Troubleshooting Inverter Generator Will Not Start - FIXED Fugi Micro

I picked up this used inverter generator. Was told the only issue was a dirty carburetor, but it would run on partial choke. Could not get it started. Cleaned carburetor and confirmed spark. It needed a long list of things to run again. Unfortunately parts are almost impossible to get for this. I probably could of split this into several videos. Here is what was wrong:
- Broken recoil
- Broken recoil rope
- Tight valves
- Broken compression release
- Broken primer bulb
- Bad fuel
- Clogged carburetor
- Broken spark plug boot
- Missing rubber foot
- Broken choke lever
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
Will Not Start, Valve Adjustment, Carburetor Rebuild, Primer Bulb, Compression Release, Surging, Recoil Rope Replacement, Spark Plug Boot, Bad Fuel, Fugi Micro, XF-SF2000, XG-SF2600, XG-SF3000, XG-SF3700, F4200Ri, F5200Ri, F6200Ri, Lifan Inverter Generator, ESI 1000i, ESI 2000i, ESI 2500iER, ESI 2600iER, ESI 3100iER, Honeywell Inverter Generator, HW1000i, HW2000i, Xplorer Generator, G2500, Magne, Magna 1000, Magna 2700, Magna 3000, Clark, IG1000, IG2200, 2000i, 1000i, Inverter Generator

[@reidmalachi-fanau4799]

You have the patience of a saint, that cord break wouldve been the end of me, especially with those generators.

[@John-vf9py]

I must say , you are the most patient, calm spoken trouble shooting genius I have ever watched yet. I repair many machines and you have shown me so much in two of your videos I have so far watched . Thank You. SUBSCRIBED

[@tomwhelan4561]

Yes' he is not full of himself,he sounds very humble to me!

[@morganrathbone7960]

@@tomwhelan4561 p

[@glennk1931]

I totally agree John.

[@johnclarke6647]

That’s a carbon resister to cut down RF interference. Take it out and use a resistance type spark plug.

[@albionwatts6000]

Goodness me... When they were serving out PATIENCE you certainly received more than your fair share sir...

[@bradmonrean2307]

I would have hit that thing so many times with a sledge, that a gentle breeze would have blown the dust away.

[@tonym6920]

Indeed, patience is a virtue. As I get older, 73, I find I run out of it quickly, lol

[@glaucouswingedgull]

I would have hurt myself, seeing how far I could throw it for distance.

[@rustybum2]

@@tonym6920 Me too at 76 !!!

[@davidmonteil6340]

@@glaucouswingedgull A 2 handed shot put throw!...lol

[@phbrinsden]

James, you get an A+++ for determination, patience and just clear thinking. A real tour de force in sleuthing out issues. Congratulations.

[@michaeltarasenkoop2389]

Either you get a good one or you get a unit filled with trouble one way or the other so you take a chance when you buy a used or factory unit that for some reason is troublesome for some reason or another had a Honda small one that you couldn’t kill until let a neighbor use it ! Used it for years cleared about 6 building lots of trees till lending it out gas into oil then oil into gas killed it !

[@robstirling3173]

The little slug in the spark plug cap is a radio interference suppressor /resistor, they often have a small coil spring behind them to ensure a good contact. The brass part has a type of R clip to make a good connection with the threaded end of the spark plug. A lot of engines now use that type of connector.

[@sth50100]

Q

[@gregdawson1909]

Get yourself a table / bench to work on, take it from me, 10 years from now you will regret every second you spend working on the floor today.

[@gregdawson1909]

posted that at literally 19 minutes in, minute later its on the bench, but seriously, after the initial it won't start, move it up to a comfortable level.

[@dljones61]

Same here James, I'll be 60 next month and can tell you, save your knees man. strap that thing to your bench with a ratcheting tiedown and save yourself some grief. :)

[@phbrinsden]

Totally agree. Save the joints and work comfortably too.

[@adamrussell4703]

I was about to say the same thing.

[@ddssdickday]

Talk about tenacious! After the starter cord handle nearly ripped your hand off, that baby would have been sitting by the curb :) Another great video.

