In post apocalyptic America, there will be just a few things alive. Two Chevy 3800’s 4 K series, Honda engines. 2 dozen cockroaches. And every generator this man has ever touched!!!
WooooWeeeeWoooh grammar police, I don't want to put words on the page in your wake so I will suggest that perhaps either you meant,( there will be just a few things still working. Or you might be suggesting that the two Chevys 3800 and anything this guy ever touched etc had found life itself and took over as a master race. Either way I had a heart attack and was compelled, nah I had a good laugh. 😂 Adhd much?
I had a Chevy 3100 V6 that had 328,000 miles on it when it was towed to the junk yard still running. I was pissed my dad junked it, needed a brake line.
James, I worked in TV production for 35yrs, your videos are in the top 2% of videos on you tube. Your lighting, sound, editing and camera work is exceptional. I like the way you keep your hand out of the view so people can see what in going on. Not enough others take the time or effort to do this. I see others use handheld cameras moving around everywhere it not visually appealing. You use it just enough to see what is going on, then back to the tripod. Excellent video, Don't change a thing regarding production.
Thanks. Have heard the same from a few others involved in TV, film and theater. It has been a challenge to get to this level. If you watch my earlier videos you will see. No tripod, no lighting, bad sound and bad editing. Had to take things more seriously when people started watching. Never expected that.
Also, James doesn't 'hog' the camera with face-time or cover up his narrative with useless music. I am a sub and a huge fan of James. He has showed me over the last 2 years how to start my own generator repair business.
One of many great things about your videos is that you not only explain WHAT you are doing but, more importantly, WHY you are doing it. While long time viewers would know why, new comers get to learn more. Always interesting and entertaining. Glad to see the engine is savable with just a few internals. Clean carb and good test shows another successful restoration. Thanks for sharing.
And James does one Storm Responder after another. Even a chimp would know what's coming next, oil check, carb clean, compression, spark. But every video is exciting new and slightly different, so well shot and lit, explained and edited. No 'look at me' rararara. Great channel, thank you so much.
I am not a mechanic. The TH-cam algorithm brought this gentleman to.my attention. I must say I am impressed. He is very thorough in his presentation, showing you each step in the rebuild. There are many people who do what he is doing, but I have never come across anyone who explains it as well.😂
I love the rope technique to polish the crankshaft. I will forever use that to polish a crank. I used to take hours to polish journals your method was fantastic.
Thorough, thoughtful, meticulous, patient, kind, articulate, professional........and "smushed"😊. What a guy. Always inspirational to watch your work. Thanks for what you do.
This reminded me of a cub cadet mower that I bought several years ago. It was a high end 21 inch cut with swiveling front wheels multiple speeds and blade engagement. Back then over $500. I had cut down a 2 inch black locust that was in my way and the grass grew up and hid the stump. Of course I hit the stump and immediately broke the crankshaft where the blade adapter fit the end of the crank. After cursing myself I went and got a new crank. It was a 6 hp Kawasaki engine and as I took it apart I was very impressed with its design. I got it all reassembled and it would not start. First thing I thought was I didnt get the timing set correctly. Before thinking I tore it down again and found the timing to be set properly. I walked away and came back a few days later. I pulled the valve cover and found that a push rod had not set in the rocker. This was the first machine I had owned with overhead valves. I shared this story with friends because I felt that other people might also not be familiar with overhead valves on small engines.
I have always thought about when I get something thats broken and I find the problem and get it fixed that feeling inside us is satisfaction and I enjoy teaching others how to fix things and get same feeling when they do it. This is a good video to teach others by, great job buddy. I know you have that feeling of satisfaction each time you get another one going again. Two thumbs up.
Glad that I am able to watch this video. We had a storm roll through here in Ohio. My power went out at 6:30 in the morning. They don’t expect to have it on till 1:30 this afternoon. So I’m watching this video on generator power 🎉
Absolute perfection. I love these extended videos. I know a lot of work goes into the editing also. Great work. I never get tired watching the Professor at work. 🙂
The editing for these long videos must take FOREVER. It is done so well. This is by far my favorite TH-cam channel because there are no ads and because the quality of the content and editing is so perfectly done. Thank you very much James...your hard work, attention to detail and quality is very much appreciated.
What an amazing video! I know a lot about law and a lot about teaching college and I know how a two stroke engine works in theory. But I don't know anything about repairing an engine much less rebuilding one. I watched fascinated as you explained what was needed and then literally rebuilt an engine, showing step along the way. By the time you were done, I felt like I could rebuild a two stroke engine. You are a natural teacher and your gift of being able to teach (rather than lecture) is the ultimate. Thank you for a great video.
Who knew wrenching could be so fun! You are so knowledgable and intuitive. It's great watching someone who knows what they're doing...and cares about doing it right. Thank you Sir for your talent and effort.
Always good to see a machine given a second life. A lot of work but worthwhile. Very good that the connecting rod did not break, unlike what we expect to see on the other unit. Well done as usual.
A couple of tips for you, If you do use that type of hone - Use engine oil and a fraction of the drill speed you had as you need to be going in and out nearly as fast as it's rotating for the correct "cross hatch" finish. Use the smallest smear of assembly lube where necessary first then oil for pre lubricating. Put the faintest smear of anti-sieze under bolt heads and lightly oiled threads for things like those Alloy Rods to reduce any gauling when torqing the cap bolts - + any incremental tightning should be at least needing 90deg. I realise it's not a Race engine but you strike me as a Guy that likes to do things as best as possible ;)
Very few people on youtube actually knows how to hone a cylinder for the right cross hatch. I see people that is professionals messing this up. Its kinda wierd actually haha
@simenk.r.8237 Yes, how very "wierd" - you misspelled that, by the way. It's a mystery how everybody can screw up their honing when they could easily look up the correct technique on the million subscriber honing channel of world-class craftsman simenk.r.8237 who generously shares his infinite wisdom in hundreds of his painstakingly edited videos. The world is lucky to have heroes like you, simenk.r.8237!
