Troy-Bilt Generator Engine Runs Well But Doesn't Put Out Power

Found this Troy-Bilt generator list on Facebook Marketplace for $150. The Engines runs well but the generator does no make power. Lets see what went wrong and fix it.
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Bad Stator, Clean Slip Rings, End Housing, Fixed, Generator, How To, How-To, Increase Voltage, Insulation Failure, Load Test, Melt Doan, No Power, Not Producing Power, Ohms Test, Powerhead Swap, Residual Magnetism, Resistance, Slip Rings, Small Engine, Stator Install, Stator, Troubleshooting, Voltage Adjustment

[@dhn1234]

This is better than Netflix or Amazon Prime TV or movies. I love his patience, cleaning, his methodical step by step, always takes carb apart and cleans it with ultrasonic, checks spark, buys broken parts, changes oil, even splits the engine to fix timing gone bad. Watching these some of us learn better maintenance requirements. James should sell these videos or get them put on PBS, likeThis Old House. James would be famous as everyone has small engine machines that are not running as they should or could. I have learned to apply many good tech ideas, Thank You, James

[@anthonymarino4260]

loves what he's doing well done

[@HeavyFCCHeavyFCC-l9m]

James is the Norm Abram (New Yankee Workshop) of generators

[@ThePearsonExperience]

I picked up the same generator last week with a blown motor... I got it for a steal... $25.00.... So this video will be priceless when I get the time to fix it... Thanks James

[@robertbunch8362]

James, you are my go-to when researching about generators. I recently brought home a Troy Bilt 6200 watt machine that had been stashed away in a shed for several years because my cousin said it never gave her any power. Finally, she couldn't even get it to start. It was filthy so I cleaned it thoroughly and made it look almost like new. The plastic tank was easy to clean out, but the carb was a mess inside. Put a new carb on it and it fired right up. After cleaning it up I pulled the cover off the end of the power head and looked at it closely. Everything looked great, but it did have a very different regulator in it from most that you show us. No voltage adjustment. I also removed it and the brushes and the brushes looked really nice, almost like new. The rings also looked almost new, but I did scotch-brite them to be sure. HOWEVER, I only get a rotor resistance reading of 6.8 ohms. That's right! Six point eight ohms! I checked it maybe a dozen times to be sure. Used two different meters, one was a Fluke 77. So, I figured it was shot. NOT SO FAST, THERE COWBOY! I finished installing the new carb and put it all back together and it fired right up as expected. But, what wasn't expected is that it showed 115 volts on my meter so I plugged in my grinder and it worked! My question is, are there some power heads that do have lower resistance rotors and a totally different regulator to work with them? Must be, because mine is working just fine! My power head is exactly like the Storm Responder one you show in this video. Everything on mine looks exactly like the Storm Responder machine you are showing. Exact engine, too. Just wondering why my rotor resistance is so low since most are supposed to be 40-70 ohms. I almost junked the whole unit because of that, but decided to just try it anyway. Glad I did! It's a nice running unit now. No load voltage of 115.6 volts with 60.1Hz. Loaded (750 watt fan loading) it goes to exactly 60.0 Hz at 114.0 volts.

[@wadepotter5377]

Who knew generator repair could be so entertaining? The production is done well and the instruction is also. I've only watched three or four to date but I know more hours are about to be spent on your channel. Thanks

[@leslycastro2131]

1:11

[@CHARLESCALHOUN-sg6ly]

​@@leslycastro2131⁰

[@comeasyouare4545]

The screw that was missing might have fallen out and been thrown into the windings, but if that were the case, you should have found the screw. Unless someone had opened the end, and removed it. Always liked a good mystery. Great video.

[@piconano]

I think the owner opened it up and saw the burnt wiring. Got disgusted and didn't bother with the second bolt. I also think if he told James about it, he would not have gotten the $150 he was asking. In James's mind, there would've been no doubt that the stator was bad.

[@jcondon1]

It’s rare to fine one with a 10hp Briggs OHV with a working engine and bad powerhead. Usually it’s the other way around.

