Mr. Condon, I am retired but I have spent 44 years working as an Electrical Engineer. I am impressed with your methodilogy in working with these generators. I have seen most of them and secondly I'm impressed with your even temper (mine is not that steady). I have learned much from watching you and I thank you for your videos.
The video helps even if I don’t use it to fix my generator. I applaud you for your demeanor and aptitude. I find I watch your videos not only for mechanical and electrical knowledge but also for your honesty, sincerity, and politeness. Gods blessings to you and yours!
Another tip, for cutting thinner gaskets, use a glass cutter to cut your gasket on top of a piece of glass. Press hard enough to cut the gasket, but not hard enough to cut the glass. This technique was used by a school teacher that needed to cut a lot of things (letters, numbers, etc), and she was able to have a nice bulletin board.
Really love your approach, wisdom, and skill. Yet for those of us (older) folk with no knee’s (!) please get a lift table (like Bruce Pender) so that when you get to our stage in life you can still walk! Great stuff and most helpful. Merry Xmas!
Jim, in addition to Bryant Fry's hint, what I do to straighten those studs is to screw a long connection nut on the stud, right to where its bent. Then you can straighten it with a ring wrench that I put on the nut. With the nut there is no way you mess up the threads. The pipe Bryant was proposing might create marks at the end, but will work as well. Hope I found the right terms, since I'm not a native speaker. Greetings from Germany Andreas
@@jcondon1 Thank you James! And your videos are very helpful. Could you please tell me, what you use as ultrasonic fluid? I have currently a similar candidate in my workshop. Unfortunately the poor thing is so old, that I can't take the easy way out and bus a new carb. Fortunately the mechanics are not stuck, just the jets are stuck and with my isopropanol water mix I am out of luck. Thanks in advance! Andreas
Hi Jim, I notice that over a number of programs that you have had several different ultra sonic cleaning baths and your latest one appears to be digital. I am old school and my experience is forty years old, and we had no ultra sonic cleaners then, but I do recall an ex-forces power bank very similar to one with cooling fans I have seen you use, before your very nice and sophisticated unit, My last experience of dismantlng small generators were the Honda E300 units, which were beautifully made, The OHC Subaru engine is new to me and I dont think I have ever seen one. As always your videos are most interesting and very instructive. Thanks for your channel. Rex
Jim, here's a tip on straightening bent studs. Slip a piece of pipe with just a slightly bigger diameter over it, and then you can nudge it back. The longer the stud, the easier it is to straighten. I have used this from time to time with none of them breaking. If it has a sharp bend, there you will have more risk of it breaking. Mustie1 uses this technique.
I have a Husky power washer that my neighbor gave to me, non-running. He admitted he never changed the oil. Ever. And it was built in 2006! It has a small flat head briggs. It looks just like your Husky generator, a red cube covered in plastic all over. A total pain to work on. I guess they cover the entire engine as they expect the average homeowner to simply add gas and connect a water hose. Simply trying to access the carb or pull the spark plug, requires removing like 12 screws and prying apart the entire machine. Kind of like working on a clothes dryer! I've basically stripped the entire housing off of it and just left the engine/pump housing mounted to the floor-frame. Much better :) It runs great, and like you said - "it earned an oil change"! I actually take the same approach! Only after I get an engine/machine running well enough that is has hope, do I change the oil. I'll add oil before running if it's low though. great video!
Well done, another one brought back to life. I was surprised you found the very long 6mm bolt at a local hardware store. I think I would not find anything of that length in my local hardware stores. I have a metal lathe and imperial and metric taps in dies so would likely have made a stud. I am happy to make such items for you if needed. Dave.
Most hardware stores do not have metric or a very poor selection. The big box store near me has almost nothing. The small little hardware store has every bolt size you could ever need and well organized...
I wonder if ACE hardware might be a better bet for these more obscure (but necessary) items. Their plumbing section seems far more complete for brass fittings than the big box stores, they might have a greater selection of studs.
Two thirds of your work is carbs James. Carburetors are precision engineered devices. The slightest deviations from the spec can render them useless. I love how you can see which deviations are causing the problem and your innovative attempts to fix them. You fix them even if they come with problems caused by slack design. It is impressive.
A little advice: before cutting off the threaded bolt, screw a nut onto it, then cut off the bolt, file it, and twist the nut from the saw side, the nut will clean and align the thread.
Brushless generators are always going to have higher total harmonic distortion. The squiggly lines at the top of the wave is the result of the circuit "ringing." This is because the capacitor and the inductor (the spinning rotor) are acting as an undampened (think of a car with no shocks) resonant circuit. The best way to stop the circuit from ringing is to add a purely resistive load like a heater to quiet that circuit down. Unfortunately it is not a 100% solution. I would say try loading it up to 50% to 65% and see how the waveform looks. Nothing beats an inverter generator with proper RFI/EMI filtering on its output.
