What Caused This Engine Damage? - Generac GP5500 Repair

I bought this generator from a local guy (Jason) who buy and sells used power equipment. I was told the engine was previously stuck. He got the engine unstuck and running well. He later sold it to a contractor who promptly returned it a few days later after the engine stopped running. The engine now makes a lot of noise when pulling it over. It still has compression. What went wrong and will it run again?
I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors.
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#Generac #GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
389cc, 420cc, Alternator, Backfiring, Bad Oil, Bonded Neutral, Camshaft, Carburetor Clean, Engine Damage, Engine Swap, Exhaust Valve Not Opening, Fixed, Generac, Generator Head Install, Generator, Hertz, Honda Clone, How To, How-To, Load Test, Repair, Rust in Fuel Tank, Rust, Small Engine, Troubleshooting, Ultrasonic Cleaner, Varnish, Will Not Start, Wire Insulation, Won't Run, Worn Camshaft, Worn Lobes

[@colin8532]

Not to say anything bad about anyone, but the gentleman you bought this generator from might want to consider spending some time watching your videos before he tries to repair anymore equipment for resale. You did a really nice job bringing this generator back to life, nice work sir.

[@YukonHawk1]

Jim should be refunded at least 100 bucks.

[@Melicoy]

Why put the same crap cam shaft back in the machine? Sorry i skipped to head removal.

[@quantumleap359]

I agree. That Generac was a pig in a poke. I would also talk to the "gentleman" you purchased this thing from.

[@budburr66]

Looks like a Florida flood victim that got power washed and put up for sale with a description of "I can't test it but it looks OK".

[@ac2329]

looks like gas in the oil and it sat and varnIshed inside the engine float was probably leaking by

[@Rorschach1024]

James, there HAD to have been a water component. You simply cannot have rust without it. It is not chemically possible. And the higher the salt/mineral/chloride content the more aggressive the corrosion is. Im thinking there was water and a lot of it in the tank, the carb overflowed and hydrolocked the engine that corrosion line near the bottom of the stroke is a smoking gun here as well as the very clear water line in the crankcase. I suspect there was bacteria in the water, which is why there was so much weird crap in the crankcase. The bateria were eating the oil and polymerizing it. Bacteria will also accellerate corrosion too, especially in anerobic conditions like under a layer of oil/gas mix.

[@suterfamily5578]

I couldn't agree more, since the water has a higher specific gravity than either oil or gasoline, the water was under the oil in the crankcase most of the time except for the times that the guy previous to you pulled the starter handle and mixed everything up; can you ask that guy if the first oil change he did was white-foam water/gas/oil emulsion that drained out? When the fuel tank is above the carb like it is in these generators, water that enters the tank falls to the bottom of the fuel and since water is significantly heavier than the same volume of fuel, it can easily blow right past the needle valve and leak directly through the intake valve and down into the crankcase.

[@danmenes3143]

Not strictly true that rust without water is chemically impossible--any oxidizer will do, including air (plus heat). But I think water is far-and-away the most likely culprit.

[@josephorr5175]

Aluminum doesn't rust (no Fe present) but it definitely can corrode in the presence of air. It will form aluminum dioxide which is a white film. I've seen a lot of it on aircraft structures. Interestingly enough, that film will also inhibit any further corrosion. But it does pit the aluminum. That discoloration is not characteristic of aluminum dioxide and may be a remnant of other ferrous parts actually rusting in that pooled water and staining the aluminum casing as a secondary effect.

[@merrittdegraw4313]

Thank You James!

[@michaeltarasenkoop2389]

Will General replace the engine ? Due to the age of the machine ?

[@steventiry8701]

The plugged vent tube forced fuel into they cylinder. That was the cylinder damage. The fuel made it into the oil where it became old and varnished the case and also held water for the rust.

[@AZVIDS]

Nah, it was re-assembled wrong…

[@AW-Services]

Another enjoyable and educational video, Jim. On first inspection and the overall exterior appearance, that generator looked pristine and didn't look beaten up or it had a hard life. Love your new load tester. Gives your videos more of a visual load representation over the use of your heaters

[@boonecountygenerators3052]

If you want to find out if a generator has a bonded neutral, it sometimes is printed right on the unit (like we can see at 34:17 and 1:14:05). There's nothing wrong with verifying that when you reassemble, but if you're going to remove the jumper, you should probably tape over the "NEUTRAL BONDED TO FRAME" label, or better yet, use a label maker and label it "FLOATING NEUTRAL."