[@jcondon1]

Thanks. Yes this one was one of the more challenging ones. It would have been an easy fix if parts were available.

[@neil6212]

@@jcondon1 Another reason to stay away from Chinesium! Most of not all of the very small inverter generators are much the same, as far as service is concerned!

[@glennk1931]

Incredible patience. That was one excellent feat to get that little guy back in business. Hats off to you.

[@adamasz54]

Another success of knowkedge+patience, yours of course! Looking at so many electronics packed up into the small boxlet together with hot cylinder does not bode well for a long, happy life... High congrats again as you packed them all with without leaving certain parts without an address! Thanks also for a perfect engineering language - many of us ME and EE could learn from you...

[@garyharrismusic]

That was a amazing display of patience and persistence! I wonder how many repair shops could have got it going. Another Great Video!

[@graybeard1952]

My garage wall would be peppered with tools and parts. You are a very patient man, James. Good job.

[@rtw8972]

Your best video yet. Your persistence is admirable. You have taught me so much in a field that I have ignored all my life. My background is industrial instrumentation,electronics,electrical power and mechanical , in that order. But with all my knowledge and 60 years of experience, I had no clue why my 1980 6kw generator was surging. Thanks for the lessons..

[@somerandomguy3868]

You're absolutely right, most people would have no idea how to get this machine to work and would very likely put it out for trash, nice job

[@scdevon]

I don't know why knock-off Chinese stuff is so hard to get parts for either since only a few factories make all of these brands of generators especially the Yamaha knock-off ones like "Westinghouse" (LOL) and Wen, etc. A U.S. company could make a fortune buying parts from the from the Chinese factory. You could match the parts up visually on a website for the generic parts and not even have to fuss about model numbers and all that crap.

[@paultennis9414]

Your patience and persistence are admirable. Thanks for sharing this video. I learned a lot.

[@davida1hiwaaynet]

Wow! That is such an intricate, complex machine. It's got such a powerful engine to be so small; because it's not limited to only running at synchronous RPM. What is the common tragedy with many Chinese products is that all that intricate engineering goes to waste when the first small problem happens when you can't get parts. You've done a great job getting it going.

[@paulboomer7109]

I am Glad to see you off your knee's and on a work bench .👍

[@er1073]

Congratulations James. Some would say it isn't worth the bother. But we must be a like because it kept testing me. Your inventor's spirit is inspiring the pressure release was a good example.

[@sharnijephson7818]

This is just what is needed for partial rv backup. Operates the ac and stuff perfectly. kzbin.infoUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y is quieter than my rv generator. Only suggestion is that it needs a fuel shutoff valve. So it is easier to store.

[@MRrwmac]

Very good update. Especially the fact that if the fuel bulb goes out, it can be taken out of the system! Great temp fix on the compression lock out!

[@jcondon1]

Thanks

[@r8118830]

I am rewatching this one - a year on. You are incredibly patient James. I have worked on becoming more patient over the last 30 years through my Buddhism. However, you obviously do not need any religious practice to supersede me. That was a labor of love.

[@Mikesorrento3344]

Nice job. It’s such a great feeling of satisfaction repairing these inverters, generators.

[@jcondon1]

I learned a lot with this one. Wish parts were available. It would have made a better repair. But sometimes just gotta work with what you have.

[@dalemartin9948]

I am amazed, you are one tuff fellow. I enjoyed every minute of your trouble shooting. Keep the videos coming. I am so glad you did not give up on that generator. Their are great lessons to be learned from your tenacity. You set a positive example you all people who watch you. Dale

[@simonarichmond3626]

Excellent, this helps me a lot I have a Clarke 2.2 Kw Inverter Generator (Model IG2200) another clone ! But now I know possible causes of malefaction . I admire your tenacity and patience ! Thank you

[@cheopr2]

" men who dont fail they keep up trying,",,,amazing James...Kudos for you...good job...

[@Steve-vz3ud]

Hey 4 years later I saw your video.i fixed my generator for off.grid use.thanx mate

[@thetruth9361]

You never let them wear you down, I love to watch you solve problems.