So many people are caught up in the clean power. My 1850 watt camping portable generator and 6250 watt generator both non inverter generators. In the 1850 portable non inverter generator is relatively quiet. Have ran things since 1994 when I bought the truly made in the USA generators both with bulletproof Briggs and Stratton engines. No electronics burned up. But the newer inverter portable generator I bought burned up in less than a few months it went back to the store tried another one and that died too. They were cheap Chinese inverter generators though. I went to Honda inverter generators now they don't seem to die and seem pretty dependable so far. But I found out the hard way if the overload light comes on in an inverter generator you better cut it off immediately and cut back the power here using. And not keep having the red overload light come on or you can burn them up like I did. Inverter generators are supposed to be so smart they don't blow a resettable breaker like the two older ones I mentioned do they just blow the inverter board.
Ive had great success with removing seized screws / jets etc from carburators by immersing the whole thing in boiling water for a few minutes. Usually frees them up a treat.
My thought on a crust old carburetor that has a stuck emotion tube and jets might loosen up were you to submerge it in distilled water and bring it to a boil. The theory is the housing will expand and less force in extracting the part will be needed.
I had a carburetor that was crusty and calcified worse than this. I took an old crock-pot and poured antifreeze (ethylene glycol) into it. Soaked the carb in that for 24 hours on low heat. Came back and all the jets came out like new and the calcification was gone and the carb looked shiny and new. Any rubber parts or o rings will suffer horribly if you use this treatment..forewarned.
@@jeffclark2725 I saw it being used in my small engine shop here in upstate NY. I tried it and was amazed at how well it worked. Ultrasonic is faster, but the glycol method is incredibly thorough. It takes the rust, calcification, carbon..everything comes off.
Nice use of alligator clips to extend the ground to the plug. I like that . Yes the brush less gensets are dirty. With each spike you see on the oscilloscope there are high frequency signals generated causing noise much like a square wave. Many folks this they are opposite and super clean.
Once again great repair. Hmmm I keep learning about generators and how to fix them from you. Except I would not mess with the power head part. Thanks for the tips on the bolts and the dirty wave from the generator. Thanks for the video's
I think you did very well with the airbox seal. Of course the inner gasket to the engine is more critical on inner hole shape than low velocity airborne gasket which keeps dirt intrusion out. My garden digger needs this treatment. Works fine without airbox but does not like filter.
One tip I learned concerning cutting off the end of the bolt is the thread and not on first cut the head of the bolt off and then run the nut over top of it to straighten the threads. It might help
I always put a couple nuts on the bolt before I cut the head off, then when you remove the nuts, it cleans up the threads. Much easier than using a die.
Another victory in the win column. I was surprised with the noisy waveform of the brushless generator output. I would have expected it to be clean, almost no distortion equal to inverter generators. No brushes to cause arcing and noise on the output. I wonder where that noise comes from.
The problem with that dirty sine wave is the high harmonics will generate eddy currents in transformer and motor cores and heat them up more than a pure sine wave would. However, that's not as bad as the pseudo sine wave of many UPS devices. Any device that uses switching power supplies will tolerate that dirty sine wave just fine. I would worry a little about refrigerator motors which unfortunately during power failures and the main things we want to keep running.
Nice little genny for emergency use, especially if there’s no room to store one of the big guys. Unfortunately a dirty sine wave and flickering output seems to be the norm with brushless generators but they get the job done in a pinch. Very nice and thorough job, enjoyed watching you bring it back to life!
Good morning, James wonderful work on the small genset. Perfect unit for a camping weekend. Just a silly note, hope that you are not using you wife's coffee cup when you drain out the carb.🤞🤞🤞🤞
So, either the hurricane bent the studs apart or some guy couldn't find the bolts and bent them apart like nails to hold the carb on. Two completely different ways to feel amazed.
I’ve fixed a couple of those. Sold by a few companies, same machine. The cheap plastic capacitor fails, no output. A real handy little machine though for light use and very portable. The China carbs are hit and miss. Some work, done don’t. Just had an Onan 4ky unit needed a carb. Bought 2 off Amazon. Neither ran well. Ended up putting a used worn Onan carb on it I had laying around. Onan carb costs a fortune compared to China made. And I am an Onan dealer !
Some carbs are way to expensive. I had a 2 cylinder Vanguard that needed a new carb. I spent close to $250! They now have clones of that carb. The clones are definitely a hit or miss, but worth a try when the alternative is crazy expensive.
@@jcondon1 My cost on an Onan 4ky carb is over $200 and as I said I am an Onan dealer ! I can and did buy Honda carbs for under $100 or maybe $125 from a Honda dealer! The last 2 Honda carbs I bought had the idle control stepper motor on it for those prices. Cummins-Onan parts prices are outrageous and lots of stuff is made in China ! I’m not working right now, had a major health issue put me out for a while. I actually grew to like working on small engine equipment and some of your videos were very helpful. You do a great job on stuff that is generally tossed out because no one wants to do this work for the must part. I’m 74, old school, I’ll try to fix almost anything unless it’s really in bad shape.
