Solved - My Generator Starts But Won't Stay Running (GENERAC COSense GB6500)

[@jefflanham1080]

I’ve got the same exact generator……..12 hours same friggin problem, PISSES ME OFF! I’m gonna bypass because at $115.00 for the part, it will probably go bad AGAIN!! Damn I paid good $$$ to have a generator OF QUALITY!!! In the year 2024 if you don’t know about carbon monoxide…….you probably don’t deserve to live anyway!!

[@EastTexasHomestead]

I’m not sure why they don’t have a recall on this yet

[@felixgazmey9647]

I appreciate the video, but wouldn't it have been simpler just to resolder the capacitor back on. seam better than risking a sock and pulling out the multimeter. Just pull out the soldering iron and be done in ten minutes lol just my smart ass two cent lol

[@celicablues]

​@@felixgazmey9647 Because it's a useless safety feature. It's for people that will run this in their garage with the door closed. Or even inside their home.

[@celicablues]

Also, I work on these every day right now. Florida. And they are brand new, lots of them, hardly any hours on them.

[@celicablues]

One more thing, the yellow wire is for the low oil pressure switch, so you've effectively bypassed that. I might need to check the wiring diagram again to confirm that though.

[@THEMOWERMEDIC1]

I’ve had a few Chinesium clone gp6500 gensets in the shop with the same issue. Thanks for posting!

[@EastTexasHomestead]

It's interesting that the clones had the same Issue

[@celicablues]

Just in case you read this. I made the comment to someone else's, but the yellow wire is the low oil cutoff switch. I think youve bypassed that. So you should probably disclaimer thay for those who wouldnt ever check their oil.

[@57haldir]

Could he/we just cut the yellow wire? Also, If he splices the blacks and plugs it back into the motherboard I don’t think it bypasses the low oil cutoff. Agree?

[@jessegarcia7383]

Man I can’t Thank You Enough, I’m in Houston and we just got hit by a hurricane. And we are without power, I went to Lowe’s also this morning 7-10-24 picked up the exact same generator and it happened on the 1st day. I saw your video and did exactly what you said and wala it’s running. Once again Thank You!!!

[@EastTexasHomestead]

What a shame! Generac has got to fix this. You’re the third person today with the exact same story. This so-called safety feature is going to kill someone. But I’m glad this was helpful and you were able to get it fixed. Great job taking care of things! We are just north of you and I’ve only had to deal with a few small power outages. Check into some of our videos on off grid solar so you can be ready next time. Stay safe down there.

[@h-townlifestyle9105]

This is day 4 whit out power I have the exact same one. From home depot And did the same problem just now

[@EastTexasHomestead]

@@h-townlifestyle9105 Sorry to hear that. Were you able to fix it?

[@geechiesghost8118]

I didn’t destroy the pc board, but I did directly connect the two black wires. It works great now. The little white box on my pc board came loose. Generator (GP6500) runs now and supplies electricity. Just pull the 2 black wires out of the connector, tape them together, and connect back for the others to work. Yellow light does blink constantly now.

[@deniseandmarkfirestine7443]

I just bought the same one, thanks for the heads - up on how to fix the issue on the genejunk!!

[@EastTexasHomestead]

It could save your life! Ok, maybe that’s a bit dramatic, but it’s a huge pain when this thing goes out when you are depending on it.

[@vazquezsantos4]

Thxs my guy this actually helped me 💯% pretty much same thing happened just a a different piece inside the box was broken but I was able to by pass it and now it’s working like new! Thxs a million

[@EastTexasHomestead]

Glad it helped!

[@57haldir]

Has anyone tried just cutting the yellow wire? Also, I’m wondering if initially unscrewing it from the frame and suspending it from a string or heavy rubber band might minimize the vibration and alleviate the problem? Yes it’s a defect and a bummer but for now we need options. No one is coming to save us.

[@johncoffman2703]

Thanks. I had mine run for 20 hours then had the same problem. I took it to the service center and said it was a bad spark plug. paid 74 dollars. I got it home and same problem. Called them back and wanted me to bring it back. So there sorry assed junk. Should sue since this is a safety issue a family could have died. I use my carbon monoxide unit anyway.