[@comeasyouare4545]

@@piconano I think James would have paid $150 for it even with the bad power head. If the owner had opened it up, it possible that that they found the screw, and removed it. The rest of it looks, and works well. And James had the spare power head on hand to replace it. It's always a gamble when you buy broken things. You look at the valve in it that you know, Which James knew the engine was probably good, since he had heard it run before buying. But Like I said: I like a good mystery.

[@hypnotherapycw]

@@piconano someone CLEARLY opened it up and didn't have the integrity to put it back.

[@gregclarke6419]

I was thinking the same thing. May not have been tightened correctly, works itself loose.

[@GearHeadBoris]

I've never had a problem yet with any of my generators but somehow got addicted to this channel full of broken ones😀 Good work here!

[@markmoran9716]

Hey, I just realized something, there are always no advertisements on these videos. Does that mean that they are not monetized? If so, hats off to you. Although, what you do and the videos that you post are valuable. I would be willing to watch some ads so you can get paid for this.

[@KensSmallEngineRepair]

Another save from Condon’s House of Power!

[@natnaelekubay4069]

A great vedio

[@gwinters6847]

I just did a slight mod on my microlite 2800, picked up for free, tuned up, oil change and replaced coil spring for choke, adjusted governor response to load applied .. voltage unloaded 125 at 61 hz, loaded 50% or 1500 watts, 118v at 59.8 hz . Quite a drop for half load. Its primary use was an RV but ATT had it in a service van, used it til it would not run steady.. My company purchased the van as a swap when the other hvac vehicles were in for repairs.. I pulled genny out and kept it til the time was right. Now I have emergency power to feed one leg on house panel for essentials.. heat, fridge and basic lighting. Made a frame, wheels and a three gallon tank with a draw fuel line since the unit has its own fuel pump, electric start .

[@shawnmrfixitlee6478]

WOW , That one really burnt up James ! They blow like a light bulb to man FAST .. glad you had the parts to make a nice generator out of it ! ENJOYED ..

[@warriordrum]

I also appreciate the careful and methodical approach. Very informative. I would buy a machine from you anytime.

[@christurner5473]

Great video as always James. Have you thought about getting a table that raises up from your air compressor so you don’t have to keep bending over and stretching your back

[@dwightosborn8400]

As I said before I would be willing to help with the purchase of that table I'm almost done with the Parts washer let me know when we start on the table purchase Animal

[@fair2middlin]

I thought all Amazon shills had the stuff Amazon sells

[@WWNF911]

I use the hydraulic lift at Harbor Freight. 500 lb. It helps get it up where you can work. I also take it with me in the SUV to help load and unload when I don’t have someone willing to help me lift it into or out of the SUV.

[@dwightosborn8400]

He's not getting any younger

[@phillipmckinney7906]

Nice Fix for a troubled Job just doesnt get much better video than this one

[@colinevans7134]

I do this myself as a hobby, best video this man has done, a very true and honest guy, just love watching other people doing this and this guy beats them all, want to see more, and more from this man. I need to subscribe kind regards colin from croydon surrey England 👍 👏 ❤

[@AlfOfAllTrades]

The damage on the stator also fits remarkably well with the missing AVR bolt...

[@jamesward5721]

If I was doing this, it died at the point I disconnected the wires... there'd be more hope of Napoleon coming back & re-connecting them properly than me doing it. I do love watching people who really know their stuff, do stuff. Great vid. :-)

[@mrpetit2]

That black tie wrap with the screw eyelet is pretty cool. 👍 I got to get some of those, handy to have!

[@whitesapphire5865]

Definitely a better machine than those offerings of last week! The part I don't get, is why it's always the windings at the bottom of the stator that seem to fail, never at the top. This looks like another classic overload situation, only this time, it never got the chance of a 'run down' to cool off before stopping. It never ceases to amaze me that people know the limitations of the machine, but still insist on demanding that little bit more than it was meant to give. Even with the bigger machines that we used to get, when my dad was still with us, it was almost always the same story, just bigger and more expensive! I must admit, I'm developing a soft spot for these Troy-Bilt generators - Familiar engines, familiar gen-ends and familiar AVR. Perhaps not for industrial use, but at the better end of the domestic brands.

[@ickipoo]

The rest of the windings looked spotless, so I don't think it was an overload. I think it was either mechanical damage to the winding or a manufacturing defect that caused a flash-over between layers.