Really excellent video! I own the same unit and I have to give it a shot of starting fluid to cold start. I left fuel in the carb for long periods of time. My bad. Probably needs carb cleaning.I do notice the lights flicker sometimes when using. Good info on the scope readings. Thx again! How the heck did those studs get bent??? Crazy!
I run two in line filters on my auxiliary fuel tank, just in case. But I deal with 4 or 6 cylinder motorcycle which have carb racks that aren’t fun to dislodge and reinstall. Can’t take the chance of any crap getting in. Also if you get some aluminum angle pieces like 1/8” stuff make some soft jaws for your vice to grab stuff like that threaded rod.
Nice find and easy fix. Would have been nice to get the original carb going, but wasn't in the cards. Watching you thread that new stud through the carb and gaskets reminded me of putting the air filter housing and bolts through the carb and ALL of the damn gaskets on a Honda GCV160 OR 190. 3-4 hands would be helpful at times. Great work, filming, audio and editing as always and please do keep em coming!
did you check compression after it ran ? Here'sanother trick . Use a 50/50% mixture of acetone and atf oil . Best penetrating oil the world has ever seen .
Wow!! You even treated us to some arts and crafts with gasket making lesson 🤣🤣😁😁 I'm happy that the clone worked out. Very good pick up for 75 bucks. Subaru/ Robins made some great stuff back in the day. Too bad they exited the genny market.
Its great learning from you and seeing your work techniques how you salvage things like those carburetor mounting bolts. I like how you distracted those bent bolts., I'll have to remember that method.
It is one of the best built small engines. I dare say better then Honda. Too bad Subaru sold them to Yamaha. Not sure if they still make these engines.
Great video, your videos are very useful teaching videos, some of best produced on TH-cam. If you ever have a chance could you do a video of the oscilloscope. Thank you for the videos you produce.
Congrats on the fix! The dirty sine wave has more to do with economics and perhaps durability rather than quality. Brushless should be the ideal generator! I don't know what a good fix might be but sensing and feed back move much faster than 60hz. My knowledge of Generators leaves a lot to be desired! Ron USA
Granted the sine wave is not ideal, but it would be okay for the fridge ( not a fancy or expensive one ) maybe the furnace, definitely a electric heater like you have
JAMES your video are always so interesthing to wach and learn,carburetors that is what i know best,and you are quite good at it ,i like your dexterity that you work with ,BUT what i hate it is when i see you with a carpenter hammer with one claw broken ... as a pro like you ,you should a least a half pound ball penn hammer ,this would complete your craftman ship ,i should say your high quality of work. By the way what is the capacity of your new ultra sound machine ?
The new one is 6 liters. That terrible hammer I stole from my son. It is basically a toy. But works good when you want to tap something lightly. I agree though it is not the best tool in the toolbox.
My small generator has a larger version of that motor and seems to have very low compression while pulling it over, but I think it's just how they are with the compression release it only has about 100 hrs on the meter and runs excellent
Got to love those carbies & bent studs... Not. You did exactly what I would have done with the one you managed to remove. I'm thinking it has a decompression device to aid starting myself.
I had the exact same generator except in mint condition. Bought on fb for 75 bucks with a bad carb...put a new Subaru carb in it and worked great. However I ended up selling it because I wanted something with cleaner power and will buy the Honda EU2200 instead.
Nice fix Jim: Do you think the generator might have been partly under water at some point. The inside of the filter housing had a rust line on it so I thought it might have been under water. Thanks for a great video.
Another great video your voiced is very calming you could do relaxation videos . WS surprised how dirty that output wave was. Will be checking it on a couple of my generators that are not inverter styles.
Hi James great sitting in your class to day I have never worked on Subaru engines before the gene looks of good quality and a easy fix on your part mate
It would be interesting to see the oscilloscope connected to your house AC utility power to see that wavefrom as a comparison. Maybe also the kill-o-watt unit showing utility Voltage and Hz.
I had planned on doing a video late September comparing the output of all different generator types vs the house AC output. Will do it at some point. Maybe a winter video?
I picked up 2 of these generators from my neighbor who was going to scrap them. Left out in the weather. Watching this video I brought one back to life. Any idea where I can get a used air box? New ones are stupid $$. Is there another option? Thanks for your great videos!