[@GeoMo52]

Gotta say, your the man! Been binging every night now, for 4 days. I felt your pain on this one.

[@scottlindsley2171]

Awesome overview, certainly helped me to get mine going. Fyi the bit that flow out of the spark plug boot is a spring! It’s about the size of the spring in a retractable biro!

[@ssshawn2008]

I found this exact same generator in a dumpster a couple years ago . It looked to be in good shape so i grabbed it . It took a lot to get it running as well . But you were lucky . This one had a plastic fuel tank . The one i have is metal and was completely rusted out . The rust and old fuel ruined the fuel pump and the primer completely fell apart . I ended up mcgyvering it together . I took out the old fuel tank completely and tossed it in the trash . I used a vaccum diaphram fuel pump from a riding lawn mower and used a 3 gallon outboard boat motor fuel tank with hose and primer bulb with a set of johnson/evenrude fuel fittings . Also, the carb is the same as the ones on honda gx160 motors . Just have to swap out the butterfly and shaft . I had the same issue with the pull start as well . Its the gx 160 pull start housing

[@jcondon1]

Very nice

[@robertcrum6169]

Glad to see you have it running again and not making a new place for window in your shop. Keep it up. Automatic!!!

[@Chris-yy7qc]

31:45 Its a resistor to supress electro magnetic fields created by the coil. Those EM fields could potentially disturb electronic devices near the generator. Sometimes these resistors are built into the spark plug boot. Sometimes theyre built into the spark plug itself.

[@tonym6920]

Whoever had this machine really beat the hell out of it. Thanks for the vid!

[@PeterLawton]

I learned something again. Thanks! The idle jet screw holds it in place so I never looked for a second, completely different function (throttle stop), but still felt I was missing something. I was.

[@dredge999]

Love the videos. I appreciate you fixing all of these machines and keeping them out of the landfill. I wish you were near me, I would pick up a couple of your repaired units if I could!

[@jcondon1]

Thanks

[@dannyj5688]

Great job as always.. Learned from this one...Never seen anyone have these issues with small engines before...thanks for sticking with it!!!

[@jcondon1]

I liked this generator a lot. Too bad there were virtually no parts available for it. Would have been a much better fix.

[@georgedemean2228]

@@jcondon1 I noticed that this generator has provisions for electric start (that's an upgrade that I wish my geny has)

[@davidmonteil6340]

Wow! Just wow! The most patience I have ever seen by anyone James. To be totally honest I 100% know that I would have scrapped that thing, if it was lucky enough to be in the scrap pile before the dump etc. Yep. Thank God there are other choices of generators to get.

[@richardpena7275]

This guy is a genius, as well as having plenty of patience. I have the same generator.

[@iantyler4045]

You have much more patience than I do. That thing is a Rubic puzzle to get apart. I think I would have taken to it with an axe after about the third pull apart but well done for your persistence.

[@superconfort]

I've learned a lot about these little engines with your videos. Thanks a lot!

[@waynedavies3185]

Lot of work being applied to this small generator to get it running. Working at an hourly rate, it would have cost more to fix it, than to maybe replace it with another running used one, but like you, I have a soft heart, and hate to see things not working, if it is possible to repair, and get it running. I guess it's the challenge of not letting the devise get the better of me and defeat me, and what I am able to do. Well done....

[@WayneTheSeine]

Man you have some patience. When seeing how hard it was to pull, I was like, that large red handle is the perfect tie point for an anchor rope.

[@stevehensonuk]

Great video! I have one of these in the UK and had to source a primer bulb assembly as the one on there had aged and got brittle. I did get one - £35 though so I'm delighted to see you explain how you could do without it (just more pulling) - thanks!

[@Bertrum123]

Hey thanks i had an idea it was fault on mine you made it so much easier seeing how the decompression release works

[@simongauthier8193]

Congrats on that one. You're a tenacious man !