[@whitesapphire5865]

@@ickipoo One thing that occurred to me was that if some foreign object had fallen into the stator, like a small screw etc., It may have led to a low resistance path to ground, and given that the neutrals were commonned to ground (frame), there would exist an almost dead short circuit between the windings and the neutral/ground, which would rapidly become a dead short, once an arc had been struck.

[@paulteirney3587]

Looking at the arc marks I would say that the bolt came out and shorted out on the copper wiring.

[@jcondon1]

Never thought of that. Makes sense given the missing bolt and the location of the burn.

[@hypnotherapycw]

@@jcondon1 so the bolt "evaporated" ... i don't think so.

[@wildefox1478]

It's a shame the powerhead failed but at least you had spare ones on hand to fix it up, nice work James! I just picked up my first portable generator off marketplace for $50, it's a vintage Sears 3000 watt with 230v output too. Looks like it might even have 12V DC output too because it has a positive and negative terminal on top of the powerhead, anyway I got the engine running and it powered up and makes power too! Will have to do a load test on it now.

[@jcondon1]

Nice

[@johnmaynard8884]

Great video, I learned a lot. I tuned my old generator and lapped the valves but have not checked the output yet.

[@Farm_fab]

Jim, speaking of shorting a generator, one of the first ones I ever got had no output, and it seems that someone did a diy and failed to break the brass between the upper and lower screw terminals on a house outlet. It started and ran, but nothing was damaged. They just got no output. Breaking that piece made the secondary on each half of the function as it should.

[@jcondon1]

Good to know. Not something I would have tried on purpose.

[@MrBugsier5]

its probably burned becouse the owner thaugth he could pull 6000 watts on one 120 volts leg instead of the 3000 each leg...we see that a lot here in europe on the 230/400 sets the selk here whit 3 legs .. a 6000 watts is then only 2000 each leg.... all burned out stators... the should buy the 230 volt 1 leg version... its mostly wrong understanding off how you can get the full power out of a set whitout letting out the magic smoke..

[@P.Trim69]

That's a good point. I say it a safe bet lot of people don't know that. I'm not electrician and yeah I might have accidentally done same thing not really thinking about it. my pops was in coal mines. I get his help a lot. But yeah that's a great point.

[@garrydonnelly6433]

Congratulations James, your eye for detail lived up to your usual high standard. Well done.

[@UdayaRai-mo4ur]

Udaya❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤❤

[@kpdvw]

another nice repair job; nice to have the needed spare parts on hand.....!

[@repairitdontwreckit4257]

Great video as always. I like the way you you figured out the wiring. It shows you totally understand how it works. A wiring diagram wasn’t required. Good job.

[@ehguy3628]

Nice video, I noted that the fuel in the jug went down very little. Seems fairly efficient for that high a load.

[@Me11oIngenuity]

I have the next version up from this one. Aside from the 15hp single piston Briggs engine sounding like it wants to scatter itself at any moment, the unit has operated pretty well.

[@rayshutsa6690]

Nicely done James you are very professional and meticulous in your diagnosis. You make it easy to understand the workings of the genarator. Thanks for another great video.

[@philliphall5198]

It’s cool how you build the loading rack for vehicles Very neat to have it ready to pickup a item if time is limited

[@andyhamilton8940]

Awesome! You did lose me on the wiring but im no electrician either!

[@davidbohner2061]

Also love the Condon cleanup and wipe down⭐️⭐️⭐️⭐️⭐️

[@paulsullivan6392]

Nicely done as usual. Impressive experience and knowledge to be able to correlate the different wiring schemes to get it to function without issue. 👍 👍

[@richardcook9738]

As always you do not disappoint! as an observer, what would think about the missing AVR screw falling out and just rattling around inside the housing until it shorted the winding to the housing?

[@martyb3783]

Great video. Thanks for taking the time to make it.