Another generator brought to the life again actually I'm addicted to your work and your videos Mr. James but I have a doubt... where do these people store their generators ?? Because most of the generators you fix are full of rust and dust. The generator should be kept in a clean place . Anyway this video helped me with a new technique specially with that stud but I don't know how these types of generators get cooled since it's closed from all sides that means no sufficient air will be there for allowing the engine to be cooled therefore the engine will always be exposed to overheating. I think this type of generator doesn't last longe. thanks a lot for the video with my regards to you Mr. James.👍
Where do you live that there is no rust or dust? Most people around my parts keep their generators in a shed or outbuilding. Anything that sits for years, even in a "clean" shop, is going to build up a layer of dust on it. Rust also, in many parts of this country with the high humidity levels, especially if it is kept in an unheated space. Where I live, I have learned to hate chrome because anything chromed that sits outside, even if out of the rain, still pits and corrodes from the humidity. My grandfather had a beautiful set of 1940s Craftsman sockets hanging on a pegboard in his barn, one socket to a peg - they hung there so long that 100% of the chrome flaked off the sockets and each socket had a pile of tiny chrome flakes underneath it on top of the work bench, when we cleaned out the barn after he passed away. I had never seen anything like that!
@@redmondjp you could wipe your generator or whatever has the capability to rust with oiled rag and that somewhat will protect it against the rust and corrosion specially if there is a high humidity. I do this thing with my generator and underneath my car also. Starting your generator for 10 min monthly will keep your engine and other parts away from getting rusted, corroded and accumulating of dust and dirt.👍
Hi James. Another great job! You are always very calm and patient when doing your jobs. If I saw my new carb leaking like that I’d be cursing like crazy. Look forward to your videos each week. You never ask for people to subscribe or give you a thumbs up like some of the other TH-camrs. I like the oscilloscope you have. Wonder if you have a link to it? Btw, if you remember I commented before how clean your hands always are. I must have jinked you as I have seen you having more cuts and scratches lately. Look forward to next fix.
Your so good with these things, most of the time it’s a simple fix but not always and you always seem to get them going….. is this generator repair your full time job James ?
It appears that you missed the holes in the upper left and upper right on the homemade gasket. The right was hard to tell if it was on the old gasket but the upper left was finally missed.
$37 for a clone? No telling what the real McCoy would have been. Those long slim studs can be problematic for just the reasons you found. You can get a clamping stud puller. There's a type that will clamp up flush to wherever it's attached. Not the Snap-On type. The one I had was a Proto. But, you can probably get one similar on the cheap.
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Mr. Condon, I am retired but I have spent 44 years working as an Electrical Engineer. I am impressed with your methodilogy in working with these generators. I have seen most of them and secondly I'm impressed with your even temper (mine is not that steady). I have learned much from watching you and I thank you for your videos.
Thanks for the feedback, I appreciate it.
My sentiments exactly!
The video helps even if I don’t use it to fix my generator. I applaud you for your demeanor and aptitude. I find I watch your videos not only for mechanical and electrical knowledge but also for your honesty, sincerity, and politeness. Gods blessings to you and yours!
Another tip, for cutting thinner gaskets, use a glass cutter to cut your gasket on top of a piece of glass. Press hard enough to cut the gasket, but not hard enough to cut the glass. This technique was used by a school teacher that needed to cut a lot of things (letters, numbers, etc), and she was able to have a nice bulletin board.
Really love your approach, wisdom, and skill. Yet for those of us (older) folk with no knee’s (!) please get a lift table (like Bruce Pender) so that when you get to our stage in life you can still walk!
Great stuff and most helpful.
Merry Xmas!
Jim, in addition to Bryant Fry's hint, what I do to straighten those studs is to screw a long connection nut on the stud, right to where its bent. Then you can straighten it with a ring wrench that I put on the nut. With the nut there is no way you mess up the threads. The pipe Bryant was proposing might create marks at the end, but will work as well.
Hope I found the right terms, since I'm not a native speaker.
Greetings from Germany
Andreas
Thanks for the tip. Your English is good.
@@jcondon1 Thank you James! And your videos are very helpful. Could you please tell me, what you use as ultrasonic fluid? I have currently a similar candidate in my workshop. Unfortunately the poor thing is so old, that I can't take the easy way out and bus a new carb. Fortunately the mechanics are not stuck, just the jets are stuck and with my isopropanol water mix I am out of luck.
Thanks in advance!
Andreas
Hi Jim, I notice that over a number of programs that you have had several different ultra sonic cleaning baths and your latest one appears to be digital. I am old school and my experience is forty years old, and we had no ultra sonic cleaners then, but I do recall an ex-forces power bank very similar to one with cooling fans I have seen you use, before your very nice and sophisticated unit, My last experience of dismantlng small generators were the Honda E300 units, which were beautifully made, The OHC Subaru engine is new to me and I dont think I have ever seen one. As always your videos are most interesting and very instructive. Thanks for your channel. Rex
Jim, here's a tip on straightening bent studs. Slip a piece of pipe with just a slightly bigger diameter over it, and then you can nudge it back. The longer the stud, the easier it is to straighten. I have used this from time to time with none of them breaking. If it has a sharp bend, there you will have more risk of it breaking. Mustie1 uses this technique.
Good tip, that would have worked well.
Do you sell generators if so how can I get one from you
another nice job. More than 60 views less than 10 minutes after the video was posted before 7 AM. Keep up the good work. Very nice explanation.