[@JJVargas4u2c]

I put it back in the case it came to Cove the plug. Thanks

[@michaelanger1392]

I think the reason why you have that board is in case you have carbon monoxide and it shuts off the generator

[@mehoff88]

Mine only has three wires a red, yellow, and black wire. Which ones do I tie together?

[@jepcozenith40]

Yes, that is an electrolytic capacitor. Depending on the solder it could start melting at 190F. Most at 800F(ish). Hopefully, that is not Texas hot. Looks like a cold solder joint. That is where the solder did not properly flow on the leads of the cap. So the cap is just touching the solder instead of adhering to it. Over time it fails. Falling off. Probably lead-free solder and poor quality control.

[@EastTexasHomestead]

😆 It gets pretty hot but not 800 degrees hot.

[@stevebost8048]

Thanks for sharing I'll make sure I don't buy a generator with this function

[@EastTexasHomestead]

That’s a good plan :)

[@r.romberg8312]

Have you had an issue of it running, but not delivering power?

[@sondrad101]

I asked him the very same thing because after following his steps I lost electricity but got no resolve from him 🤦🏻‍♀️🤷🏻‍♀️

[@rlowe3]

To shut down, just shutoff the fuel.

[@roel209ful]

The choke close it lol

[@speakinechos]

What is the part number for a new part to replace this if it breaks rather than just bypassing it

[@sondrad101]

I have the same issue and I called Generac. They told me that the new part # is 10000032946 for $359.99 which is a rip off: especially, since it's evidently a frequent issue.

[@patriciocampuzano4522]

He’ll no

[@EastTexasHomestead]

Wow! Instead of recalling a bad design, they want to charge half the price of the generator for us to fix it?

[@jefflanham1080]

……I miss Radio Shack…..at least then I could fix it a little more professional.

[@orlypalomar]

So close... using an RPG to take out a bee. It was a potentially easy and cheap repair with the decapitated capacitor, IMHO. I guess the root cause of the failure is that whoever made that module, didn't care to secure the electronic components in glue or potty. Generators produce a lot of vibration and is the main reason why electronic components that are left "flapping in the wind" will eventually work its way out of the circuit board... one way or the other. People going this route ought to check local state laws on circumventing or disabling safety devices on generators. Nevertheless, I enjoyed the video.

[@GZEPOL-gr2ml]

I just bought mine this afternoon and it started and runs but produces not Energy! Why, help! 🤷🏻

[@EastTexasHomestead]

Be sure to check the breaker on the far right. See here: kzbin.info/www/bejne/eGPXhpWKqMxlnrssi=kdy085cJ73c769oS&t=204

[@JamesWebb-i4w]

Thank you very much for showing how to fix this problem. I have the same generator, with the same problem. I thought it was a fuel problem. I changed the carburetor, and it still shut off. Followed your directions and it fixed it. Thank you very much for the help !!

[@EastTexasHomestead]

Thanks for sharing

[@justinweber7547]

Bro you are awesome I have a different board but the same problem. My red was labeled 120v green was ground and one black was ignition coil and the other ignition switch. Pull the box and it works but dont shut down but thats no issue because I generally cut the fuel and let it drain the carb.

[@EastTexasHomestead]

Glad it helped and thanks for sharing!

[@melanierazo5901]

Man thank you for this video! Day 6 of no electricity, we bought this 2 days ago only ran for 4 hours and it turned off. This has helped my dad fix the issue thank you 😢😢😢😢

[@EastTexasHomestead]

That's so frustrating. I'm glad he was able to get it fixed. Do y'all have power back on yet?

[@timm1065]

Should have just cut the top two prongs off the board and put it all back together. Seems it would have worked still.

[@EastTexasHomestead]

maybe so

[@chelsw9764]

You are an absolute life savor!! Issue is fixed now the piece was different but who cares, my $1200 machine is not junk anymore n that's great!!!

[@EastTexasHomestead]

That is great!!!

