Jesus' Love, and those that are practicing sin will have a big nightmare when left after the rapture example woman dancing in topless bar practicing sin , will NOT go in the rapture when it happens abruptly , and many other examples of willfully practicing sin daily .matthew 25 :1-13 parable of the 10 virgins, 5 were wise 5 were foolish and payed a severe price . Acts 3:19 all unrepented sins19 Repent ye therefore, and be converted, that your sins may be blotted out, when the times of refreshing shall come from the presence of the Lord. romans 10:9-10 That if thou shalt confess with thy mouth the Lord Jesus, and shalt believe in thine heart that God hath raised him from the dead, thou shalt be saved.For with the heart man believeth unto righteousness; and with the mouth confession is made unto salvation. Please seek Christ Jesus NOW with your heart, please repent change while theres still time left ... raptureready.com

[@rogerd4559]

@@russellbonesteel1115 There is a little woman in China who posts Videos on KZbin that rewires 100 KW generators like she was washing dishes. Maybe you should contact her

[@osvaldocardoso9316]

We have used the kzbin.infoUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y for probably 30 hours with our camper and it’s been great! The noise level is really only noticeable when running the AC and other appliances like the microwave, hair dryer, or coffee pot. It’s not huge like other ones and it has wheels so even at 90lbs, I can move it!

[@CharlesM-dp4xe]

Just so you are aware ... I'm a Ham and operate and repair a number of different radio types including RADAR, I have seen incidents in the past where in many Chinese knock-off feed line cables the "copper" center conductor is often some obscure alloy made to look like copper but in fact is something else. It nearly always refuses normal solder. The soldered joints easily crumble and break and attempting a normal repair is virtually impossible. I believe the coil windings are made of a similar product. I see this quite often and reading resistance values are always skewed out of normal specs. This usually speaks of coil windings made with very cheap product instead of actual copper. Be ware ! Good video .

[@jcondon1]

I have seen the same. The solder is nearly impossible to stick and the wire usually just crumbles when trying to work with it. So I do not try and repair them anymore. The only repair that can be done is to rewind with copper.

[@fitter70]

What I like is that you never give up no matter how bad the generator is.

[@antoniohuertas8909]

I love how you went through every aspect of the generator. You tested and found everything that was wrong with it and got it to running like new again. It's apparent you're very familiar with generators but that's why we need people like you and your experience on KZbin to show us regular folks what to look for and how to diagnose problems. Thanks again for another great video.

[@johncourtneidge]

Yes!

[@cbauer72]

The original owner really did a good job of polishing a turd. From the tank and the frame, it looked like almost a brand new generator. But then you look at the oxidation on the top of the engine, the cover on the stator, the wheels, the internals of the panel, etc and you can see that thing had a lot of moisture exposure.

[@KensSmallEngineRepair]

It was literally under a deck on the beach of Long Island Sound. Salt Spray continuous!

[@patagualianmostly7437]

@@KensSmallEngineRepair Yes, occurred to me the previous owner must live very close to the coast.....!!

[@joesinakandid528]

Sure looked likes a "Bits-a This One and Bits-a That One FRANKEN-GENNY"

[@billyroberts405]

@@KensSmallEngineRepair 🥼👩‍👦👩‍👦👩‍👦👩‍👩‍👧‍👧👨‍👩‍👧‍👧

[@jeremydewolfe8026]

Well, I audibly said “Yessss!” When you said you were going to drill open that breaker! I love seeing not only the main reason for failures, but the specific reason. Cool to learn how the breakers work too. Ty!

[@giggiddy]

Absolutely. I am a strong troubleshooter not because I'm anything special. But because I learn what each part does to make something work. Knowing the theory of anything mechanical will make you appear like a wizard when things fail. But knowing what parts should be doing is 3/4 of the battle trying to get something working again. Repair is just eliminating what works until you find out what doesn't. Does that make sense???? I know what I'm trying to say and I definitely agree with you. Cheers

[@davelee9087]

I agree with the "Why did it break" attitude, and not just toss it and replace. Knowledge is understanding.