I have a Husky power washer that my neighbor gave to me, non-running. He admitted he never changed the oil. Ever. And it was built in 2006! It has a small flat head briggs. It looks just like your Husky generator, a red cube covered in plastic all over. A total pain to work on. I guess they cover the entire engine as they expect the average homeowner to simply add gas and connect a water hose. Simply trying to access the carb or pull the spark plug, requires removing like 12 screws and prying apart the entire machine. Kind of like working on a clothes dryer! I've basically stripped the entire housing off of it and just left the engine/pump housing mounted to the floor-frame. Much better :) It runs great, and like you said - "it earned an oil change"! I actually take the same approach! Only after I get an engine/machine running well enough that is has hope, do I change the oil. I'll add oil before running if it's low though.
great video!
Well done, another one brought back to life. I was surprised you found the very long 6mm bolt at a local hardware store. I think I would not find anything of that length in my local hardware stores. I have a metal lathe and imperial and metric taps in dies so would likely have made a stud. I am happy to make such items for you if needed.
Dave.
If you have one nearby, Fastenal can have a lot of unexpected items in stock.
Most hardware stores do not have metric or a very poor selection. The big box store near me has almost nothing. The small little hardware store has every bolt size you could ever need and well organized...
I wonder if ACE hardware might be a better bet for these more obscure (but necessary) items. Their plumbing section seems far more complete for brass fittings than the big box stores, they might have a greater selection of studs.
Two thirds of your work is carbs James. Carburetors are precision engineered devices. The slightest deviations from the spec can render them useless. I love how you can see which deviations are causing the problem and your innovative attempts to fix them. You fix them even if they come with problems caused by slack design. It is impressive.
Thanks
A little advice: before cutting off the threaded bolt, screw a nut onto it, then cut off the bolt, file it, and twist the nut from the saw side, the nut will clean and align the thread.
Great tip, thanks!
Brushless generators are always going to have higher total harmonic distortion. The squiggly lines at the top of the wave is the result of the circuit "ringing." This is because the capacitor and the inductor (the spinning rotor) are acting as an undampened (think of a car with no shocks) resonant circuit. The best way to stop the circuit from ringing is to add a purely resistive load like a heater to quiet that circuit down. Unfortunately it is not a 100% solution. I would say try loading it up to 50% to 65% and see how the waveform looks.
Nothing beats an inverter generator with proper RFI/EMI filtering on its output.
The problem is they don't make 10,000w and higher inverter generators. If they do i haven't heard of them
@@faststang85 honda makes a 7k that you can parallel with another 7k. But it costs many mortgage payments.
Harbor freight makes a 9500 inverter generator
Yes that generator may be expensive but it is the best that you can buy
So many people are caught up in the clean power. My 1850 watt camping portable generator and 6250 watt generator both non inverter generators. In the 1850 portable non inverter generator is relatively quiet. Have ran things since 1994 when I bought the truly made in the USA generators both with bulletproof Briggs and Stratton engines. No electronics burned up. But the newer inverter portable generator I bought burned up in less than a few months it went back to the store tried another one and that died too. They were cheap Chinese inverter generators though. I went to Honda inverter generators now they don't seem to die and seem pretty dependable so far. But I found out the hard way if the overload light comes on in an inverter generator you better cut it off immediately and cut back the power here using. And not keep having the red overload light come on or you can burn them up like I did. Inverter generators are supposed to be so smart they don't blow a resettable breaker like the two older ones I mentioned do they just blow the inverter board.
Another gem of a video
Hlad I just found this video!! Answered my question as to what my 1850 Coleman is supposed to put out-1500watts!!!
James, I’m surprised you didn’t try penetrating oil to try and free that stuck carburetor. It couldn’t hurt.
That was going to be plan B. Was actually going to drop it in evaporust for a could days.
slide a piece of copper tubing over the bent portion, use a smooth jaw adjustable wrench over the copper tube and tweak as needed!
Ive had great success with removing seized screws / jets etc from carburators by immersing the whole thing in boiling water for a few minutes. Usually frees them up a treat.
My thought on a crust old carburetor that has a stuck emotion tube and jets might loosen up were you to submerge it in distilled water and bring it to a boil. The theory is the housing will expand and less force in extracting the part will be needed.
I had a carburetor that was crusty and calcified worse than this. I took an old crock-pot and poured antifreeze (ethylene glycol) into it. Soaked the carb in that for 24 hours on low heat. Came back and all the jets came out like new and the calcification was gone and the carb looked shiny and new. Any rubber parts or o rings will suffer horribly if you use this treatment..forewarned.
Usually your putting in sew seals and O rings anyway,gonna try that idea,
@@jeffclark2725 I saw it being used in my small engine shop here in upstate NY. I tried it and was amazed at how well it worked. Ultrasonic is faster, but the glycol method is incredibly thorough. It takes the rust, calcification, carbon..everything comes off.