The Engine Dr. wins once again. I am amazed at the number of FUBAR generators in your area and even more astounded at the lack of attention to oil level by their owners. I can only assume the owners are very affluent and treat their equipment as consumables.
I think it's likely a matter of ignorance of small engines. Many people do not know that you should be doing your first oil change at the ten hour mark. I think people believe that they only take their car in for oil changes once or twice a year and the generator gets way less use than the car so why would you need to check it! Ask me how I know 😂😂
Thanks for the video James. The one thing about your videos is that you talk people through them when you are working which I think is brilliant. Cause not a lot TH-camrs do that. Thanks again George in England, UK 🇬🇧 😂👍
James, you can buy feeler gauges with a .002" step for a "go-no-go" effect. Also a couple of old school references on small engine rebuilds: To be perfectly accurate there is a measurement of "pull" on the feeler gauge. Depending upon the actual part being measured 1-3 ounces is a good "thumb" however, there is also supposed to be oil present. We used Ring end gaps of .0025"- .0035" for every 1 inch of cylinder diameter. An old example used to be "A 4 inch cylinder can use from .010" - .014" Ring end gap. Larger if it is a very hot applications like Turbo or Supercharged. We rebuilt a lot of engines with those specs and never had a piston stick or use excessive oil. Good video, thanks for offering it. ben/ michigan
You and Mustie have taught me so many things about all engines and generators the past year it would have taken me years to learn at a trade school. Thank you.
James, I am a 72 year old retired computer engineer and I am amazed at your knowledge on small engines. I am trying to get my Campbell Hausfeld 4800 watt generator that's VERY old. I've learned a lot from watching your youtube page! Especially this "Two Catastrophic Engine Failures presentation.Great Job!
A tip: I had a rotor that would not come off and would mushroom the pusher rod. Did two things: i used a small slug of brass between the rod and the pusher bolt. The main help was sneaking about 4 turns of #16 wire around the front of the rotor shaft and positioned them near the fan. brought the two leads out to a "Hot Rod" handheld induction heater. Fifteen seconds of the heater and the pusher bolt had the rotor off. It is fairly easy to thread four turns around the shaft. I had considered using a small torch but fire hazard negated that idea. I had fought this for hours trying everything hydraulic, and slide hammer... nothing worked. It was so easy with the induction heater it surprised me!
I'm damn near 64 years old and you are my new hero.I'd give almost anything to be as neat and well organized and especially as knowledgeable as you are. Three thumbs up bro.
I would be pretty pissed to find a used ring in a supposedly new ring set, especially at that sort of price. Most ring sets are under £10 in UK but some B&S sets are around the price you suggested. My guess is that someone bought that set, swapped the top ring then sent it back saying that they bought the wrong set, and the vendor didn't check closely enough (or was the one who did it depending where you got them).
When you find that sort of disappointment it's always difficult to know whether you send it back on a matter of principle, and mess up your schedule in the process, or just find a way round it. Very annoying when you open the package and it's not got the correct contents.
That’s exactly what happened someone said F this I’m not paying $50 for rings and swapped one out. I just hope he doesn’t let them slide and gets his damn money back!
Yes it's a long video but with great information. Showing specs and exactly what goes into repair and rebuild is worth it's weight in gold. Great job 👍🏼
I really appreciate your videos. You are very detailed which is appreciated very much. I will say that at the 1:22:20 time in the video, you mention adding oil so you don't forget because you are getting excited at nearly being done. I can certainly appreciate your thought process here. I'm not a small engine mechanic. I do have a lawn care business, so in order to save money, I do all of my own maintenance and so far, all of the repairs on my equipment I have done myself. Prior to going into the lawn care business (which is a retirement job for me just to stay active) I had a 54" John Deere Z425 zero turn mower that I had been using on my own yard and on my neighbors yard. I continued using that mower on my yard and my neighbors yard even after starting my lawn care business rather than using one of my other zero turn mowers on these yards. I developed a slow oil leak either on the sump gasket or PTO shaft, but I always checked the oil level prior to using it and would simply top it off once every couple of months as it needed oil. One day I did my yard and almost all of my neighbors yard when I started smelling burned oil. I only had a couple more passes to make on my neighbors yard, so I finished it and went back to my shed and started checking on the oil smell. I had no oil left that was visible on the dip stick. The mower was still running fine at that point when I parked it. I added oil up to the full line and there was a slow but steady dripping leak while sitting and it got worse when the engine was running. Either the gasket or the seal had seriously failed. I pulled the engine on it and pulled off the sump and replaced the oil pan (sump) gasket and the PTO seal. I reassembled the engine and put it back on the mower. Installed the PTO pulley and reattached the deck. I was so excited to have completed the job. I fired it up and it ran like a champ even under a load from the deck for about 1 minute and then I heard a "clink" sound and it wasn't running correctly. I turned it off and soon realized I hadn't added oil to the engine. I had failed to fill it up in my excitement over "completing" the job. I of course added oil, but that did nothing to help. It will run on one cylinder now, but that is all it will do. That was two years ago and it will still run on one cylinder, but it won't power the deck. I appreciate you saying what you did at the 1:22:20 mark. I've been there and failed to remember to do a very simple and basic task and I assume as a result I ruined a good engine. At some point I keep thinking I will pull that engine again and figure out what the damage actually is, but I just haven't gotten to that point yet. I have two good 52" Scag Tiger Cat II mowers that I can get the job done with and have no pressing reason to tear into the other mower. I'm sure that at some point I will get there, but I'm just not there yet. It was a bit defeating to have that happen. I have rebuilt a few smaller engines on walk behind mowers since then and they have all worked fine, but that taught me a lesson I will not forget. Keep up the great work!!!