[@PepperLewisAndCo]

I lucked into a pile of around 30 generators recently. I had planned to scrap them until I came across your videos. Hopefully, I can make a few of them run and make more than I would have in scrapping them

[@CraigWaterman]

"I make it earn an oil change" -- This is solid advice. Avoiding wasting money on new oil and disposal, and time, if the engine is junk to begin with. Love your videos (as do all the little carbs in my garage)

[@turnbullfl4114]

I always keep some good shape used oil around for such situations.

[@danburch9989]

This is one of those things that wasting a $4 quart of oil on an engine that might be bad is better than trying to run the engine that might be good on that contaminated oil.

[@CraigWaterman]

@@danburch9989 oh I agree. In general it's good advice, but that milkshake really needed to go, a good choice *not* to make it earn it, this time :)

[@giggiddy]

@@CraigWaterman Agreed sir.. I change my oil annually in equipment that may have only seen a few hours run time for the year. But I save that "used" oil and use it in engines that I'm not sure deserve a fresh oil change. If I'm sure she's a runner/keeper, she gets an oil change with the best. Cheers!

[@Tony-rl2fr]

As a life long mechanic, techie, general all around Jack of all trades, master of none, I salute you sir. Very nicely done! Great job and presentation. Thank you!

[@ronnyfry89]

I just want to mention that I really like the fact that James owns up to his mistakes. I think that is a big reason why he's become so successful and so good at this.

[@johncourtneidge]

Yes!

[@michaeldevens4392]

I appreciate the fact that you never give up, and your curiosity.

[@tonygriffiths2485]

I reckon 90% of that was caused by inadequate care of the machine itself. Leaving it out in the open, or maybe in a hazardous environment. Just look at the state of the micro switches, which you say weren't as bad as some you have seen. That was a surprise to me. Aluminium wire in the stator didn't seem to be the problem there, God knows what that was. A difficult, hard working solution to several problems there, adequately dealt with in a logical and most enjoyable way. I got a lot out of all that. Thankyou :)

[@jerrygilles9612]

James knows his stuff about electronics .

[@howieab606]

Very well done, thanks for the education with no distracting music or showmanship. Greatly appreciated.

[@VidelicetMoi]

This was the best video you have ever done. There is so much information and all the troubleshooting to boot! If this doesn't win a KZbin Oscar (I am prescient; it's coming), I don't know what will. Thanks for all that was accomplished.

[@jcondon1]

Wow, thanks!

[@ericvaughn1126]

Agreed. Jim always does excellent troubleshooting, but this video would be a great one stop reference for what to check, how to check and what normal values should be. Literally a "clinic". Thanks again JC!

[@giggiddy]

@@ericvaughn1126 Well said. I agree with all of you.

[@lynnpierce3843]

You are very good at filming and discussing your reasoning. I fixed cars for many years and your channel brings back memories of crazy diagnosis of cars. Keep on trucking. I really enjoy your work. Because of watching you I bought a fixer upper generator. Found owner had left gas on. Filled engine with gas. No damage. Lucked out. Yea free generator!!!!!!!

[@jcondon1]

Cannot beat free! Nothing to lose but a little time.

[@timothyjdehart6396]

You are alot like me. If I'm that far in I want to know WHY it failed. Found material and workmanship to be more common than not as the cause. The fact that you went that extra mile makes me give you an A+. Great work!. My background is QA and re-writing practices in Telecom, FiberOptics, and Electrical systems. We fine design flaws , improve using better materials and manufacture practices. You EARNED your A+. TJ DeHart.

[@jcondon1]

Thanks

[@erickcarb3789]

Thanks!

[@jcondon1]

Thanks Erick!!

[@er1073]

I wasn't sure that the replacement rotor would work because of the position of the magnet I guess that makes no difference. Yes this looked like a really well kept generator at least the nice shinny engine and tank! Somebody made the remark "the original owner really did a good job of polishing a turd" I agree with that remark I am glad your buddy was looking out for you at $80.00 it was still pretty steep. It was unbelievable how lean that if it was the original carb was running so lean. So in the end you triumphed over the broken equipment. Thanks for sharing your video and knowledge James. Ed

[@ItllBurnOff]

You went over so much stuff so clearly in that video. That maybe my favorite video so far. As always thank you James

[@bobadam7021]

This one had all the in depth work I wanted. I like seeing why things failed, like that circuit breaker. Then you went back and attacked that rotor, just because it didn't work out this time doesn't mean it won't work out every time. Great video.