@@wxfield
The cleanest cylinder in any engine is the one with the blown head gasket leaking coolant into it.....
Nice use of alligator clips to extend the ground to the plug. I like that . Yes the brush less gensets are dirty. With each spike you see on the oscilloscope there are high frequency signals generated causing noise much like a square wave. Many folks this they are opposite and super clean.
Sometimes you need an extension, especially on stuff like this covered in plastic.
Once again great repair. Hmmm I keep learning about generators and how to fix them from you. Except I would not mess with the power head part. Thanks for the tips on the bolts and the dirty wave from the generator. Thanks for the video's
Thanks for posting this, big help with getting mine fired back up!
I think I am getting addicted to your wind chimes...
I think you did very well with the airbox seal. Of course the inner gasket to the engine is more critical on inner hole shape than low velocity airborne gasket which keeps dirt intrusion out. My garden digger needs this treatment. Works fine without airbox but does not like filter.
As a working small engine mechanic in the real world you would just bend the stud back in place.
LOL, you sent me down a rabbit hole when you pulled out that oscilloscope! Now I want one...
EXCELLENT job as usual. The endgrain of a block of wood works good as a backer when punching holes in gasket material.
Best part was seeing the hand carved stool, fun look inside the shop:)
One tip I learned concerning cutting off the end of the bolt is the thread and not on first cut the head of the bolt off and then run the nut over top of it to straighten the threads. It might help
I always put a couple nuts on the bolt before I cut the head off, then when you remove the nuts, it cleans up the threads. Much easier than using a die.
Another victory in the win column. I was surprised with the noisy waveform of the brushless generator output. I would have expected it to be clean, almost no distortion equal to inverter generators. No brushes to cause arcing and noise on the output. I wonder where that noise comes from.
The problem with that dirty sine wave is the high harmonics will generate eddy currents in transformer and motor cores and heat them up more than a pure sine wave would. However, that's not as bad as the pseudo sine wave of many UPS devices. Any device that uses switching power supplies will tolerate that dirty sine wave just fine. I would worry a little about refrigerator motors which unfortunately during power failures and the main things we want to keep running.
yes fridges are one of the important thingd to keep running. maybe spending a little more, on a cleaner would pay off in the long run.
Nice little genny for emergency use, especially if there’s no room to store one of the big guys. Unfortunately a dirty sine wave and flickering output seems to be the norm with brushless generators but they get the job done in a pinch. Very nice and thorough job, enjoyed watching you bring it back to life!
Thanks
Nice video, thank you! The studs are just short pieces of all thread available at H.W store! The Bolts were a good fix! Ron USA
Good morning, James wonderful work on the small genset. Perfect unit for a camping weekend. Just a silly note, hope that you are not using you wife's coffee cup when you drain out the carb.🤞🤞🤞🤞
Looks like it must of been dropped at one time to bend those studs.
The seller didn't lie, it needed a new carb.
So, either the hurricane bent the studs apart or some guy couldn't find the bolts and bent them apart like nails to hold the carb on. Two completely different ways to feel amazed.
That’s a version of the Coleman power mate mega pulse some had 3.5 Briggs or the subie engines.
You fix many more of these generators I am going to send you to Lake Mead or Lake
Powel to fix the generators at Hoover Dam. lol
Great video. Did anyone notice that the control panel advertises it as an OHV while the engine is OHC?
I’ve fixed a couple of those. Sold by a few companies, same machine. The cheap plastic capacitor fails, no output. A real handy little machine though for light use and very portable. The China carbs are hit and miss. Some work, done don’t. Just had an Onan 4ky unit needed a carb. Bought 2 off Amazon. Neither ran well. Ended up putting a used worn Onan carb on it I had laying around. Onan carb costs a fortune compared to China made. And I am an Onan dealer !
Some carbs are way to expensive. I had a 2 cylinder Vanguard that needed a new carb. I spent close to $250! They now have clones of that carb. The clones are definitely a hit or miss, but worth a try when the alternative is crazy expensive.
@@jcondon1 My cost on an Onan 4ky carb is over $200 and as I said I am an Onan dealer ! I can and did buy Honda carbs for under $100 or maybe $125 from a Honda dealer! The last 2 Honda carbs I bought had the idle control stepper motor on it for those prices. Cummins-Onan parts prices are outrageous and lots of stuff is made in China ! I’m not working right now, had a major health issue put me out for a while. I actually grew to like working on small engine equipment and some of your videos were very helpful. You do a great job on stuff that is generally tossed out because no one wants to do this work for the must part. I’m 74, old school, I’ll try to fix almost anything unless it’s really in bad shape.
Really excellent video! I own the same unit and I have to give it a shot of starting fluid to cold start. I left fuel in the carb for long periods of time. My bad. Probably needs carb cleaning.I do notice the lights flicker sometimes when using. Good info on the scope readings. Thx again! How the heck did those studs get bent??? Crazy!