Really impressive, James. I realize that I need at least four new tools in order to do this sort of stuff justice but at least you walked us through the process in a straight-forward way. I can't thank you enough.
I've never done Small Engine tinkering, so your videos are chock full of learning experiences. However, finding that out of spec #1 ring was amazing. I confess I would have made the mistake of just throwing a "brand new" part in without checking. Thank you for that valuable lesson.
I normally use an ad blocker browser to watch TH-cam, so I never see ads. But I happened to load up this video in the actual TH-cam app and was pleasantly surprised to see that your videos aren't monetized!? This is some great info and entertainment you're giving away for free! I do appreciate it, great job as always.
Jim, as ever, you're "the man" when it comes to fixing generators. It was lucky that Jason's generator was repairable. I hope the other one is just as repairable. I'm looking forward to seeing the video for that one.
Excellent job as always, I'm thinking those rings were sold and returned with the top ring switched with what they were intended to replace, accidentally or on purpose who knows, either way this engine runs great
Very nice to see you working on something older. Your expertise as always shows that something that is older can be useful when cleaned up and maintained. Have an old 1850 powermate and your posts on upkeep and maintenance really makes a difference. Keep posting as it really helps us DYRers.
Textbook presentation. Having worked in a machine shop for several years, I can appreciate the attention to every detail of reassembly.Thanks for the video.
Your videos are always so amazing, I learn so much from these. The knowledge I've gotten from your videos has made me more comfortable with the idea of working on small engines with this level of depth.
You are impressive, as usual Jim. This was totally worth 2 hours of my time. Thank you for explaining your decision tree and including your thought process.
Hi James. Just want too say your videos are part of my up in the morning having coffee and see what your fixing today. I have learned quite a bit from watching your channel. Thanks for explaining and showing how you do it. Thanks again and keep up the good work.
@jcondon1 one point I'd make the bolts likely didn't stretch, the aluminum rod cap squished out from under the bolt. Aluminum expands 4 times more than steel, so it will flow outwards and mushroom. This is the same failure mode that makes aluminum wiring dangerous too.
Found this recommendation from Winco. REMOVING AN ARMATURE OR ROTOR FROM THE ENGINE CRANK SHAFT The armature/rotor is just taper mounted to the engine crank shaft and held in place the bolt running down the middle of it. Remove the bolt or nut and washer before continuing. You will need a flat metal bar and good steel hammer. Insert the flat metal bar between the end of the armature/rotor and the engine, so that is rests on the engine crank shaft. Strike the metal bar crisply with a steel hammer. This will set up a vibration in the hardened crank shaft, the vibration should break the seat between the armature/rotor taper and the engine crank shaft taper.
Great video of course. Admirable how you quickly shifted gears from swap to total rebuild. Thanks for working on exactly the same mower that my son in law has so that the carb cleaning went smooth as silk
You were very lucky with that Engine, great video well done james keep up the great work you do fixing stuff once again well done can't wait for part two.
Great rebuild and great to watch. The time flew by at my end, but I bet it was a long slog at yours! The sound that made as it unlocked was worrying for a moment, and made it seem as though something had just flown apart inside, but I guess it's the feel of the tool as that happens that gives you encouragement, and that can't be conveyed in a video. We just hear "clonk" and think, "uh oh ...".
It's awesome how much patience you have! I can't believe how much of a pain in the bum those generators are to work on!! These videos taught me to run from repairing them
Jim, not criticism , but my dad used to photocopy pages from various manuals (Chilton's, Haynes, etc), for what he was working on, and he put sheet protectors on them, and in that manner, he kept them nice. Just an idea for you.
"While we have it apart, let's fix it right." Wow. If there were a Nobel Prize for integrity, this guy would be in a tux on his way to Stockholm. And how about that out-of-spec top ring right out of the box from Briggs? James, it was handy the existing top ring was in spec, but I think B&S owes you one! I've been working on small engines longer than you've been alive and I still learn something new every time I watch one of your videos. If there were more people like you in this world, the generators you work on wouldn't be such crucial necessities in what we (western industrial civilization) are facing this year (2024). Keep up the great work and thanks for sharing it with all of us!
Excellant restore. Gives me ideas what to check for if my generator goes. Right now is an after market carb on it and it hunts while running which leads me to believe it might be a carb issue. It's a UST GS-5500.
It never ceases to amaze me that with a couple of mods like larger better bearing, oil pump, replaceable cylinders, oil low and over temp alert and stop that these engines would last almost forever!
This was supposed to be a quick engine swap video, but I knew your curiosity would get the better of you even when you freed the engine off and the diagnosis of big end failure was obvious . As soon as you said "we've come this far so let's go a little further" I knew the engine swap out video was almost certainly turning into an engine rebuild video ! 😅 . I'm the same. I wouldn't have been able to resist opening up the crankcase ! 😂 However, compared to a car engine it's not that much work to strip a small single pot ohv engine so it's not gonna be a potential waste of half a day's work and the shop floor covered in parts and oil. Another great video. John, Nottingham, UK
Excellent video. Very detailed. I love your work ethics. One thing surprised me that you didn't change valve seals. Engine has heated up at some point which changes rubber characteristics. If I had opened up engine I would definitely change them. Just my thoughts. Great video again.
I love your vlogs Jim as always very interesting and informative and you are very mathodical and careful in your prep. Probably yours are the best videos I watch on TH-cam. Stay safe and well
You are building a legacy that will serve others for years to come. One day, I hope to make as big a contribution to the world as you a making with this content. It is not only about the equipment, but the technique, the patience, the dedication, the critical thinking, and much more you are teaching here. Bless You!