[@mrwebber35]

This is what Powermate claims about bonding the neutral tot he frame: The neutral is bonded to the frame to allow for the generator to be used as a portable and allow for the frame not be grounded as per USA NEC250.234A. In other words the frame absolutely must be grounded if the neural becomes floating in all situations. Explains how RV's can just start up their little genies without any concerns.

[@quantumleap359]

James, I just want to congratulate you on your superb mechanical and electrical skills! Everything is by the book! No shortcuts, no half-a$$ed work. Thank you for excellent videos.

[@shatnersufolanded7785]

I was given a Coleman 2000 year model Maxxa 3000 almost brand new looking after diving in I found rust all throughout internals and especially bottom of crank the exhaust valve had alot of crispy critters sludged up on it I would have never attempted to overhaul it if it had not been for your videos. I really am thankful your here on KZbin.

[@venenareligioest410]

James, you have made my day - thanks for your hard work 👏🏻👏🏻👏🏻

[@mohibhad8542]

James I have to admit that you are the best content maker on youtube. All your videos are very well made. Excellent video and audio and best care for details. Thank you

[@dagrote1]

I think I can cancel Hulu now.

[@lleavell92630]

James, the only experience I had with an engine that nasty inside was when someone (I suspect a recently fired employee) added sugar to the oil and it looked about as bad as this example. The engine was replaced in that instance too.

[@jimthesoundman8641]

How would sugar hurt the oil? I thought you were supposed to put it in the gas tank so it would be burned in the cylinder and produce massive amounts of carbon.

[@marynunn1708]

Love this video in particular because I own a GP5500. Nice to know what breaks and how to fix it when it does. Will pay more attention to internals and oil because of this. As for why the first engine was so rusty, my bet is on being left in cold, humid environment without the airbox, possibly for years. Great job giving her a new life!

[@jayneubauer3401]

exactly my thoughts as well, as I purchased a GP5500 used. It had low hours, but issues. Fortunately it was related to the rust in the tank, and my nephew is a really good small engine mechanic. It is nice to see what goes wrong with these.

[@tc1904]

Jim, watching you work is like watching a surgeon perform heart surgery! You are a master of your craft👍

[@melkiorwiseman5234]

Any day with a new video from James is a good day. 😃

[@stevewarren3051]

It's generator season. I hope that means more vids from master mechanic James.

[@DanKoning777]

How funny-while watching a different Generac video [GP7500E rebuild] from a month ago [great content], this one popped up. [29:21] "...the guy said it was stuck and he freed it up-and then he sold it. And I can see why it was stuck." And now we can see why he sold it. 😂 Btw, why your channel doesn't have 500k+ subscribers is a mystery to many of us I'm sure. Well done and a 👍 as always. God bless.

[@andymann9861]

Great video, James! Glad to have you back!

[@oldguysoldbikes]

As always James, entertaining as well as educational.

[@davehammond9796]

Good job, you've gotten a load bank, no more dragging out the portable heaters.

[@mjg263]

Another brilliant repair and another generator brought back from the dead! I dunno, that crankcase looks to me almost like it had seawater in it, that corrosion was really bad. Great work and attention to detail, James!

[@mrobi5797]

Excellent video James. Thanks. I enjoyed the description on the Floating Neutral/Bonded Neutral ground. Keep on the good work and best wishes for the Holidays.

[@Amy_McFarland]

Another option would be user error. You never know what someone may have put in with the oil unknowingly or thinking it would help somehow.

[@jcondon1]

Was thinking the same. It could have been an additive if some sort.

[@philliphall5198]

No it’s defective cam , this is the 6 one I’ve seen now, they don’t want to warranty anything 😢😢

[@nspro931]

@@philliphall5198 No argument about warranty, but they are not going to warranty an engine that sat half full of water and rust.

[@rosewood7592]

I'm very new here. I knew nothing about carburetors but after watching 10+ videos of yours I know I could take one apart and clean one and reinstall it. I'm addicted to your videos!

[@joelonderee2872]

I just came across your videos a couple of weeks ago and have watched dozens of them. They are great and I have learned to much. Thanks for the great education and please keep up the excellent work. Your narration is especially valuable.