[@ron827]

Love all your helpful videos and your wood ramps with side guides. Yes, I saw you invert one of the neutral ring terminals so they fit better back to back on the stud. Not your first rodeo. :-)

[@Maxxarcade]

The original label on the replacement stator showed 5000/6250 watts, and the frame of the generator says 6000/8250. I wonder if the ratings were inflated, or if the new stator has smaller gauge wires? Both engines were around 10HP, so I wonder where the difference in power comes from? I've also wondered if you could add an AVR module to a generator that didn't come with one? It seems like the module would just replace the bridge rectifier in the non-AVR powerhead, but I wan't sure if there was differences in the exciter windings or not.

[@jackiesmith1161]

James, I'm about 80 years old and 50 years ago I was in a shop where they took these small engines and put them on go carts to race. They modified them to about 60 horse. But it's been many years, and I might be wrong. There's a forum for racing go-karts and mini bikes where they take a lot of predator engines and modify them to race. My point is you might look there for parts, they use predator engines because they're cheaper to buy and modified than USA made engines would be now. I was thinking about your valve seal on your himmie 402, I believe.

[@larrykelly2838]

Nice job Doc., that will make someone a great backup generator.

[@1989kling]

Keep up the awesome content. Trust me I’ve learned a lot from your videos 👍👍👍

[@watermanone7567]

Really nice job James. Lucky you had a spare power head. Thanks for the video.

[@jeffreyhaynes5774]

James for President,good job.

[@jackiesmith1161]

Love your content, and your detail, add to my Knowledge every day, and motivated me to get out and repair some small Engines.

[@woodydel]

I have watch many of your videos and learned a lot, all for free! Something I've noticed is so many of the machines like this one look like new. Finding a good generator is like going to the casino.

[@morphshag]

I was given a 2000w generator. about 10+ years old but hardly used and has sat in a shed for years. When I fired it up the first time the Volt meter on the front was showing 50v only and didn't have enough power to spin an electric drill. Letting it run for a good 10 minutes the Volt meter started to bounce around finally settling at 240v. SUCCESS!! until it cools down and goes back to only outputting 50v. I'm yet to investigate firther.

[@jcondon1]

Would bet a bad AVR or voltage regulator.

[@theroadrunner556]

Sounds like it could be a bad capacitor if your generator is brushless. Bad caps sometimes start working when hot, but stop when cold.

[@DeadKoby]

Fine work as always. The top mystery is why did the stator fail in the first place? I'm assuming if someone was overloading it that could happen...

[@deangentles4966]

Hi James great sitting in your class today mate This gene looks like new very big burnout on this one easy to find the problem which is a bonus good job on the electrics James thank you for sharing your knowledge with us

[@RustyNail5856]

Another great video, at least you could see it without a lot of looking . that was a fast and a good one.

[@FruitTreeForest]

nice repair! I am learning a lot.

[@alialhaidary1072]

Always informative. Thank you.

[@GuysPlayingWithTools]

Good vid! I have to be careful watching your videos, I usually stick with lawn equipment but you make me think I can use your videos to get up to speed and expand out to generators.

[@Jaysgold]

Doesn't put out... sounds like my wife.🤣🤣

[@sbc383zz]

She doesn't tell me NO. lol

[@YukonHawk1]

That was one nasty blown winding. I got a little worried when the head wouldn't fully insert. But you got it. Nice job.👍👍

[@jcondon1]

Same here. Was beginning to think I measured wrong.

[@MichaelDillin]

Great video great explanation. I especially liked when you cleaned it up warmed my heart.

[@Jon_Ericson]

Outro is great. As well as all of your videos.

[@scottdenhamrealestate7716]

Jim, Another good video. I like the ramps you made to get the generators in and out but looks like it can be difficult and even dangerous at times by yourself. Have you thought about getting a small riding lawnmower size trailer with a gate? congratulations on passing 70,000 subscribers.

[@hypnotherapycw]

totally agree. was thinking the EXACT same thing.

[@zrkn1]

A mighty fine unit there, seems to perform better on every run cycle. It is such a pretty red also.

[@butler386]

Excellent analysis and diagnosis. Great testing to make sure of the correct wiring. Fixed another one. Off hand how many generators do you think you have fixed and or repaired. Thanks for the videos and information.

[@brngrofdeth]

Very impressive as always, James. Love your content. Very detailed and flawless. Love and blessings from Ontario Canada!

[@haneyoakie14]

Excellent point on vetting a generator vs new, especially in todays manufacturing climate in China.