[@protechmachinery1]

I have the same unit but won't start at all. Nothing when I pull. It was working one moment. Turned off. Topped with gas. Tried to turn back on. Nothing. Ran it for one storm. Then for 2 hours on the next storm. And that's it. Less than 50 hours. I'll check the cosense module but it's a different issue. Mine won't start at all compared to yours flashing and then stopping. Mines not flashing at all. Trying to think what the issue could be on a nearly new unit like yours.

[@Darjan_Spasojevic]

Try spraying ether to see if it will start. Might just need a carb clean and new fuel.

[@marktomlinson3448]

Disconnect the oil sensor switch and try it. If it runs, you either have too low oil or you need a new switch. This is a common problem with lots of equipment. The oil switch is in the same stop circuit as those 2 black wires. the switch shorts the wire to ground when it thinks that the oil is low, and that prevents the engine from running.

[@coyotesden]

I have had to do this to 3 Dewalt generators all using the same Generac COSense garbage over the last year or so. I said f it and just cut the black wires and crimped them together. None of mine were the Capacitor, all of them had water corrosion on the board shorting them out, the conformal coating was not complete on any of them and that is the spots that corroded.

[@EastTexasHomestead]

you would think they would either fix the problem or stop using the faulty safety product. I guess it just looks too good in the marketing.

[@rpfl5586]

Took mine out and now it runs great again but doesnt produce power? Any ideas? Thanks

[@EastTexasHomestead]

@rpfl5586 Be sure your 30 amp AC Breaker is turned on. That's about the only thing I can think of. I just used mine again this weekend, and it works great.

[@ThePirate045]

We got this generator and had the same issue. We lost power in Houston and your video saved us thanks!

[@EastTexasHomestead]

Glad it helped. Sorry Generac is still selling such a bad product.

[@johnseavey6622]

Good luck with staying together without being soldered

[@EastTexasHomestead]

Time will tell

[@rpfl5586]

Couldnt youjust cut the 2 black wires and wire nut them together? Great video. Thank you

[@57haldir]

Yes. And I think if you then plug it back into the mother board you don’t by pass the low oil cutoff.

[@hugoaguilar7060]

I just bought mine yesterday and had it on all and it has the same problem thanks

[@EastTexasHomestead]

Sorry to hear that. Generac really needs to get this figured out

[@jasonflyte3175]

Thank you! This saved me big time!

[@EastTexasHomestead]

@@jasonflyte3175 glad to hear it!

[@philliphall5198]

Thank You’ll for information and advice Good to know how to fix it and no more trouble

[@EastTexasHomestead]

Glad to help

[@roncyrier]

amazing! Thanks. That was very good advice.... and just in time. I was just about to go buy a Honda generator for 900 bucks! so nice. We are in a hot climate too in Baja California Sur so I like your theory. Oddly my little blue transistor was fine, but the little square one was wiggly. Dumb stuff.

[@EastTexasHomestead]

Glad it helped!

[@marktomlinson3448]

That blue thing is an electrolytic capacitor. It is easy to obtain another new one with the full leads, and solder it through the holes on the board. You have to install it with the correct polarity though, which you might be able to figure out by comparing with how the similar smaller ones are installed.

[@jhpfmj]

I can't believe that I just found your channel. Also just bought that security torx set per your link. I didnt have the security set.

[@EastTexasHomestead]

Thanks for using the link! Did you have the COsense issue too?

[@jhpfmj]

@@EastTexasHomestead No, Sir. I Have a much cheaper piece of junk. I was watching random generator repair vids and this one popped up.

[@RolandoGuevara-qe7sr]

Very nice thank you for this video it helped me out a lot

[@EastTexasHomestead]

Glad to hear it!

[@Falconsfight]

I liked the video, but my only problem is where you had your generator. It should be atleast 10 feet away from any structure. This is to help in case your generator should short out or catch fire. Muchless to reduce the risk of carbon monoxide poisoning.

[@EastTexasHomestead]

In a perfect world, that would be great. How do you run your generator out in the middle of your yard in the middle of a storm? I run mine on the covered porch of my barn, which is at least 10 feet from the door. It's >50ft from my home, where I would be using it.