[@skysurferuk]

Perfect camerawork. Thanks for posting.

[@Willy12927]

As always, it's a pleasure watching you apply your diagnostic skills and knowledge.

[@guataco]

You work a lot in the cold, hope you are well. Notice the new ultrasonic bath👍🏻. The Husky is happy now.

[@williamyorkolepossum]

Enjoyed watching you repair that one. Was not sure about that carb. Boy do I miss tinkering with that stuff. Too old now.

[@robertmanssen5261]

I repaired two rotors by crimping copper wire to the aluminum wire and then soldering the copper wire to the slip ring terminals. Worked great.

[@r8118830]

What was those rotors on Robert? I would like to know where aluminium is used as rotor wire on small machines.

[@robertmanssen5261]

@@r8118830 They were on two Firman generators. The aluminum wire must be cheaper than the copper. Made China.

[@raymondpetrovits2336]

Perseverance and a willingness to move forward no matter the problem. Patience must be your middle name. Meeting one problem after another and conquering. Super problem solving. Another great video

[@mmcc310]

Everyone should ask those friends to subscribe, even if they don't watch! I've learned so much watching his vjdeos . He deserves a bigger audience for sharing his knowledge.

[@jcondon1]

Thanks. Never set out to get subscribers, but they keep coming.

[@ericvaughn1126]

@@jcondon1 The finest quality in the genre will cause that to happen! 😉

[@josejnieves1224]

James I never tire in watching your generator videos, I have learned a lot . Believe it or not while in Puerto Rico was on facebook marketplace looking for old defective generators to attempt to get them to run and none to be found but I did locate (3) running from $100 to $300. One even was electric start with bad battery but with an 85 foot extension cord heavy duty. While in NY ,found a brand new one 3750 watts with 10 hours for $100.00 ,yes $100.00 go figure. I finally located a Chicago Electric 7500 watts electric starter ,no battery 16 HP also no power. I got the motor running real good so far, ordered a battery and filter which was missing. I'll be attempting to get it to power up with what I have learned from your videos. Many thanks

[@claudewilkerson5162]

thanks to your youtube page i have just finished repairing my onan rv generator that shop wanted $2000 plus labor to replace stator and bad rotor, that was 3 years ago. i bought a new generator and kept old one. i tried to repair bad slip ring but failed and found new rotor and stator for ABOUT $425. I now have a working spare to keep or sell. Thanks for excellent videos

[@boblynch7348]

James, it occurred to me that you may have been trying to solder an aluminum wire from the rotor winding to a copper terminal (perhaps chrome plated) also on the rotor circuit. If so, the regular solder and flux used for a copper to copper joint won't work properly. An aluminum to copper solder joint requires a different flux. Maybe even a different solder. That would explain why the solder wouldn't flow onto the aluminum wire in your numerous attempts. As always, a very informative presentation. Thanks.

[@r8118830]

Soldering aluminium wire to copper wire is extremely difficult. It requires higher temperatures that are closely controlled so that the aluminium does not melt. Precision tools are needed so that the heat can be delivered to the aluminium through the aluminium oxide that forms on the surface. Specialist flux is also needed. It is better described as brazing than soldering. I recall once cutting off a copper braid tail connected to a thin aluminium bar inside a vehicle alternator. It certainly caused me a problem. I should not have done it. I ended up reconnecting the new replacement parts by soldering a copper spade connector to the copper wire and pushing the end of the spade connector over the flat thin end of the aluminium bar so that it was a tight fit. It was not ideal but it worked. I never made that mistake again. Ever since then I usually use a thin round splice with small brass screws on either end. The wires are pushed into the ends of the splice. Ideally the copper should not touch the aluminium and electrical connection is through an internal brass shaped piece with the screw threads fitted into either end. The outside diameter of the splice is always larger than that of the wires so doing this is not always suitable.

[@eduardedwin3431]

I've started watching your videos (from the very first one) since November '22 up until now. Notice in this video you got a new ultrasonic cleaner. Nice. And thanks for the knowledge, especially on the circuit breaker and how it works. Surprised to see how simple it was.