[@er1073]

I learned a lot as usual thanks James. Ed

[@chavescrave]

Another great video Jim. Thanks for what you do.

[@peteschofield8159]

James another informative video lesson. The biggest compliment I personally can offer you is, I would definitely buy a refurbished generator from you…. Take care.

[@fierodough]

I’m impressed with your temporary fuel setup. (The bottle, stand, filter and valve) would you be willing to make a video describing it? I’d like to make my own. Thank you!

[@soniaayala5416]

Helo from P.R.! Good job and professional.I learned a lots.Thankyou.

[@lewiemcneely9143]

A-PLUS! I was with you about the starting and stopping, especially the stopping. The 1st time it seemed to wind down a lot faster than usual but it was fine on the 2nd. Everything getting seated in I guess. Happy weekend and GBWYall!

[@johnables6069]

Best video seen yet. Please do one on honda gx270 9 hp generator. Pull start, not battery electric please. Havent found one yet.

[@joewest1972]

I really enjoy your videos and I admittedly have a weakness with understanding generators I would like to suggest that with your approach doing very basic from the beginning generators 101 as though you were telling it to someone in 6th grade who knows nothing about generators a complete video on that would be I am sure one of the most popular leave no stone unturned explain all the parts all the resistance has everything and it would be such a winner

[@peterclark6290]

Same as other comments. It's never too late to start looking after your back James. You can strengthen it (your core) with the Plank exercise (2+ minutes) or you can use those ramps, get an electric winch and drag it onto a bench or the obvious, a hydraulic lifter (building your own would be a video) or use a simpler engine lifter. When it goes life becomes miserable (even then the Plank helps a lot). Just do it buddy.

[@willboudreau1187]

To paraphrase Orson Welles, "be kind to your lower back because you'll miss it when you no longer have it." Lower back abuse can turn into sciatica, and I don't give a shit how women say childbirth is the most painful experience there is - let me tell you, I've had a broken leg set so I know what pain so bad it makes your forehead perspire is, and I'd rather take getting a broken leg set than I would live through another 3 months of sciatica. Your life, and all muscular movement with in, will come to a screeching halt if you abuse you back enough to get sciatica. Just sayin'.

[@peterclark6290]

@@willboudreau1187 Best exercise I've found: Start with the 'plank' (work up to two minutes or longer) then turn over and; keeping your shoulders square on the floor, roll your tucked legs gently, left and right. You might feel a small click or two. It's one of the core exercises. Got it from an Argentine stuntman, the first thing I do every morning. New life if it works for you.

[@harveypaxton1232]

Love your Videos. You really need a hydraulic lift table so you are working at a comfortable height. When you get older your back and knees will really thank you for it.

[@michaeltarasenkoop2389]

I always wounder why the windings in the stator are so thin and the coting on the wires is so little what if they were to increase the wire size and double the insulation on the winding wires I worked at a place that had the insulation on the wires that we had to use was double the regular size of the insulation on the wires it was at a sewer plant ! Could it help from burn outs ?

[@troymurphy6471]

Great job, your videos are edited well and you stay on the point of why I was watching the video and easy to understand. 5******

[@Lennyj24]

Your videos are great. Very informative

[@Ernest_son]

nice job. any thoughts on what may have caused that stator burnout?

[@duanek9892]

There is another youtuber (Linguoer), a young lady in China that manually rewinds generator heads & electric motors which makes for interesting viewing. It's remarkable to see something like that being repaired.

[@jcondon1]

She definitely has some skills.

[@drunkingsailor2359]

I love it when a plan works out smoothly,,,= easy money

[@r8118830]

So you are building up quite a stock of working rotors with no stators. I recall you using one a few weeks ago. I wonder if you will use any more.

[@edt1940]

James, I have observed you doing this resistance check no, no, many times. You hold the probes on the wires by pinching them with your fingers. Now you have pit the resistance of your body in parallel with the reading you are trying to make. Try pinching the two probes with your fingers and measure your body resistance. I do, however, love your channel.