[@robmochdre]

I’ve been watching your videos for a while now, I have a sawa Fuji 1000 inverter generator I bought it under similar circumstances. But luckily it runs a genuine Honda fifty . The pulse pump gave me a real hard schooling Had it to pieces thinking it was a carb issue The fact that it needs a decent amount of fuel in tank And primed using starting fluid did the trick for me , runs really lovely now . Thanks for taking the time to make these videos they have genuinely helped me

[@jcondon1]

Thanks.

[@probeteam9936]

YOU ... are a better man than me gunga din. You get extra points for rolling around on the floor with this stuff... me? My bones are too old and tired to be rolling around on concrete... I'm a bench kind of guy. Great job... thank you for your time and this video...

[@Bulletman426]

That was a good fix! I probably would have thrown it a few times, but you held your cool. Nice!!

[@Maurice1151]

Mate! I feel your pain! You’ve got a lot of patience.

[@nestorlugo.]

I already got my Generac GP6500e humming like a bee now I'm in search for an inverter generator. Thanks Mr. C

[@jcondon1]

Thank you

[@truthseeker9001]

Super interesting. I could watch you working on these all day. If you would find a Honda EU 2000i not working, it would be awesome seeing you troubleshooting it. I have one and it does not start

[@hal-rekabi6724]

You have a lot of patience. I was swearing several times specifically when it pulled back your hand. Great job though. I also believe fixing is much more satisfying than throwing good products. Manufacturers although make parts these days unobtainable which should change.

[@jcondon1]

It would have been an easy fix if parts were available.

[@alext8828]

@@jcondon1 , I can't help believing that these parts must be interchangeable and that the information is just not available. It really doesn't make sense to me why manufacturers would not use supplies of parts already on the market and used by other companies. There seems to be a high commonality with all these machines and telltale stampings abound, but no info is available on Google. There are parts companies that only sell to dealers, like STENS and some others and I wonder if they have better catalogs and manuals than we have. You proved that when you got the Honda recoil that fit your unit. I remember auto parts catalogs that omitted part numbers for certain cars so you had to go to the dealer. This is the same kind of nonsense but everyone loses. You did a great job and I'm glad you succeeded. I absolutely hate throwing things out. To me, it's like a sick patient that needs some help. Thank you for helping.

[@davidmonteil6340]

@@jcondon1 Makes me appreciate my (recoil accessible with only a few screws removed) Honda Ex1000 generator that much more. I rewound the recoil start spring on my honda using several tie wraps, put the spring in place, and then gently cut the tie wraps and it worked. Tie wraps are good..

[@JohnLIpe1]

This one is definitely a 4 thumbs up for patients and perseverance

[@ricdenali4213]

I thought you were gonna give up on it, glad you stuck with it !

[@jcondon1]

Thanks

[@thatflippinrabbit954]

Admire your determination,i would have thrown that thing in the bin ages ago out of frustration.

[@jcondon1]

Yes, was not a fun one.

[@jimhager8583]

James you did it again. Thank you for sharing all your knowledge about generator's.

[@larrykelly2838]

Way to go Doc, persistence pays off.

[@jcondon1]

Thanks! It is a nice machine, to bad parts are not available.

[@YukonHawk1]

Man....talk about a complete tear down. Great job and perseverance

[@jcondon1]

Thanks

[@marccrane4830]

Gas looks like they used "Storage Fuel Stabilizer" that's red in color.

[@agentcovert]

That or its tax free gasoline..dyed for off road use only..but yes most likely a fuel stabilizer..

[@skonky]

@@agentcovert i don’t think they make tax free gas, i know of offroad diesel/ heating fuel, but never gasoline

[@paulmoffat9306]

@@skonky They do, but it is not generally sold at a pump. You need to go to a 'fuel depot' to get it. Off Road gas, or Farm use gas.

[@jonminer9891]

Hi, James. Just found this old vid. I'm sorry it hurt you. I would probably have tried out some cussing at that point. Thanks for sharing! Stay Healthy!