Maybe this is just my OCD, but I noticed that (if you are looking at the power head) the right Stabilizer for the Power Head is Squashed compared the the one on the left (@7:05). This is confirmed when the Stabilizers are removed. The Power head is at least 1/4"- 1/2" lower on the right side. Something is misaligned. Which will lead to unnecessary wear and tear on it, since that Stabilizer is taking the bulk of the weight of the motor and Power Head. My uneducated guess is that the Frame for the motor is bent by 1/16"-1/8". I am just an "Arm Chair" viewer, but something doesn't look right with this generator within this time frame The Engine rebuild was Great! Very precise and almost Surgical! Thank You very much for this upload. I always look forward to your videos.
Great video. Very good narration on the step by step teardown. And I learned a clever way to polish a crankshaft with a rope. I would have used sodium hydroxide to remove the aluminum from the crankshaft rather than acid, however. NaOH would readily dissolve the transferred aluminum but would not be corrosive to the carbon steel crankshaft at the low temperatures and short time duration involved. Caution: NaOH also dissolves skin as fast as aluminum. Neutralize with vinegar.
That number 2 piston ring being out of spec was either a manufacture problem or it has been used before. Something I would never have though of. Even checking it would have passed me by. A lot of work went into that lovely sounding engine. Well done and thanks. Cracking to watch :)
I think this video is a message to 99% of the other videos where people are doing this without a torque chart and measuring tools. I have rebuilt two car engines using this kind of care and proper tools with torque charts and degree wheels. Toyota was straight up torque to point but BMW in some parts required degreeing after reaching the desired torque called bolt stretching. You also have to remember to not miss any bolts or they will fall out later and cause serious engine problems.
Hi James. As normal a great video. As a race engines builder, I’d like to suggest your next video like this, use your dial bore gauge and micrometer to calculate the rod to pin clearance. It’s not hard and more reliable
Your instruction is so good that all a person needs to start a small engine repair is to watch all your videos, buy a few tools, learn to read manuals and blowup drawings, and your about ready to go!
I have been trying to explain that to a bunch of whiners who say they can't get a job with no experience and can't get experience with no job. TH-cam has a wealth of step by step to learn a career!!! Buy some used tools and get hustlin'!!!! They obviously have money to buy iphones, beats by dre and weed.
Thank you all the way to 1978 in high school memories. Rebuilt one. Learned what other kids do fill cylender with oil. I could not figure out what I did ? Instructor said I been at this a long time try draining oil from cylinder. Quick fix lol
I really enjoy these videos because anytime I see someone using good mechanical practices I am typically amazed. Most videos I see are done by people thinking that they are doing things properly or at least in a workman like manner. I have been a professional mechanic all of my life from early childhood to my seventies. The little things that many miss such as ring end gap, ring type like a dykes ring or taper ring. Small but really important things that are unfortunately not noted by some. The method of polishing the crank journal was refreshing. I have done it many times using my lathe and very fine Japanese water stones. They both do a good job. Enough blathering on from me. All I can say is Bravo! Good job through and through. Best Regards Al in Virginia
In post apocalyptic America, there will be just a few things alive. Two Chevy 3800’s 4 K series, Honda engines. 2 dozen cockroaches. And every generator this man has ever touched!!!
Those, and a few skeletal 7.3 Ford pickup engines in salvage yards
WooooWeeeeWoooh grammar police, I don't want to put words on the page in your wake so I will suggest that perhaps either you meant,( there will be just a few things still working. Or you might be suggesting that the two Chevys 3800 and anything this guy ever touched etc had found life itself and took over as a master race. Either way I had a heart attack and was compelled, nah I had a good laugh. 😂 Adhd much?
Nice!
I had a Chevy 3100 V6 that had 328,000 miles on it when it was towed to the junk yard still running. I was pissed my dad junked it, needed a brake line.
I have a 4.0 Ford areostar 2wd 587987 miles
James, I worked in TV production for 35yrs, your videos are in the top 2% of videos on you tube. Your lighting, sound, editing and camera work is exceptional. I like the way you keep your hand out of the view so people can see what in going on. Not enough others take the time or effort to do this. I see others use handheld cameras moving around everywhere it not visually appealing. You use it just enough to see what is going on, then back to the tripod. Excellent video, Don't change a thing regarding production.
Thanks. Have heard the same from a few others involved in TV, film and theater. It has been a challenge to get to this level. If you watch my earlier videos you will see. No tripod, no lighting, bad sound and bad editing. Had to take things more seriously when people started watching. Never expected that.
Yes, they are very well done. You're a natural.@@jcondon1
Also, James doesn't 'hog' the camera with face-time or cover up his narrative with useless music. I am a sub and a huge fan of James. He has showed me over the last 2 years how to start my own generator repair business.
Amazing video work 😊
@@dadskrej5226 ONly Youuber that I have never seen his face!
One of many great things about your videos is that you not only explain WHAT you are doing but, more importantly, WHY you are doing it. While long time viewers would know why, new comers get to learn more.
Always interesting and entertaining.
Glad to see the engine is savable with just a few internals.
Clean carb and good test shows another successful restoration.
Thanks for sharing.
And James does one Storm Responder after another. Even a chimp would know what's coming next, oil check, carb clean, compression, spark.
But every video is exciting new and slightly different, so well shot and lit, explained and edited. No 'look at me' rararara.
Great channel, thank you so much.
That Briggs engine will run better than new. You basically hand built it with loving care and precision. Excellent work!
Yes!
That's the way it goes with mass-produced products. You get a bunch of mostly-finished parts mostly-correctly assembled.
Very interesting, do you complain or inform someone about the old ring u received?