[@leandrolaporta2196]

Excellent, I learn a lot with your videos, also the way you make them is very unique and I like it, the other day a friend of mine had a problem with his Honda EU20IS , so I check it out, carb issue, fix it right away and he said, you know a lot about this , me: no, I just watch James Condon channel, i learn everything about generators there, that and messing around with mine xD thank you

[@tonyktx44]

Hi James What usually causes those burnouts ? Love your vids....

[@jcondon1]

Bad insulation and vibration from the engine.

[@williamchow1624]

Great repair video. I was motivated and bought a cheap $99 Walmart generator. It arrived broken. I guess I have something to fix.

[@SalYourPalChencho]

How do you find replacement stators? Enjoy your videos! Learning a lot!

[@imouse3246]

Ask the original owner if he wants it back ...... for a price. 🤑

[@brianhind6149]

++++++++++++++++++++ One learns something everyday ! "Powerhead " ......I wondered what the Hell you were referring to as the "powerhead " I suspect that the term is usual to the small power generator market, because generators used to supply tens of kilowatts do not use the term. Your series of generator videos are truly excellent, & your descriptions of what you are doing & why must be a boon to the private owners & DIY crowd. I commend you on your great camera work, your locution while explaining what you are doing, & the audio on the channel is superb. Thank you for your efforts, rest assured they do not go unappreciated.

[@jcondon1]

Thanks!

[@DavidBrown-lq2qp]

Another informative video James,thank you for your all your info as always .

[@chucktrotter9699]

6.3.22 Another fine video James. I like the comment about the bonded and floating ground if going to connect to the house for power.

[@polishhotdog933]

You know your stuff, no doubt about it.👍🏻

[@tubeDude48]

This was quite interesting...Thanks Jim!

[@tinkmarshino]

Much better than I thought it would be... thanks.

[@jameschainey2343]

Why couldn't you install the bolts and put the selections back together?

[@christianrickman4243]

You would snap the bolts.

[@jameskenney5623]

If you are asking why not just suck the housing together using the bolts, it's because you don't want to crack the housing or strip the bolts. Tapping it in place with a mallet is much safer than trying to force it together and risk cracking or stripping something.

[@nekotherion7317]

Thanks for the good content James. Keep it up man

[@thomasesteb9589]

Very nice job and well narrated, for todays prize for being attentive , I think you missed the second fastener on the brush mount assem. On the Troy Built. Thanks for teaching us ! Tom~

[@davidrobins4025]

Another great video. Thanks for the description.

[@anthonyjones5711]

Thank you for all the great videos and all the effort you put into making them. Tony, in the land of 230/400V 50Hz (UK)

[@philliphall5198]

I didn’t see you double check electrical nuts tight but I hoping you did it

[@cbauer72]

I own that generator's twin. It's an old Y2K generator by father bought. I'm pretty sure it's never been started. It's had a cushy life sitting in the corner of the garage under a tarp. Any recommendations on what to do before powering it up?

[@Rorschach1024]

has it ever had fuel in it? If so you most likely need to drain the tank and clean the carb.

[@davidduma7615]

and change the oil

[@cbauer72]

@@Rorschach1024 I'm pretty sure it's never had fuel. I honestly don't think it's ever been started. Obviously checking the oil level is a must, that goes for all engines. Governor arm too. Was going to take the plug out and pull it over a few times to make sure the oil gets splashed around inside the sump but wasn't sure if there was anything else to check.

[@P_RO_]

@@cbauer72 Check that the governor, throttle, and choke linkage seem to move freely and be ready for an emergency shutdown as well as fuel leakage. If it doesn't want to turn over, a couple seconds of PB Blaster or WD40 into the spark plug hole and let it sit overnight.

[@ericvaughn1126]

Good stuff and pays to have parts on hand. Good insight on moving the end housing over. Cleaned up really nice and is a Hoss at 8200 watts. If you guys get the storms you, Ken or Gary just posted about it will surely go to good use.

[@brianwood5220]

Great job Janes. Thanks for sharing

[@jcondon1]

Thanks Brian

[@philliphall5198]

If you buy a new generator, take cover off and check all nuts and bolts 😮. Just a good idea to prevent trouble

[@duaneclarke7411]

Well James it is a wet and cold night here in South Aussie land and I put you up on the big screen in the lounge and as usual I enjoyed your show , not as good as Top Gun 2 but great thanks 👍