[@tbas1972]

I used you water trick to get a rotor off at work the other day, worked like a champ. I should of took a video and tagged you in it but I forgot

[@rcf8367]

It’s great when you do the post mortem diagnosis on parts! As much as inflation have increased electrical part prices & scarcity, it pays to drill out rivets & repair some of them.

[@rickolson9011]

Love when you dig into component failure--like circuit breaker -not an expensive part. On the other hand, I sure would like you dig at least a step or 2 deeper into that expensive rotor. Most of us won’t have a very specific rotor sitting on the shelf. What failed in the rotor? Please! A failed rotor would have many of us giving up rather than buying a replacement on a hope. Generally electrical parts are not returnable. Love you very informative videos and frequently comment.

[@russellbonesteel1115]

Mr. Rick I Vaguely recall Reconditioning Rotors for Alternators in my High school Shop Class????!!! Cheers!~ Russell

[@joy5608]

Q

[@ron827]

Good job as usual. My first thought was the brushes were squealing because they might have worn slightly different on the other slip rings. Did you compare slip ring diameters? Polishing the slip rings might have helped. It is a true gentleman who admits his mistakes. I think we can thank some CA attorneys for overly lean running engines. :-)

[@pdlngsqrs9547]

Extremely impressed with your detailed analysis and dogged determination to make this, as the gentleman below noted💩, into a nearly a “swiss” watch. Kudos!👍

[@paulmurphy5964]

Funny moment when you said ‘just kidding’ as you were replacing the rusty black cover! I said OMG as you did that. Your voice changed tone in latter half of video. Maybe because it was minus 5F. Thanks for such great videos James.

[@oldsranch]

Well done! The Generator Whisperer strikes again!

[@RobertMChambers]

That generator got caught in a flood, there was corrosion in places that wouldn't get wet in the rain. Good project, nicely filmed!

[@Joe-S-AK.andID.]

Or it was under a tarp that flapped in the wind.

[@danschilz3693]

Always amazed at your attention to detail and going the extra mile to finish the job. Looked like the previous owner thought this was a "submersible" generator... Amazing how some people make a substantial investment in equipment then abuse it this way. Thanks for the great video!

[@George-mn4wf]

We think you should run for President, James!

[@danburch9989]

I've learnd a lot about generators and especially cleaning carburetors. This is another inexpensive win for you. The frame of the generator is in remarkably excellent condition compared to all the corrosion on the engine and power head. I imagine this came from two bad generators combined into one bad generator before you got it. Probably an underwater recovery.

[@jcondon1]

I agree. Something did not seem right as the frame looked in perfect condition.

[@iandownie9848]

@@jcondon1 Generators like any electric or electronic equipment do not swim very well and usually die as a result.

[@haroldtanner9600]

Thanks for showing how the circuit breaker worked.

[@rich10849]

It's extremely satisfying to watch someone work who really knows what he's doing. I hope spring gets here soon. I shiver watching you pull starting an engine in your driveway in sub zero temperatures. Good job abd great video.

[@jcondon1]

Thanks Rich!

[@garykintzler4273]

I think it is great that you have the no give up attitude. More people should be like you.

[@Me_rubin54]

Love the explanation of the circuit breaker. Seeing it trip with heat applying was a good lesson. I did not know you could fix them.

[@pierrelabrecque8979]

At just over 1/2 way through vid i got the idea that it was left in a basement that flooded or used often in the rain which could explain missing/soggy air filter. this was a very informative video. Thank You!

[@philipbreau1246]

Great video. I have a brand new generator that doesn't need maintenance or repairs. When that day comes, this will be my go-to. Thanks for posting.

[@electricboatal]

OK James, you got me again. When you were installing the rusty cover I immediately thought you should clean it and paint it. Regards Al Hartley

[@greg.goergens6315]

Hey James another thing that I learned over the years is if you have a jet that is drilled too large it can usually be soldered shut and re-drilled.

[@tim0877]

True

[@paulmallery6719]

Put a piece of wire in it

[@ronzek3207]

Thanks for the video, your electrical skills are spot on, soldering needs a refresher course in cleaning, material should be spotless.

[@peterfong2241]

Blessed love bro, I have learned a lot from you, I do have one, it's a Honda I will have to look up the numbers, but am building up my courage to repair it myself, am an engineer by profession, but never fix a small engine yet, am a born fixer so I will get there soon, many thanks bro, watching from Jamaica west Indies !!