But the new owner could run it out of oil all over again love and care down the drain 😢
I am not a mechanic. The TH-cam algorithm brought this gentleman to.my attention. I must say I am impressed. He is very thorough in his presentation, showing you each step in the rebuild. There are many people who do what he is doing, but I have never come across anyone who explains it as well.😂
I love the rope technique to polish the crankshaft. I will forever use that to polish a crank. I used to take hours to polish journals your method was fantastic.
Thorough, thoughtful, meticulous, patient, kind, articulate, professional........and "smushed"😊. What a guy. Always inspirational to watch your work. Thanks for what you do.
This reminded me of a cub cadet mower that I bought several years ago. It was a high end 21 inch cut with swiveling front wheels multiple speeds and blade engagement. Back then over $500. I had cut down a 2 inch black locust that was in my way and the grass grew up and hid the stump. Of course I hit the stump and immediately broke the crankshaft where the blade adapter fit the end of the crank. After cursing myself I went and got a new crank. It was a 6 hp Kawasaki engine and as I took it apart I was very impressed with its design. I got it all reassembled and it would not start. First thing I thought was I didnt get the timing set correctly. Before thinking I tore it down again and found the timing to be set properly. I walked away and came back a few days later. I pulled the valve cover and found that a push rod had not set in the rocker. This was the first machine I had owned with overhead valves. I shared this story with friends because I felt that other people might also not be familiar with overhead valves on small engines.
Man you are definitely a master technician,mechanic,
As a machinist I was impressed
I have always thought about when I get something thats broken and I find the problem and get it fixed that feeling inside us is satisfaction and I enjoy teaching others how to fix things and get same feeling when they do it. This is a good video to teach others by, great job buddy. I know you have that feeling of satisfaction each time you get another one going again. Two thumbs up.
So many people get satisfaction from wrecking things and it's because they don't know how to fix them, a big fail in our education system.
Glad that I am able to watch this video. We had a storm roll through here in Ohio. My power went out at 6:30 in the morning. They don’t expect to have it on till 1:30 this afternoon. So I’m watching this video on generator power 🎉
Absolute perfection. I love these extended videos. I know a lot of work goes into the editing also. Great work. I never get tired watching the Professor at work. 🙂
The editing for these long videos must take FOREVER. It is done so well. This is by far my favorite TH-cam channel because there are no ads and because the quality of the content and editing is so perfectly done. Thank you very much James...your hard work, attention to detail and quality is very much appreciated.
You inspired me to go fully rebuild my old Hyundai 3500 watt generator. Thanks. It’s running perfectly now,
What an amazing video! I know a lot about law and a lot about teaching college and I know how a two stroke engine works in theory. But I don't know anything about repairing an engine much less rebuilding one. I watched fascinated as you explained what was needed and then literally rebuilt an engine, showing step along the way. By the time you were done, I felt like I could rebuild a two stroke engine. You are a natural teacher and your gift of being able to teach (rather than lecture) is the ultimate. Thank you for a great video.
Who knew wrenching could be so fun! You are so knowledgable and intuitive. It's great watching someone who knows what they're doing...and cares about doing it right. Thank you Sir for your talent and effort.
Always good to see a machine given a second life. A lot of work but worthwhile. Very good that the connecting rod did not break, unlike what we expect to see on the other unit.
Well done as usual.
Watching you pull down and rebuild an engine and generator never gets old. Nicely explained. Thanks
A couple of tips for you, If you do use that type of hone - Use engine oil and a fraction of the drill speed you had as you need to be going in and out nearly as fast as it's rotating for the correct "cross hatch" finish.
Use the smallest smear of assembly lube where necessary first then oil for pre lubricating.
Put the faintest smear of anti-sieze under bolt heads and lightly oiled threads for things like those Alloy Rods to reduce any gauling when torqing the cap bolts - + any incremental tightning should be at least needing 90deg.
I realise it's not a Race engine but you strike me as a Guy that likes to do things as best as possible ;)
Very few people on youtube actually knows how to hone a cylinder for the right cross hatch. I see people that is professionals messing this up. Its kinda wierd actually haha
@simenk.r.8237 Yes, how very "wierd" - you misspelled that, by the way.
It's a mystery how everybody can screw up their honing when they could easily look up the correct technique on the million subscriber honing channel of world-class craftsman simenk.r.8237 who generously shares his infinite wisdom in hundreds of his painstakingly edited videos.
The world is lucky to have heroes like you, simenk.r.8237!
@@Lokomowal Between him and all the heroes like you correcting spelling and message content, we will soon be living in utopia!😒
All good advice, especially about the cross hatch. A drill with a two speed gearbox can help there.
The Engine Dr. wins once again. I am amazed at the number of FUBAR generators in your area and even more astounded at the lack of attention to oil level by their owners. I can only assume the owners are very affluent and treat their equipment as consumables.
I think it's likely a matter of ignorance of small engines. Many people do not know that you should be doing your first oil change at the ten hour mark.
I think people believe that they only take their car in for oil changes once or twice a year and the generator gets way less use than the car so why would you need to check it!
Ask me how I know 😂😂
Thanks for the video James. The one thing about your videos is that you talk people through them when you are working which I think is brilliant. Cause not a lot TH-camrs do that. Thanks again George in England, UK 🇬🇧 😂👍
James, you can buy feeler gauges with a .002" step for a "go-no-go" effect. Also a couple of old school references on small engine rebuilds: To be perfectly accurate there is a measurement of "pull" on the feeler gauge. Depending upon the actual part being measured 1-3 ounces is a good "thumb" however, there is also supposed to be oil present. We used Ring end gaps of .0025"- .0035" for every 1 inch of cylinder diameter. An old example used to be "A 4 inch cylinder can use from .010" - .014" Ring end gap. Larger if it is a very hot applications like Turbo or Supercharged. We rebuilt a lot of engines with those specs and never had a piston stick or use excessive oil. Good video, thanks for offering it. ben/ michigan
❤
That's a brand new generator again, great repair, thanks for sharing.