[@ablelock]

Really nice job on fixing this up. I enjoy watching you cause you’re a thorough on what you do and I am that way on what I do in my business as well and you sound like you have a lot of patience with these things, and sometimes they even aggravate you, but you don’t let it push your button enough to push you over the edge you’ll always have the right answer on fixing it eventually, good video like I said keep up the good work we look forward to the next episode.

[@RiverratGoRVing]

Miss all the heaters that you use to test with, but you need newer technology as well. James, as always, your work and information really helps us DYIers. Thank you. Keep posting.

[@stoptheirlies]

Hi James, your attention to detail is awesome, well done mate I enjoy every minute, oh! I have also enjoyed the bit of variation from Generators recently too. Bob. UK

[@josephephraim5135]

I admire your attention to detail and your perseverance, working to overcome the hurdles to get to the prize. Great work James!!

[@daviddamico4288]

Nice work Jim , glad you got it fixed

[@charleskwakye2137]

I am glad to see you start this generator.

[@GNX157]

The video where you first discovered the issue with the stator wire terminal insulation causing a charging problem, is probably in the top 5 must-watch videos on your channel. Very informative and eye opening new issues found.

[@jonminer9891]

Happy to see your vid again. And as always, it is a pleasure to see how you think through the problem. Thanks for sharing! Stay Healthy!

[@jeromekurtzsr878]

Hi James, No matter what the day brings, You always come through with a great video thank you so much. You always do awesome work and I’m always looking forward to a new video every single day, you are an inspiration on small engine repair. Again thank you so much for your hard work…. until the next video. Have a great day.

[@robertcochran7103]

I am so impressed with the teardown procedure and the excellent diagnostics. I learned from this video. Thank you!

[@PeterHynes]

Another great video James - that engine looked like it was pulled out of a swamp! It would be fascinating to know how that happened. I though at first it must have been in a flooded basement or similar, but the generator assembly would also have been affected by that and didn't seem to be at all. Also interesting to see that familiar THD issue with the inflection in the back end of the AC sine wave - you would think that the manufacturer would improve the generator assembly to address that design issue. Thanks again for the fascinating content and locating these very interesting repair cases - very enjoyable to watch! Merry Christmas mate.

[@pc5569]

I unbounded mine and have that plug you showed as my bonding when I need it. Great work.

[@padraiggluck2980]

Very nice work, James. ⭐️

[@norseman3303]

Absolutely outstanding video. I have a GP7000 that was given to me and I'm looking forward to checking it out. Thanks!

[@mattaniahdavid1048]

This is only my second video watching Mr. Condon, and I must say extremely fascinating and enjoyable to watch. I would classify you as a Master Mechanic but to see the inside of an engine, small as it might be, but still the same as a larger counterpart, thank you for your tutorials. Very enjoyable. I love to learn new things!

[@nyquistsenior2634]

Always enjoy your videos James!

[@jfolck1886]

I've seen this video on my recommended page a few times now. So I decided to watch it. When I saw it was an hour and a half long I thought to myself there's no way I'm going to make it through this whole thing. Here I am an hour and a half later and I only skipped a few of the slow parts. Very interesting to see the diagnosis progress with the first engine.

[@jasonstarnes3838]

Great work, i cant believe someone unstuck that engine and sold it, and didnt clean it up any better. What a mess.

[@simeonmendez5964]

I'm learning a lot from your videos and I like the way you explain . Also I like how thorough you are about cleaning the machines and putting them back together. Thanks for the knowledge .

[@jesterr7133]

I love adapting various items for small engine work. I have an entire antique dental tool kit that I use for small engine work. I have scalpel, forceps, and all the various picks. I use welding tip cleaners for carb jets. Once you get into this hobby, you are always looking for something you can use. Whenever I encounter some odd type of tool, I am immediately assessing it to see if thee is something I can use it for, lol.

[@tomwolf9420]

Like the fact that you verbalize your thought process. Allows me to improve my ( barely to no existing 😂) diagnostic and fixing skills

[@nederlandhiker2]

Great video. Very educational, good trouble shooting. Thanks for sharing!!

[@chadbarchus3373]

Great video man ,you've really stepped up your game on editing/ speeding up the bolt installs . Also the test rig looks great !

[@somerandomguy3868]

Very nice build

[@wizzkidelectronics]

never thaught of closing the choke as the bowl goes empty . good stuff james

[@HipaParts]

Very informative generator repair video. Thanks for sharing.