[@peterfong2241]

Blessed love, when I start to fix it I will inform you, or even asking for some guidance, in the meanwhile I will jus keep watching your videos !!

[@edhansen8531]

Pretty indepth and thorough , I like it alot. I know it can be a guessing game at times, but yours are educated guesses. Although intense, your voice is very calming, instructions are precise and any mistakes are explained keep up the good work..

[@jcondon1]

Thanks Ed

[@rustyrepairs2565]

Excellent tutorial as usual! I also appreciate that you shared your "rookie mistake". You're hardly a rookie.

[@michaeltarasenkoop2389]

James you are amazing in finding a fault ! If I was stuck on a island with one generator to use I would want you as my partner in case we loose power to the island ! I wish I had room to tell you a story about a generator on a island that a service mechanic told me about while fixing a generator problem ! You would die laughing! Next time you won’t be leave it !

[@francisbailey3831]

Good morning, James. Wonderful video on the and trouble shoot, as usual during a cup of coffee on a cool Thursday morning hear in NC. I enjoy watching your video's very much every week. Stay Safe and healthy James. 👍👍👍👍

[@ronaldclark2624]

Nice video, thank you! They make a chemical stripper for copper wire! If they used aluminum then the connection is compressed to copper eyelet for soldering but must have copper to aluminum salve! Aluminum oxidation seems to be the problem there! Your solder pullet worked good! It has been many years! Ron PTL, USA

[@jimturpin]

Great video for anybody looking for an all encompassing repair experience, lol! Had a little bit of everything wrong with it. FYI, multiturn potentiometers are notorious for backlash, so it is likely the wiper didn't move completely back which is why the after setting voltage was a little bit higher. Thanks for taking the time to share this repair with us, it was not only entertaining, but a highly educational demonstration of troubleshooting technique.

[@markwiley9516]

Great job James glad you have the patience to do a job like that look forward to the next live stream with ken

[@moya034]

James, for flux I recommend good old fashioned rosin, like Kester 186, with that stuff you will feel like you can solder anything. I would also ditch the mechanical solder pickup for copper solder braid wick.

[@subtext9881]

I agree. Rosin is always you friend. You could also try a specialized solder, like SN100C (but I am sure there are many alternatives).

[@pauladams9477]

@@subtext9881 Yeah.......but if the wire is aluminium you can not solder that

[@moya034]

@@pauladams9477 The possibility exists the wire may have been copper clad aluminum, and James scraped off the copper clad. I don't know. The rotor was probably junk anyway, but there is a small chance attacking the original joint with solder wick and a heaping load of Kester 186 may have salvaged it.

[@JimPeachley]

James, do yourself a favor and find a pump-up work table/cart. Take it from another Jim, the floor gets farther and farther away every year; no need to ruin your knees prematurely. Keep the great content coming.

[@cbauer72]

Well, that explains why I can't ever find good deals on generators. James has his minions get them! (j/k) Love the videos. Keep them coming.

[@MrKidi39]

I know right?? I never find deals

[@dquick282]

James… great repair again. Especially when you tore apart the circuit breaker. Very neat demonstration how they operate. Also I wish praying for yeah when you trying to repair that rotor wire but learned alot. Thanks again for providing such an amazing video on generators. You have me hooked. Keep making great material.

[@johncourtneidge]

Agreed!

[@jonminer9891]

Hi, James. Some very good clues and tips in this video. Experience is what you have a ton of. Thanks for sharing! Stay Healthy!

[@cszulu2000]

Happy to see that sometimes it is not just one thing wrong... And I am not the only one who has those challenges...

[@gregorypiercesr.794]

Great video and I never get bored watching your videos, you have to be able to jump in and figure it out. 👍👍

[@philipbreau1246]

Use a stripping gel to remove the varnish from the magnet wire. Gel Insulstrip was what I used in the 80's. It's safest since there's no risk to knicking the wire. Once the varnish is removed, use alcohol to clean and neutralize the gel.

[@dbriddie9525]

LOL, how many of us were shouting at the scream, "For God sake you cannot use that end cover like that!!!" 🙂

[@wildefox1478]

Great video, it's always handy having spare parts laying around, nice work on this one James!