You and Mustie have taught me so many things about all engines and generators the past year it would have taken me years to learn at a trade school. Thank you.
James, I am a 72 year old retired computer engineer and I am amazed at your knowledge on small engines. I am trying to get my Campbell Hausfeld 4800 watt generator that's VERY old. I've learned a lot from watching your youtube page! Especially this "Two Catastrophic Engine Failures presentation.Great Job!
A tip: I had a rotor that would not come off and would mushroom the pusher rod. Did two things: i used a small slug of brass between the rod and the pusher bolt. The main help was sneaking about 4 turns of #16 wire around the front of the rotor shaft and positioned them near the fan. brought the two leads out to a "Hot Rod" handheld induction heater. Fifteen seconds of the heater and the pusher bolt had the rotor off. It is fairly easy to thread four turns around the shaft. I had considered using a small torch but fire hazard negated that idea. I had fought this for hours trying everything hydraulic, and slide hammer... nothing worked. It was so easy with the induction heater it surprised me!
I'm damn near 64 years old and you are my new hero.I'd give almost anything to be as neat and well organized and especially as knowledgeable as you are. Three thumbs up bro.
Love your channel. First time i used plastigage was 1962. I
was 15 years old and rebuilding the flat head 6 in my 1953 studebaker.
I would be pretty pissed to find a used ring in a supposedly new ring set, especially at that sort of price. Most ring sets are under £10 in UK but some B&S sets are around the price you suggested.
My guess is that someone bought that set, swapped the top ring then sent it back saying that they bought the wrong set, and the vendor didn't check closely enough (or was the one who did it depending where you got them).
When you find that sort of disappointment it's always difficult to know whether you send it back on a matter of principle, and mess up your schedule in the process, or just find a way round it. Very annoying when you open the package and it's not got the correct contents.
That’s exactly what happened someone said F this I’m not paying $50 for rings and swapped one out. I just hope he doesn’t let them slide and gets his damn money back!
Yes it's a long video but with great information. Showing specs and exactly what goes into repair and rebuild is worth it's weight in gold. Great job 👍🏼
James, your videography and audio has really become top notch !
Bravo....
Very complete and professional job! Better than new! Excellent Work!
I really appreciate your videos. You are very detailed which is appreciated very much. I will say that at the 1:22:20 time in the video, you mention adding oil so you don't forget because you are getting excited at nearly being done. I can certainly appreciate your thought process here. I'm not a small engine mechanic. I do have a lawn care business, so in order to save money, I do all of my own maintenance and so far, all of the repairs on my equipment I have done myself. Prior to going into the lawn care business (which is a retirement job for me just to stay active) I had a 54" John Deere Z425 zero turn mower that I had been using on my own yard and on my neighbors yard. I continued using that mower on my yard and my neighbors yard even after starting my lawn care business rather than using one of my other zero turn mowers on these yards. I developed a slow oil leak either on the sump gasket or PTO shaft, but I always checked the oil level prior to using it and would simply top it off once every couple of months as it needed oil. One day I did my yard and almost all of my neighbors yard when I started smelling burned oil. I only had a couple more passes to make on my neighbors yard, so I finished it and went back to my shed and started checking on the oil smell. I had no oil left that was visible on the dip stick. The mower was still running fine at that point when I parked it. I added oil up to the full line and there was a slow but steady dripping leak while sitting and it got worse when the engine was running. Either the gasket or the seal had seriously failed. I pulled the engine on it and pulled off the sump and replaced the oil pan (sump) gasket and the PTO seal. I reassembled the engine and put it back on the mower. Installed the PTO pulley and reattached the deck. I was so excited to have completed the job. I fired it up and it ran like a champ even under a load from the deck for about 1 minute and then I heard a "clink" sound and it wasn't running correctly. I turned it off and soon realized I hadn't added oil to the engine. I had failed to fill it up in my excitement over "completing" the job. I of course added oil, but that did nothing to help. It will run on one cylinder now, but that is all it will do. That was two years ago and it will still run on one cylinder, but it won't power the deck. I appreciate you saying what you did at the 1:22:20 mark. I've been there and failed to remember to do a very simple and basic task and I assume as a result I ruined a good engine. At some point I keep thinking I will pull that engine again and figure out what the damage actually is, but I just haven't gotten to that point yet. I have two good 52" Scag Tiger Cat II mowers that I can get the job done with and have no pressing reason to tear into the other mower. I'm sure that at some point I will get there, but I'm just not there yet. It was a bit defeating to have that happen. I have rebuilt a few smaller engines on walk behind mowers since then and they have all worked fine, but that taught me a lesson I will not forget. Keep up the great work!!!
That kind of knowledge doesn’t happen overnight my friend it’s a pleasure watching you
Well done, James! Looking forward to #2.
The long detailed videos with serious problems are the best
Keep them coming
James, this has to be one of the most detailed videos on a small engine rebuild that I have ever watched!!
Once again, your knowledge, skill and a few parts have managed to bring this back to full working order. Excellent job, James. Thanks for sharing.
Really impressive, James. I realize that I need at least four new tools in order to do this sort of stuff justice but at least you walked us through the process in a straight-forward way. I can't thank you enough.
Thanks
I've never done Small Engine tinkering, so your videos are chock full of learning experiences. However, finding that out of spec #1 ring was amazing. I confess I would have made the mistake of just throwing a "brand new" part in without checking. Thank you for that valuable lesson.
Easy listening engine overhauls with James...It's just like a broken drum....you can't beat it.