[@Falconsfight]

@@EastTexasHomestead True, but I have a Gentent canopy to protect my Generac RS8000E. There are methods to protect your generator from the elements from building PVC/ tarp configurations to making a generator shed. My unit is about 20ft from the house and secured with a heavy duty chain. The first thing stolen in a disaster are generators.

[@jessegarcia7383]

Will do and Thank You once again

[@EastTexasHomestead]

You bet

[@mazensholakh9529]

Was having the same issue of the generator turning off. I removed the CO sense and it’s working fine, but now I don’t have ac power

[@EastTexasHomestead]

Check to make sure the breaker on the far right of the plugs is flipped on.

[@mazensholakh9529]

@@EastTexasHomestead it is :/ Not sure if there’s another issue now

[@EastTexasHomestead]

I’m really not sure. I’ve had others say this after “fixing it” but don’t know why. Maybe double check the wiring. Did everything look the same as mine or was it a different wiring configuration?

[@jepcozenith40]

Yeah, looking a the stills in the video. You can see on the PCB that the gold is showing around the holes where the cap was. Now, look at the connector on the PCB. Solder flows up the leads. That is how the solder should have flowed up the leads of the cap.

[@EastTexasHomestead]

It may have been easier to simply solder the thing back on. I’ve just never attempted it.

[@jepcozenith40]

@@EastTexasHomestead regardless, it is working. Not gonna run the gene in the house anyway.

[@nater6604]

Thanks a bunch for making this video. I have the same exact generator I bought like 2 years ago because of a snow storm. The generator sat in my garage ever since never even put fuel in it. Tried to run it today to power my welder for the first time and nothing. Made a couple of connectors taped up the empty leads and it worked perfect. 😎👍

[@EastTexasHomestead]

I’m glad it worked for you! It’s a shame a good brand is shipping out trash and not standing by the product.

[@sondrad101]

Sir, I did everything in your video: my generac gp6500 starts and turns off just fine now. The conundrum is that now that I did everything that you shared, step by step, my generator no longer provides power or electricity. By chance did you encounter this and if so will you please share the resolution so that my gen provide electricity again? Thank you in advance and standing by for your convenience. 🙏🏼🙇🏻‍♀️

[@EastTexasHomestead]

That’s so strange. I haven’t had that issue, but maybe someone else has and will be able to give direction.

[@daltongriffin1700]

Did you ever figure it out? I’m having the same issue after the bypass

[@57haldir]

Try instead just jumping the black wires then plug the harness back into the mother board.

[@whitesabre9974]

Thank you so much for posting this fix. Purchased mine this morning due to hurricane Beryl. Ran two hours and stopped. COnon-sense!

[@disorderlymovement]

I'm in same boat. 59 hours on mine. Same issues as this, but not sure I want to take apart and void warranty. Yet, my 88 degree interior of home disagrees and says DO IT! Have you tried this yet? Curious if it fixed your issue?

[@whitesabre9974]

@disorderlymovement Haven't tried yet. We reduced the load on the generator and are managing with only one window unit. In addition to dealing with the results of Beryl, our entire family is really sick. So far reducing the load has helped...we will see.

[@disorderlymovement]

@@whitesabre9974 Thank you for the response. I did go through with the work after some reluctance. Yet, only to the point of removing the "control unit"/board. My capacitor was still in place. Yet, with removing the board, the generator is running great. Has gone for a solid 6 hours now with no issues. The on/off switch does not work, but I can carefully pull the spark plug wire or just starve it of fuel when I decide to shut it off. Hope you are able to get yours working 100%. Again, truly appreciate your response and wishing you restored power very soon. Let's hope that is the last storm for Houston for the season.

[@EastTexasHomestead]

I’m glad you had success getting power! Now let’s hope you get grid power back up soon.

[@KevinAndErica]

Great job brother 💯🫡

[@EastTexasHomestead]

Thanks!

[@lysanconstructionllc300]

gracias a este video me ahorre 800 usd

[@EastTexasHomestead]

👍