[@bigchiefbear]

Outstanding video Jim. Totally fascinating. You are the main man for these type s of problems.i noe feel invigorated to go repair something lol. Thank you for sharing your knowledge and skills. Cheers Jason. Boston. UK.

[@jimjones6419]

I'm learning so much from your channel. Thanks so much for doing this. ❤

[@redneckbryon]

You would think a company like Generac who builds, portable and standby generators would build a Quality Product. I had a 5500W portable Generac years ago, had well over 1000 hours on it, it ran strong and produced power with no major repairs ever. When we were looking at having our standby generator installed, we were originally going to go with Generac after speaking to some electricians who installed them, they basically advised not to go with Generac. From what I was told, they are having engine issues, on a lot of their units that are being produced and replacement parts are hard to get.

[@philliphall5198]

On the fourth one I called them and they refused to admit the camshaft are bad, one of them belongs to my brother and I know he serviced it, only 34 hours, he’s a retired diesel mechanic 😊

[@jankamp8177]

Well done James

[@sabahshaman6581]

I loved this video. Thank you for the upload.

[@MrRedPants]

James. I don't think I've ever watched a video of yours where you said, yeah, that's good enough. Right down to scraping off the blue protective covering. Inspiring

[@MrDirkad]

You sir, are a godsend to small engine repair. I would let you work on my stuff any day of the week. I have yet to see a short cut I wouldn’t take. Great Job!! Your earned a subscribe from me! Hard to do.

[@marcusdoolette1547]

Always learn something from watching. Thanks.

[@stevespawn1]

You hold my attention-really enjoy your videos

[@arlodewald5378]

Thanks James for all of the hints and advice on things to look for the novelist person to be able to repair there own gas powered equipment . Also how important it is too torque every nut and bolt to proper specs . Maybe other people how repair equipment for resales will take the extra time to do things professionally .

[@phillipthebigj8971]

Thanks James great vid as always.

[@superfram81]

this is the best channel on here if you want to learn step by step

[@Jameson4327]

Another educational video. Well done.

[@watermanone7567]

Excellent work James, I had a 3000 watt champion that someone put bar and chain oil in. Took me a long time to clean it out and many oil changes and used some marvel mystery oil during the changes. Came out o.k. but the bar and chain oil was only in it for a few months and the machine did not run much with-it in. Customer said it runs good now. He uses it at his camp. Thanks for the video.

[@basilbrushbooshieboosh5302]

Learned a lot, thanks.

[@nightsaber2272]

Cool testing box :)

[@peterouellette3874]

Nice going, James

[@spudman9367]

Thanks for covering the floating, bonded neutral issue and hooking up to a house

[@MikeSilver200]

You can make a rotor wrench out of plywood. It fits over the flats on the rotor itself. You're an excellent mechanic James.

[@dougpeters6058]

Talking about the bonded vs floating neutral seems like you were talking directly to me.

[@DOCGENIUSWILSON]

Great job James...Peace

[@johncourtneidge]

Very nice, as always, thank-you. Out of interest, I love to see a clean up of the original engine's internals. Oh well. Again, thanks!

[@kendoeditionfuego1619]

Admiro todos tus videos, no existe un generador eléctrico el cuál tú no domines por completo.. a la verdad que eres un buen técnico, felicidades por la ardua labor....

[@wirksworthsrailway]

I was fascinated! Really very interesting!

[@rodneymiddleton9624]

Looks like fuel filled the crankcase and it did the same thing as it does to the tank. Can’t have enough spare parts. I picked up a rough Honda EU3000is the other day. It is going to be a challenge. Thanks Jim!

[@loucinci3922]

Enjoyed the video. Thanks for sharing.

[@steveklassen696]

James, your camera work and editing is great. It goes unappreciated for sure, but not by me. At 12:30 you take off a heat shield. You totally ignoralate on the bolt, teetering on the edge of it rolling off, and then you move onto the next camera angle without showing yourself grabbing it. All the ocd people are just dying. Genius!