Thanks for all your step by step tear down and rebuild..
I normally use an ad blocker browser to watch TH-cam, so I never see ads. But I happened to load up this video in the actual TH-cam app and was pleasantly surprised to see that your videos aren't monetized!? This is some great info and entertainment you're giving away for free! I do appreciate it, great job as always.
If he doesn't monitize his videos Google might still put ads on it and not share the revenue.
Another Storm Responder saved from junk yard.Great video James,always look forward to Thursdays
Jim, as ever, you're "the man" when it comes to fixing generators. It was lucky that Jason's generator was repairable. I hope the other one is just as repairable. I'm looking forward to seeing the video for that one.
You are still amazing. Even after watching you for ages. Well done Sarah. !!!
Thank you for the video. Always nice to see / hear your thought process on repairing these.
Excellent job as always, I'm thinking those rings were sold and returned with the top ring switched with what they were intended to replace, accidentally or on purpose who knows, either way this engine runs great
I agree
Very nice to see you working on something older.
Your expertise as always shows that something that is older can be useful when cleaned up and maintained.
Have an old 1850 powermate and your posts on upkeep and maintenance really makes a difference.
Keep posting as it really helps us DYRers.
Textbook presentation. Having worked in a machine shop for several years, I can appreciate the attention to every detail of reassembly.Thanks for the video.
I really enjoyed this teardown. I like seeing things analyzed and then repaired.
Great video James, your details are first class.
Your videos are always so amazing, I learn so much from these. The knowledge I've gotten from your videos has made me more comfortable with the idea of working on small engines with this level of depth.
I learn something every time I watch your videos ❤thank you again
Thanks!
You are impressive, as usual Jim. This was totally worth 2 hours of my time. Thank you for explaining your decision tree and including your thought process.
Unequivocally the best teaching small engines & generator repairs & exceptional productions on TH-cam! Such a perfectionist at Both! Excellent, James.
I almost think I could work on an engine. Not quite...but almost. I enjoy trying to think ahead about your next step. Sometimes I guess correctly. 😊
Excellent as usual James, I also received parts that were supposed to be new and turned up slightly used. Thanks for the video.
Hi James. Just want too say your videos are part of my up in the morning having coffee and see what your fixing today. I have learned quite a bit from watching your channel. Thanks for explaining and showing how you do it. Thanks again and keep up the good work.
@jcondon1 one point I'd make the bolts likely didn't stretch, the aluminum rod cap squished out from under the bolt. Aluminum expands 4 times more than steel, so it will flow outwards and mushroom. This is the same failure mode that makes aluminum wiring dangerous too.
Found this recommendation from Winco.
REMOVING AN ARMATURE OR ROTOR FROM THE ENGINE CRANK SHAFT
The armature/rotor is just taper mounted to the engine crank shaft and held
in place the bolt running down the middle of it. Remove the bolt or nut and
washer before continuing.
You will need a flat metal bar and good steel hammer. Insert the flat metal
bar between the end of the armature/rotor and the engine, so that is rests
on the engine crank shaft. Strike the metal bar crisply with a steel hammer.
This will set up a vibration in the hardened crank shaft, the vibration should
break the seat between the armature/rotor taper and the engine crank shaft
taper.
Great video of course. Admirable how you quickly shifted gears from swap to total rebuild. Thanks for working on exactly the same mower that my son in law has so that the carb cleaning went smooth as silk
Thank you for the extended video. Excellent job
Fantastic job, thanks again for sharing. Since I have been watching your channel I have completely rebuilt three generators. Thanks for all the info.
Nice
You were very lucky with that Engine, great video well done james keep up the great work you do fixing stuff once again well done can't wait for part two.
An absolute pleasure to watch your videos James. Such an informative and honest channel
Great rebuild and great to watch. The time flew by at my end, but I bet it was a long slog at yours! The sound that made as it unlocked was worrying for a moment, and made it seem as though something had just flown apart inside, but I guess it's the feel of the tool as that happens that gives you encouragement, and that can't be conveyed in a video. We just hear "clonk" and think, "uh oh ...".
It's awesome how much patience you have! I can't believe how much of a pain in the bum those generators are to work on!! These videos taught me to run from repairing them
Jim, not criticism , but my dad used to photocopy pages from various manuals (Chilton's, Haynes, etc), for what he was working on, and he put sheet protectors on them, and in that manner, he kept them nice. Just an idea for you.
Good idea. I have a few critical information sheets that could use that.
@@jcondon1 or just laminate your sheets will last for ever then :)
Or scan and save what you need and print the pages as often as necessary. You'll always have a fresh copy so you can make notes and get them greasy.
@@hugh007and you can write measurements on them, very handy if you're checking specs, you can write out what yours was right next to it.
I usually print out sheets for a particular job, doesn't matter if they get ruined.
Excellent. It is a pleasure to watch you work. Thank you for putting in the extra effort so that we can watch over your shoulder!
"While we have it apart, let's fix it right." Wow. If there were a Nobel Prize for integrity, this guy would be in a tux on his way to Stockholm. And how about that out-of-spec top ring right out of the box from Briggs? James, it was handy the existing top ring was in spec, but I think B&S owes you one! I've been working on small engines longer than you've been alive and I still learn something new every time I watch one of your videos. If there were more people like you in this world, the generators you work on wouldn't be such crucial necessities in what we (western industrial civilization) are facing this year (2024). Keep up the great work and thanks for sharing it with all of us!
Great Teardown James! Front Row seat to see the repair!
I never noticed while lapping the valves the change of sound as the compound disperses, now I do. I really appreciate the help.
Really liking the recent long formats, James! Keep 'em coming!!