[@paulparkitok1437]

Thank you for what your doing Your clarity in explaining each and every step and in depth know.i learn so much from you Keep up the good job your doing

[@davidsmith-ih2kk]

When I first saw this generator I thought it was a Honda clone, it looks just like a compact Honda generator, I believe a 1000i, so it's not surprising the starter assembly is a Honda but being Honda it probably was not cheap, but at least you got the part from Honda. I honestly thought it was a Honda when I first saw it. Great video James, always a pleasure watching a professional at work thank you for an informative video very entertaining thank you again.

[@MrMultitool]

You should really feel proud of yourself. You did a great job.

[@billhartsfield424]

You have more patience than I do !

[@hans429]

32'' the Peace with 4000Ohm is a noise reduction for radio interverence...so your neighbor doesnt loos picture in the TV when you run ya generator....

[@harrydoroba4699]

I got a Clarke with the same starting problems it kicks back and hurts my rest one out of ten times so thanks James I will get it sorted this weekend. Thanks. Harry UK.

[@harrydoroba4699]

Sorry it should be a comment for the last video I watched, about the Clarke starting problems.

[@CajunGreenMan]

Your patience rivals that of Mustie1 or Job. Great work!

[@jcondon1]

Thanks

[@brucecliffe6213]

I have a 4.4KVA unit like the ones you were talking about here in Australia. Electric start, remote start, etc. The primer bulb broke leaking fuel every where and I could not get a replacement. So I blanked off the one and only line to the primer bulb housing (yep, that is right, only one line performing both input and output for the primer bulb) and the generator started OK. This is now the worry, parts are an issue but the machine is quite good otherwise. By the way I could have bought 4 of these Fugi Micro generators for the same price as one Yamaha. We recently bought a Yamaha 2200, that is how I know , we saw the light. Thank you for the videos. Best regards from Australia.

[@jcondon1]

It is a nice machine. Wish parts were available. In my case it would have been an easy fix with a couple of new parts.

[@iandennis7836]

Bluddy 'ell, al that just to get the pull start off. You have more patience than I, James........😁

[@Hydrogenblonde]

That was a very helpful video. Thank you.

[@Dustin_the_wind]

Thanks for sharing James.

[@ronaldclark2624]

Thanks for the very nice video! Some time back they began using carbon instead of wire for distributor to SPlug connection. I believe the purpose was to reduce radio interference caused by a hotter spark? SPlugs today are good for 100K miles the last I knew. Carbon conductors are brittle and they used to break. What's the latest? I retired in 2006 at age 66. I am not a mechanic. Living is learning! My real interest is in Armageddon and associated criteria. I find it most interesting! Ron

[@Jason-rs6co]

good work you have a lot off patience

[@james35546]

Your videos are extremely helpful. Keep up the good work

[@dimalranasinghe8152]

Thank you so much for sharing your experience.

[@jime9305]

Nice work...useful to me even though I don't have that exact generator, I do have a Chinese one in that wattage range, so seeing this one torn down and analyzed is very insightful, thanks

[@wazza33racer]

I bought a similar but different generator new...........and the sticker for start/choke to run was on back to front LoL. But I had no idea these small engines had a decompressor/compression release in them, interesting. 10/10 for persistence and working out a fix ))

[@jcondon1]

Thanks

[@TheChargeShow]

Again, another brilliant video.

[@Damon0306]

Great Job!

[@bluefluteman]

Excellent video thank you Sir!

[@JS-sh3nq]

Great video as usual. Keep them coming.

[@sairaqsa]

Good job man.

[@wendywendyclare]

thank you so much for your insight, i did not have do as much as you did James. you helped me out just fine. thank you

[@southernhawaiianbeginningb673]

Absolutely amazing.

[@duncanpage1556]

Nice work!!

[@joesinakandid528]

May I suggest: 1- Check oil level ( *especially* if it has low oil pressure switch). 2- Spark check (over 7 minutes in before you happened to mention you had done this). 3- Pull plug and inspect. Insert a little gas into cylinder before replacing plug. 4- Then try to pull start ON A TABLE OR BENCH. 5- If it briefly starts then repeat to see if it makes electricity and if so then flush tank & replace old fuel with new fuel. 6- If the carb won't support starting then clean it completely. 7- If it is too hard to find parts for then put it up on ebay as a parts only sale. And lastly - never use a torque wrench for anything except torquing a nut or bolt. Go find a cheap breaker bar for breaking loose and removing bolts in the future.