I run two in line filters on my auxiliary fuel tank, just in case. But I deal with 4 or 6 cylinder motorcycle which have carb racks that aren’t fun to dislodge and reinstall. Can’t take the chance of any crap getting in. Also if you get some aluminum angle pieces like 1/8” stuff make some soft jaws for your vice to grab stuff like that threaded rod.
Pulling a carb rack for any reason is a lot of work.
Nice find and easy fix. Would have been nice to get the original carb going, but wasn't in the cards. Watching you thread that new stud through the carb and gaskets reminded me of putting the air filter housing and bolts through the carb and ALL of the damn gaskets on a Honda GCV160 OR 190. 3-4 hands would be helpful at times. Great work, filming, audio and editing as always and please do keep em coming!
Thanks Erik!
did you check compression after it ran ?
Here'sanother trick . Use a 50/50% mixture of acetone and atf oil . Best penetrating oil the world has ever seen .
Wow!! You even treated us to some arts and crafts with gasket making lesson 🤣🤣😁😁 I'm happy that the clone worked out. Very good pick up for 75 bucks. Subaru/ Robins made some great stuff back in the day. Too bad they exited the genny market.
They are some of the best engines I have seen.
Sounds pretty good with the clone carb
Thankfully that carb worked out well.
glad you put the oscilloscope on it , it would be great if you can show that more on future gen sets. good vid thanks
You work is the best ever and amazing
I would recheck the compression after running it -- Bet it would be better! -- Just saying James
Its great learning from you and seeing your work techniques how you salvage things like those carburetor mounting bolts. I like how you distracted those bent bolts., I'll have to remember that method.
I’m working on one. The HU 2250. Low power output. I took off the cover and I don’t see brushes where they normally should be.
Hi, James. Another puzzle was solved. Thanks for sharing! Stay Healthy!
Thanks
I saw the OHC on the valve cover and was skeptical about the "C". Upon removal of the valve cover there it was: the overhead cam!
It is one of the best built small engines. I dare say better then Honda. Too bad Subaru sold them to Yamaha. Not sure if they still make these engines.
Maybe think about buying a lasercutter for creating gaskets. Falcon2 20W for example.
Great video, strange that those studs were bent but at least it didn't need too much work, nice work James!
When you cut a bolt you can put a nut on the bolt & back it out after cutting the bolt & it will help reset the threads
Thanks. Good tip
Great video, your videos are very useful teaching videos, some of best produced on TH-cam. If you ever have a chance could you do a video of the oscilloscope. Thank you for the videos you produce.
Straighten those studs in place, it's easy with a box end wrench and two nuts....
Very good technical steps 😃
I think some acids clean old carb
But new one good Idea
Thanks for this video
I’m learning so much from you about gensets, thanks. 👍
Another great repair always enjoy watching you fix them
Like this one. Thanks for the wave form of brush less regulation. An invaluable piece of info for me.
Congrats on the fix! The dirty sine wave has more to do with economics and perhaps durability rather than quality. Brushless should be the ideal generator! I don't know what a good fix might be but sensing and feed back move much faster than 60hz. My knowledge of Generators leaves a lot to be desired! Ron USA
Cleaning/freeing up parts: transmission fluid bath overnight, in an electric crock pot is a miracle worker …
Granted the sine wave is not ideal, but it would be okay for the fridge ( not a fancy or expensive one ) maybe the furnace, definitely a electric heater like you have
JAMES your video are always so interesthing to wach and learn,carburetors that is what i know best,and you are quite good at it ,i like your dexterity that you work with ,BUT what i hate it is when i see you with a carpenter hammer with one claw broken ... as a pro like you ,you should a least a half pound ball penn hammer ,this would complete your craftman ship ,i should say your high quality of work.
By the way what is the capacity of your new ultra sound machine ?
The new one is 6 liters. That terrible hammer I stole from my son. It is basically a toy. But works good when you want to tap something lightly. I agree though it is not the best tool in the toolbox.
The rings probably need to seat again after sitting up for quite a few years. The compression may increase after a few hours run time.
Thank You James!!!
My small generator has a larger version of that motor and seems to have very low compression while pulling it over, but I think it's just how they are with the compression release it only has about 100 hrs on the meter and runs excellent
Got to love those carbies & bent studs... Not. You did exactly what I would have done with the one you managed to remove. I'm thinking it has a decompression device to aid starting myself.
I had the exact same generator except in mint condition. Bought on fb for 75 bucks with a bad carb...put a new Subaru carb in it and worked great. However I ended up selling it because I wanted something with cleaner power and will buy the Honda EU2200 instead.
The EU2200 is a very nice generator.
Nice fix Jim: Do you think the generator might have been partly under water at some point. The inside of the filter housing had a rust line on it so I thought it might have been under water. Thanks for a great video.
Do not think so. The person I purchased it from had beach front property. Think the salt and humidity got to it.