Excellant restore. Gives me ideas what to check for if my generator goes. Right now is an after market carb on it and it hunts while running which leads me to believe it might be a carb issue. It's a UST GS-5500.
It never ceases to amaze me that with a couple of mods like larger better bearing, oil pump, replaceable cylinders, oil low and over temp alert and stop that these engines would last almost forever!
This was supposed to be a quick engine swap video, but I knew your curiosity would get the better of you even when you freed the engine off and the diagnosis of big end failure was obvious . As soon as you said "we've come this far so let's go a little further" I knew the engine swap out video was almost certainly turning into an engine rebuild video ! 😅 . I'm the same. I wouldn't have been able to resist opening up the crankcase ! 😂
However, compared to a car engine it's not that much work to strip a small single pot ohv engine so it's not gonna be a potential waste of half a day's work and the shop floor covered in parts and oil.
Another great video.
John, Nottingham, UK
Excellent video. Very detailed. I love your work ethics. One thing surprised me that you didn't change valve seals. Engine has heated up at some point which changes rubber characteristics. If I had opened up engine I would definitely change them. Just my thoughts. Great video again.
Great job done mate.
I've been watching your channel for many months now and surprised I not seen a diesel generator there yet.
It was fun seeing the rebuild.. we do not do that any more.. Good one 👍👍
I love your vlogs Jim as always very interesting and informative and you are very mathodical and careful in your prep. Probably yours are the best videos I watch on TH-cam. Stay safe and well
You are building a legacy that will serve others for years to come. One day, I hope to make as big a contribution to the world as you a making with this content. It is not only about the equipment, but the technique, the patience, the dedication, the critical thinking, and much more you are teaching here. Bless You!
Always enjoy your vids! I like your process and methodical approach to solving the problem. I learn a great deal from your work Thanks so much!
Iam over here in Northern Indiana by the looks of the radar they was pretty strong storms over your way did it cool you off any it's miserable here
Hey man, thanks for the concern, we are all good... @@coltsjason
This video depicts the best simple "head" job I have seen on TH-cam.
Hi James - great video again - you need to connect the earth strap from the power head to the frame.
... I do not know about others, but, there is ALWAYS something new to learn... I'm only 73, so thanks a bunch ...
Maybe this is just my OCD, but I noticed that (if you are looking at the power head) the right Stabilizer for the Power Head is Squashed compared the the one on the left (@7:05). This is confirmed when the Stabilizers are removed. The Power head is at least 1/4"- 1/2" lower on the right side. Something is misaligned. Which will lead to unnecessary wear and tear on it, since that Stabilizer is taking the bulk of the weight of the motor and Power Head.
My uneducated guess is that the Frame for the motor is bent by 1/16"-1/8".
I am just an "Arm Chair" viewer, but something doesn't look right with this generator within this time frame
The Engine rebuild was Great! Very precise and almost Surgical!
Thank You very much for this upload. I always look forward to your videos.
Fargo ND loves your videos. I’m addicted to watching them. Thank you!
Great video. Very good narration on the step by step teardown. And I learned a clever way to polish a crankshaft with a rope. I would have used sodium hydroxide to remove the aluminum from the crankshaft rather than acid, however. NaOH would readily dissolve the transferred aluminum but would not be corrosive to the carbon steel crankshaft at the low temperatures and short time duration involved. Caution: NaOH also dissolves skin as fast as aluminum. Neutralize with vinegar.
That number 2 piston ring being out of spec was either a manufacture problem or it has been used before. Something I would never have though of. Even checking it would have passed me by. A lot of work went into that lovely sounding engine. Well done and thanks. Cracking to watch :)
just found you, excellent vlog, thank you, not a dull moment anywhere. looking forward to the next one. kind regards Dave UK
Always enjoy watching your videos. You explain everything in detail. Thank you.
I think this video is a message to 99% of the other videos where people are doing this without a torque chart and measuring tools. I have rebuilt two car engines using this kind of care and proper tools with torque charts and degree wheels. Toyota was straight up torque to point but BMW in some parts required degreeing after reaching the desired torque called bolt stretching. You also have to remember to not miss any bolts or they will fall out later and cause serious engine problems.
Hi James. As normal a great video. As a race engines builder, I’d like to suggest your next video like this, use your dial bore gauge and micrometer to calculate the rod to pin clearance. It’s not hard and more reliable
Your instruction is so good that all a person needs to start a small engine repair is to watch all your videos, buy a few tools, learn to read manuals and blowup drawings, and your about ready to go!
I have been trying to explain that to a bunch of whiners who say they can't get a job with no experience and can't get experience with no job.
TH-cam has a wealth of step by step to learn a career!!! Buy some used tools and get hustlin'!!!! They obviously have money to buy iphones, beats by dre and weed.
Thank you all the way to 1978 in high school memories. Rebuilt one.
Learned what other kids do fill cylender with oil. I could not figure out what I did ?
Instructor said I been at this a long time try draining oil from cylinder. Quick fix lol
I love your patience in your narration. I’ve learned a lot watching your videos.
I really enjoy these videos because anytime I see someone using good mechanical practices I am typically amazed. Most videos I see are done by people thinking that they are doing things properly or at least in a workman like manner. I have been a professional mechanic all of my life from early childhood to my seventies.
The little things that many miss such as ring end gap, ring type like a dykes ring or taper ring. Small but really important things that are unfortunately not noted by some.
The method of polishing the crank journal was refreshing. I have done it many times using my lathe and very fine Japanese water stones. They both do a good job.
Enough blathering on from me. All I can say is Bravo! Good job through and through.
Best Regards Al in Virginia
Nice.
Always looking forward to Thursday morning’s video.
Very good video.Really informative. Thanks a lot.
That is exactly the same kind of generator I used to backup my 8ft mobilehome and works great. Great video