[@butler386]

Dad Gum surging anyway. Seems like that is one of weird things to fix but a replacement carb worked perfectly. Great repair of the generator and panel on this generator. Thanks again for the video's.

[@billclinton6040]

One thing nice about those plastic gas tanks is that with all the water in the gas, you don't have to worry about rust in the tank.

[@Got2Learn]

Love your way of working and love your channel, keep it up!

[@marcboislard1231]

Love your videos and really appreciate the fact that you don’t use a background “MUSIC”

[@gjkozy]

I have had problems with soldering such as you demonstrated, I used the low temp aluma weld with a pen type of heat gun.

[@67mlb67]

Another great video James! Lots of good information in this one!

[@jimpickett9974]

James I was watching your video today and saw you having trouble soldering the wire on the armature and just wanted to let you know that you might need to use silver solder on something like that because it works differently than flux solder and you might have a better result, but you have to get it really hot that's the secret.

[@alanwatkins7420]

Never watched you before I am now hooked not mechanically minded as a rule I am more electronics but I found this fascinating you are a meticulous and clever man the wife has just informed me I have been watching you for 4 hours so I'm off to bed now trust me I'll be back haha

[@knowone6214]

James.....looks like that Husky has been drowned or under water at one time and I thought I was the only one that still uses a trigger solder sucker.....good job

[@BreathingFire]

Thanks for good video. I am working with industrial gensets, but still was very interesting to see this micro power unit repair step by step. 👍👍👍 Cheers!

[@watermanone7567]

Very nice job. I have had some luck with taking the limiter caps off with a Durmil tool. Also like your new ultra sonic cleaner and drill press. Nice to see shop upgrades. Many thanks.

[@rodneybrand8521]

Hey James..that gen.looks like it's been under water or left outside or in a wet basement...you handled it well.. You sure come up with some great deals..Cheers 🥂🥂🥂🇺🇸🇺🇸🇺🇸⚓⚓⚓

[@jcondon1]

Thanks. Definitely left outside for some period. Probably after it stopped making power. The guy selling it also was right on the ocean, so the salt in the air did not help any.

[@davidduma7615]

@@jcondon1 yeah but he cleaned the tank and frame to sell it.

[@andyrichardson6188]

@@jcondon1 Guessing the salt air is what corroded the breakers.

[@davelee9087]

@@jcondon1 With the water in the tank, and the amount of rust and corrosion, I was ready to bet it was completely underwater for a period of time. The salt air could do that though, but the fuel contamination just added to the mystery. Nice final product though.

[@BruceBoschek]

Yep! 😢

[@jbugjc1]

Your are the man James, great video, same issue i’m having with my neighbors unit, just no AVR on his. Now I have more info, gives me more to look at. Thanks for the video.

[@victorbellan8357]

Nice repair and explanations on what you are doing !

[@tomconnors6310]

Intersting videos James. I am looking to get a generator and now I know what to look for maintenance wise.

[@daleyurk4369]

James, it would be really interesting to see what the diameter is of the jet on the new carb compared to the old one. Nice video!

[@jozefsoemotinojo4324]

😮😮😮😮😮😮😮😮😮😮😮

[@jozefsoemotinojo4324]

😮😮

[@howieab606]

The surging got me thinking about a 10K "leading brand" generator I purchased a number of years ago from a local shop. When we went to test it after the electrician was done, it surged like yours did towards the end. Sent it back for "service", and when i got it back there was no change. So I sent it back and got a refund. To this day I don't understand why they couldn't have fixed it, I guess they didn't try too hard. At the urging of some co-workers i purchased a Honda and 10 years later I still love the Honda, great machine.

[@jcondon1]

My backup generator is a Honda. Not sure its age, has to be 15+ years old. Never a problem.

[@freddesjardins7399]

Sweet presentation! ❤️ just fantastic video also many thanks for your time in putting this video together, I was in tv engineering and always loved to tinker with engines and old clock movements. I got all the tools but my age is slowing me down at nearly 81 in July😝; I liked how you cleaned the carb with the ultrasound unit (same way I clean my clock movements) this generator was a nice find looked like it might been used in a salt mine 🤣 however the paint appears to be I perfect condition. Again many thanks for a 5 Star presentation.

[@jcondon1]

Thanks Fred. Was an odd one how perfect the frame was and everything else corroded like it was.