[@woodstover]

I second that emotion on not using the torque wrench for any thing other than torqueing up.

[@hanspaulavisser855]

Hi James, I really loved your video on the generator and picked up some clues where to look why mine isn't starting. Haven't yet kicked a goal though. Thank you for the great effort filming it all. :-)

[@kthwkr]

Shoe Goo will hold that primer bulb on. Shoe Goo - it's not just for shoes anymore. I use a tube of Shoe Goo every month or so and I haven't glued shoes for years. It's like an RTV that dries fairly hard but has just a little bit of flexibility. And it bonds to everything. However, if later you decide you want it off you may not be able to get it off. I used it on my washing machine knobs. They cracked and I used Shoe Goo to not only hold the cracked parts together but to build up and a space that previously was just open so that the knob would be stronger than original. I had one of the those blue outlet boxes in a wall that cracked. I gobbed in Shoe Goo and rigged up something to push the box in place while it dried. That was 10 years ago. That outlet box still works just fine. Fixed my CPAP mask.

[@reypanelo]

another awesome video, learning a lot from you. Thank you

[@jcondon1]

Glad to hear it!

[@hikurukutai]

cheers bro that is what is wrong with my machine, got the shell off though it was ceased they are a good inverter, had mine over 8 years I suppose they are not meant to last for ever but with guys like you who knows

[@catcam]

Thanks for great content ... just subscribed !!

[@denmanshaffer2773]

I can’t believe you had the patience to keep fooling with that thing.

[@MariaEngstrom]

I think he likes generators because many of his videos is about them. :)

[@kirkb2286]

I hope they paid you to take it. 🤣🤣 Seriously I really enjoy your videos. I have started to find Gen and repair them due to your inspiration….Thanks again

[@Mr_Tecumseh]

I have the honeywell version, found it at curb free. All of its parts are intact. It doesn't generate power, the indicator light says overload. Not sure if its worth fixing. But it runs perfect. One of the tiny wires broke off that sensor on the carb so it runs only at full throttle. Easy fix for someone good at sottering. Maybe I'll part it out and sell its parts online, unless fixing the inverter is easy and cheap. If not part out.

[@jcondon1]

Would part it out. The inverter is potted and not serviceable. Might be able to buy a replacement inverter, but they can be very pricey.

[@jambenzman]

Great job

[@thimothelamoureux5718]

Such a great video! Thanks for making it. I don't yet know what's up with my similar generator (made by King Canada: KCG-2000i) but it makes me second guess taking it apart ;)

[@thepickn]

You're son probably loves you for your motor skills that's why he comes to watch having children gave you the pachants to do so well.

[@therealchayd]

I have a 2.2kw version of one of these branded by Clarke (UK). It was nice to know who the actual manufacturer was so I can find out what the stator voltages should be as there's no output and I've already replaced the inverter module to no avail. Thanks for the information!

[@jimmybrad156]

Did you manage to get a good deal on the inverter module? Ones I've seen cost hundreds!

[@therealchayd]

@@jimmybrad156 Nope, the only one I could find was from Clarke themselves and cost me around £200 and the 🤬 thing still doesn't work. The generator has since been dumped in the pile of "to do later" projects.

[@willrobbinson]

that little slug is a resistor for radio noise suppression 4k ~ ect but also a lot of spark plugs have these inbuilt so can test by meter measure top connector to the center electrode, anything above 20k or so will start to give a weaker spark ,have found some old plugs 40k + so its worth testing

[@trevorhalford8410]

Sweet! Nice job but I'm really wondering how long it will take to wear through that wire and it fall in the engine. It works well tho. :)

[@doose911]

I was thinking of the same thing!

[@jeffreyhaynes5774]

Weld it in place,remove the wire.