[@paulwatts3328]

Been following and watching for a while. Psst.. watch and learn all the hidden tips and tricks.I thought I knew stuff but I am just a hack and you are the real deal.Thank you for sharing content ,delivery and presentation are over the top.I am a better mechanic because of James Condon Cheers

[@Rick-S-6063]

Things didn't look too promising at the beginning but they had really turned around at the finale. You do good work. My generator is a Honda EN3500 with the GX240 engine. I replaced the original oil drain plugs with two Gold Plug MP-01T magnetic drain plugs. They're a good investment that'll keep metal shavings from circulating and prevent further damage. Chances are they'll fit the majority of the "Chonda clones."

[@james35546]

Another excellent video. Thanks

[@johnclarke8180]

Awesome job!

[@kiowablue2862]

*_Excellent_* presentation, as are all of your repair video-productions. One minor point. Hertz is the unit of measurement of _frequency._ So instead of saying the "Hertz is low," you say the _frequency_ is low.

[@basilbrushbooshieboosh5302]

I like it that he cleans the (whole of the) gear well. I watch this other guy that does mostly m'bikes. He seems know what he 's doing but he picks them up usually filthy (dirt bikes) and sends them off filthy.

[@Rick-hp6fu]

Brother, you are a master at troubleshooting and your attention to detail is impeccable. I love your video content. Watching you repair and fine tune these machines has taught me so much, allowing me to get my small engines (mower, snow blower, etc.) tuned back up and running like new, all due to carb issues. I have a Westinghouse genny that I've never had to use but run occasionally and I know that if I run into any problems with it, I can likely get it back up and running like new. Keep up the awesome work!

[@rkins100]

Nice job Jim - was nice to have a donor engine. Learned a bunch so thanks.

[@johnlomasney]

Excellent good work

[@JR-bj3uf]

That's some amazing water damage. That almost looks like salt water damage. Great video as always.

[@user-ui4iv8dz3w]

Durning most of the 1st part of the video, i was telling myself over and over, "wow, that is a clean machine." Then BAM! learned my lesson don't judge it by it's looks. I'm with you James, something other than oil was put into that crankcase some additive or something that started to eat away at the aliumin much less the iron also.

[@joshuagraber1148]

That 1st engine would definitely run just fine. Put a new cam shaft in and get rid of the surface rust, clean everything up real good. Shame to see it all thrown out.

[@phillipbecker453]

I agree, the first engine could have been honed and cleaned up a bit and been serviceable for a standby Jenny. A little oil usage but usable for emergencies.

[@unwired1281]

Great video 👍‼️

[@redwolf230]

Give the bore a light hone and maybe the rings might still be good. Had one of those in a month ago and the guy was so happy I was able to bring the motor back

[@ChrisDart4232]

I like the way the auto-text says 'Applause' when you hit it with a hammer!! Seriously though, very interesting stuff - well explained.

[@billclayton8127]

I really enjoy your videos. At one hour and 18 minutes you are installing the gas shut off at the bottom of the tank. The first day on my apprenticeship my journeyman corrected me on the proper use of a crescent wrench. You are using it backwards. 😊

[@karirautio]

The moving jaw is weaker than the fix jaw. When using backwards there is much less leverage to this weaker jaw.

[@jasonthewiczman5442]

Doing great, enjoyed the video

[@tallalahmad2013]

Great work

[@Rorschach1024]

James I'm kind of surprised you didn't ohm out the rotor and stator before you went to all the trouble of assembling it to make sure you weren't wasting your time.

[@jcondon1]

I took the guys word that it was making power. He is pretty honest with me. Have purchased a lot from him over the years.

[@williamfoote2888]

@@jcondon1He sold you a pig in a poke on this one.

[@phillipbecker453]

I only trust the words of two people, me & GOD.

[@billhenry7833]

Lol

[@ayozhek1898]

Still sounds like there is a rough bearing in there. Thanks James.

[@kiplandingham322]

Felt a chill watching you use a root canal drill....yikes! Thanks for another great video.

[@drunkingsailor2359]

Nice Jenny, someone will enjoy this when nessasary.

[@dadskrej5226]

Another great video James! A word of caution when hammering on the crankshaft bolts to remove the rotor and/or the flywheel. Crankshafts are not designed for side-loads, mainly rotational loads. Beating on either end too much will break the crankshaft. 2 or 3 whacks is about all the crank will stand before breakage internally.

[@adulaney2004]

It is common practice to do this on many aluminum-block engines. This is why Briggs sells a flywheel knock-off tool. Now, if it was a Kohler engine, there's a very real chance it would break.

[@np1000]

Your videos are extremely entertaining.