Almost new dual fuel Champion generator locked up after one year. I probably overpaid for it. With any luck it can be repaired. Otherwise I might be able to take advantage of the 3 year warranty that Champion offers on their generators. Either way, this generator will run and make power again.
Champion Rebuild Video Series:
Champion Generator Engine Locked Up After 1 Year - Fixed (part 1): (this video)
Like New 80s Powermate Found in Garage (part 2):
https://youtu.be/YdeczolUUCU
Champion Duel Fuel Generator Engine Rebuild (part 3):
https://youtu.be/JWbiL0fEKpc
Generator Engine Bogs Under Load - Excessive Governor Droop (part 4):
https://youtu.be/DhiaBPIYxts
Generator Model: 201035
Engine (458cc): R460N-VP
Additional short video on the cause of the failure. It was not the keepers fault:
https://youtu.be/ghdvJN2tQ5A
Exhaust Spacer: https://www.ebay.com/itm/263039623380
Air Box: https://www.ebay.com/itm/334043875743
Parts needed to rebuild engine:
13010-Z6B0210-00A0 Connecting Rod Assembly
13121-Z100110-00A0 Pin, Piston
13122-Z100110-0000 Circlip Ø21 × Ø1
13111-Z6B0210-00A0 Piston
13200-Z0J0110-00A0 Rings
12140-Z6B0210-0BA0 Head
12121-Z6B0110-0000 Exhaust Valve
12111-Z0D0210-0000 Intake Valve
12131-Z6B0110-00A0 Head Gasket
12109-Z0D0110-00A0 Keepers (Valve Lock Clamp)
Trashed NAC NGK Generator Series: https://www.youtube.com/playlist?list=PLoj6DvbhMTzteT1KT4km_vsaJDke96-jR
Will it Work? Making a Honda GX390 / Clone Compatible:
https://youtu.be/Ykbj-CLimig
I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors. Recently I have been using Simple Green PRO HD with good results.
Visit My Amazon Store:
https://www.amazon.com/shop/jamescondon
3 Jaw Puller: https://amzn.to/4aY2TJu
3-Pound Hammer (ESTWING MRF3LB): https://amzn.to/3vWQFSB
3/8" Flare to NPT: https://amzn.to/3Achkga
Amprobe ACDC-52NAV: https://amzn.to/3vRgRy7
Borescope (DEPSTECH DS520): https://amzn.to/3VJMEd0
Drill Step Bit (Irwin 10234): https://amzn.to/3LVie31
Kill A Watt: https://amzn.to/3Ui8WTU
Micro Drill Bits (Gyros): https://amzn.to/3yGlyfn
Oscilloscope: https://amzn.to/3UkttqL
Propane Quick Connect: https://amzn.to/3YveUmS
Squeeze Bottle: https://amzn.to/4cW0GjF
Test Tank: https://amzn.to/3wi6DXG
If you want to donate to the channel, you can use the YouTube "Super Thanks" feature or via PayPal: https://www.paypal.com/paypalme/jamescondonYT
#GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
201035, 358cc, Alternator, Auto Choke, Champion, Cracked Piston, Dropped Valve, Dual Fuel, Engine Replacement, Fixed, GX390, Generator, Hertz, Hole in Piston, Honda Clone, How To, How-To, Keeper Failure, Load Test, Locked Up, New Engine, Power Quality, Quality Control, R460N-VP, Repair, Repower, Seized, Small Engine, Solenoid, Stuck, THD, Valve Spring, Valve Spring Retainer, Troubleshooting, Wiring
00:00 Intro
01:59 Triage Stuck Engine
11:34 Tear Down
36:38 The Carnage
51:15 The Plan
53:53 Build
1:30:03 First Test
1:40:29 Propane Test
1:46:08 Finishing It Up
1:46:51 Gasoline Load Test
1:55:46 Propane Load Test
1:58:54 Adjust Carburetor Jetting
2:03:51 Gasoline Load Test #2
2:05:38 Outro