[@lawrencepevitts2434]

I loved when you took the circuit breaker apart. I generally like to do the same when I replace a part like that. Excellent video as usual.

[@FarmCraft101]

Nice work. I hate it when I can't get a carburetor figured out, but sometimes that's just the way they are. They seem so simple, and usually worked well when new, so why it insists on hunting/surging now? I have a generator that runs exactly like that. I put a clone carb on it and it's better, but still surges a bit without load.

[@jcondon1]

If it gets better with a little choke then the jetting is off. Otherwise have seen the issue caused by a missing anti surge spring. The Mikuni carbs on these Subaru engines are very lean. The tiniest bit a plaque will cause them to surge.

[@YukonHawk1]

Great team work between you and Ken. Nice!!!

[@ussreeves]

So informative! Thanks for sharing this in-depth repair on both ends of the unit. I’ve learned some new things.

[@mattyal9347]

Lol! That new cover on the powerhead looks great and it was funny when tou pretended to use the rusty old cover.

[@seamannn577]

Great video . After learning all the good things you show, you should have a lot of master diy students 🙂 Thanks 👍

[@michaeltarasenkoop2389]

I can’t Waite to tell you a service tech was sent to a private island in the Caribbean they lost power the problem was a guy was given a job to check the oil level in the generator he had to take a reading of oil pressure on the only gen every day and Wright it down ! He did day one reading 100 next day 90 next day 80 every day the pressure was going down every day until gen blew up when asked why he didn’t report problem he said he was only told to write down the pressure not to report to anyone if there was a problem he did his job !

[@jared5862]

I recently commented on another video about saving my rotor when mud dobbers built a nest on the rotor and corroded a wire in two. I did eventually get it soldered back together and I have tested it pretty well and it seems to be holding up. What I found out though is a lot of the rotors have copper coated aluminum wire to save on money. This makes it extremely hard to get the solder to stick to it. It took me a solid 1.5 hours of trying over and over before I got mine soldered. So don’t give up on it. I think if you stick with it you’ll eventually get a good solder joint on it and you’ll be back in business. Also I’m commenting half way through so I hope it’s not fixed by the end of the video or I’ll feel stupid. 😂😂

[@jcondon1]

I am not that surprised that aluminum was used. Not nearly as good or repairable as copper. I wonder how much money was saved by doing that?

[@jared5862]

@@jcondon1 well I’m not sure. I did recently price the copper wire to rewrap that rotor myself and I guessed at how many linear foot I would need so it could be more or less but I figured it was going to be about $50 just for the copper wire to rewrap it. Maybe I’ll see if I can find some copper coated aluminum just to see what the difference is. If I find some I’ll let you know what it comes out to. Also on the same line what’s your opinion on this? That rotor wire broke right where the wire crosses over from one rotor half to the other. If my soldered connection fails I thought about just taking the wire and unwrapping one wrap from each half so that I have about a 20” tag on each side and then strip, twist, and solder them together at the same point. (Trimming off the excess of course). Every video I watched rewrapping a rotor this is how the halves were joined. So I thing a solder joint there will be fine but the real question I wonder about is will unwrapping one wrap from each side affect the power output? Surely the number of wraps wouldn’t be that critical I wouldn’t think. In the videos they didn’t even count wraps. It was more of visual of, yeah that looks like enough wire.

[@andyrichardson6188]

@@jcondon1 If you try to solder that again, make sure you use lead-free solder. Leaded solder apparently won't stick to aluminum. Your flux may not work with aluminum either. I'm thinking a crimped connection would be better. Not sure if that's possible.

[@dlaitch]

An excellent easy to hear and follow analytical repair job !

[@williamstucke5445]

Very useful, indeed James. Thank you. Some questions: - 1. You used a Torque Wrench on a number of occasions. What did you set it to, for each size / location bolt? 2. I didn't see a capacitor anywhere, to provide a phase shift for the starting of the generator. Was one used or not? If not, how did it work? 3. You mentioned 2 additional windings. Starting and sensing. Can you tell us more about these?

[@shaneweatherall8666]

Hi James, those rotor electrical connection points are not soldered, they are glued on with an electrical conductive adhesive. It can be bought on line from Amazon. I enjoyed this video, well done.