Those were some filthy signwaves.
Very compact and neat generator.
Nice fix James, soothing to watch some how. Regards from Spain.
Another great video your voiced is very calming you could do relaxation videos . WS surprised how dirty that output wave was. Will be checking it on a couple of my generators that are not inverter styles.
Hi James great sitting in your class to day I have never worked on Subaru engines before the gene looks of good quality and a easy fix on your part mate
I love the Subaru EX engine line. Very well made and undervalued. Parts are expensive though.
might try soaking the carb in the ultrasonic with marvel mystery oil to loosen up the stuck parts
hey little fly. even the flys like James Condon
I think a PB Blaster bath is in order or at least a Gunk Carb bath with the ultrasonic.
It would be interesting to see the oscilloscope connected to your house AC utility power to see that wavefrom as a comparison. Maybe also the kill-o-watt unit showing utility Voltage and Hz.
I agree.
I had planned on doing a video late September comparing the output of all different generator types vs the house AC output. Will do it at some point. Maybe a winter video?
So relaxing, almost hypnotic to watch these shows. Im addicted.
Excellent Work.10/18/2022yr
I picked up 2 of these generators from my neighbor who was going to scrap them. Left out in the weather. Watching this video I brought one back to life. Any idea where I can get a used air box? New ones are stupid $$. Is there another option?
Thanks for your great videos!
Another generator brought to the life again actually I'm addicted to your work and your videos Mr. James but I have a doubt... where do these people store their generators ??
Because most of the generators you fix are full of rust and dust.
The generator should be kept in a clean place .
Anyway this video helped me with a new technique specially with that stud but I don't know how these types of generators get cooled since it's closed from all sides that means no sufficient air will be there for allowing the engine to be cooled therefore the engine will always be exposed to overheating.
I think this type of generator doesn't last longe.
thanks a lot for the video with my regards to you Mr. James.👍
Where do you live that there is no rust or dust? Most people around my parts keep their generators in a shed or outbuilding. Anything that sits for years, even in a "clean" shop, is going to build up a layer of dust on it. Rust also, in many parts of this country with the high humidity levels, especially if it is kept in an unheated space. Where I live, I have learned to hate chrome because anything chromed that sits outside, even if out of the rain, still pits and corrodes from the humidity. My grandfather had a beautiful set of 1940s Craftsman sockets hanging on a pegboard in his barn, one socket to a peg - they hung there so long that 100% of the chrome flaked off the sockets and each socket had a pile of tiny chrome flakes underneath it on top of the work bench, when we cleaned out the barn after he passed away. I had never seen anything like that!
@@redmondjp
I wonder what dust covers are for?
An old blanket or old bedsheets might work at a pinch....?
@@redmondjp you could wipe your generator or whatever has the capability to rust with oiled rag and that somewhat will protect it against the rust and corrosion specially if there is a high humidity.
I do this thing with my generator and underneath my car also.
Starting your generator for 10 min monthly will keep your engine and other parts away from getting rusted, corroded and accumulating of dust and dirt.👍
Hi James. Another great job! You are always very calm and patient when doing your jobs. If I saw my new carb leaking like that I’d be cursing like crazy. Look forward to your videos each week. You never ask for people to subscribe or give you a thumbs up like some of the other TH-camrs. I like the oscilloscope you have. Wonder if you have a link to it? Btw, if you remember I commented before how clean your hands always are. I must have jinked you as I have seen you having more cuts and scratches lately. Look forward to next fix.
I have a link to the oscilloscope in the description of the video. Its a cheap one, but still gives a lot of insight.
Another master class repair thanks .
Don’t you get tired of working on the ground? Perhaps a jackable table would be a good investment for your back and knees. Great videos by the way.
Another generator saved from the scrapyard, clear diagnosis with a positive ending. However why do you keep working on your hands and knees.
Another successful rescue !! Thoroughly enjoyed as always ! Wish you & youre fam a Merry X-mas !!
Thanks, you too
It was a great job! It always is!
Your so good with these things, most of the time it’s a simple fix but not always and you always seem to get them going….. is this generator repair your full time job James ?
Not my fulltime job, just something I do part time.
Great work good machine
It appears that you missed the holes in the upper left and upper right on the homemade gasket. The right was hard to tell if it was on the old gasket but the upper left was finally missed.
I was hoping for you to do another compression test to see if improved by running !
Good one James 👍.
Most small engine mechanics always do a float needle leak test by blowing into the carburetor inlet gas line and moving the float to check the seal.
$37 for a clone? No telling what the real McCoy would have been. Those long slim studs can be problematic for just the reasons you found. You can get a clamping stud puller. There's a type that will clamp up flush to wherever it's attached. Not the Snap-On type. The one I had was a Proto. But, you can probably get one similar on the cheap.
Subaru parts are not cheap. I needed the air box on this machine for another project. OEM part was over $100.