Engine Rebuild - Seized LiFan Generator (Part 2)

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In part 1, I tore down this 420cc LiFan Chinese Honda clone engine and determined the connecting rod was binding on the crankshaft. A new connecting rod has been ordered. Lets rebuild the clone engine. While rebuilding, I discovered the connecting rod is not the only issue. If you missed part 1 see the link below in the description.
Part 1: • Seized LiFan Generator...
part 2: • Engine Rebuild - Seize...
Part 3: • Generator Build - Seiz...
Rato Engine Service Manual: drive.google.com/file/d/1Hq2B...
Generator Model: LF8500iE
Engine Model: LF190FD-13111
Rotator Cap and Stem Seal: amzn.to/33nmVjL
Connecting Rod: www.ebay.com/itm/164094457155
Push Rod Guide: amzn.to/3nD74nU
Ignition Coil: amzn.to/3Kp7R5y
Oscilloscope Multimeter: amzn.to/3FEMUA8
Lapping Tool: amzn.to/3AaXZI0
Lapping Compound: amzn.to/3tBdhof
Roloc Bristle Disc: amzn.to/3tATdlJ
Nyalox Brush: amzn.to/3qD2Uy5
Feeler Gauge: amzn.to/3A96fYU
Micrometer: amzn.to/3A93CX8
Torque Wrench: amzn.to/3FDme2D
Plastiguage: amzn.to/3tCAari
Ring Compressor: amzn.to/3fyStFN
Assembly Lube: amzn.to/3A9q02y
Compression Tester: amzn.to/33Mg2Im
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner www.harborfreight.com/1-gallo...
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
15HP, 190F, 420cc, 8500iE, Backfiring, Bad Connecting Rod, Compression Release, Connecting Rod, Generator, High Compression, Honda Clone Rebuild, Honda Clone, Honda Rebuild, Ignition Coil, LF190FD, Lapping Valves, Lifan, Locked Up, Micrometer, Muriatic Acid, Nyalox,Plastigauge, Popping, Pushrod Guide, Ring Compressor, Rotator Cap, Seized, Small Engine, Timing, Torch Spark Plug, Troubleshooting, Valve Clearance, Valve Lash, Weak Spark,

Опубликовано:

19 янв 2022

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Комментарии : 415

@TheDamowalshe 2 года назад

I'm sure I've seen a Mustie 1 video going back a few years, that had a missing rotator cap, he was stumped, but was able to ascertain by finding a diagram, that showed it was correct and manufactured that way. Thanks.

@justonnie 2 года назад

I do appreciate how the box of the cloned connecting rod states beware of imitation.

@jcondon1 2 года назад

Also interesting that this connecting rod was sold as a direct replacement for this generator/engine, yet it did not fit.

@objection_your_honor 2 года назад

I can watch your videos all day long. The hour went by too quickly. Can't wait to see part 3.

@jaystradinger4352 2 года назад

Just a couple of engine build practice comments: install grudgeon pin circlips with the gap in line with the rod, that is, either up or down. These engines don’t spin very fast but it’s still good practice. Second, a convenient valve lap technique is using tubing/fuel line on the valve stem from the back side of the head results in better control and feel in the lapping process.

@jcondon1 2 года назад

Thanks for the tips.

@THEFALCON58 2 года назад

and a cornless drill clear tube and stick on the stem side.?

@billclinton6040 2 года назад

This is great content, and I loved every minute of it. I watched Part 1 and didn't think you'd be willing to rebuild this engine. So great job and kudos! We live in a throwaway society, and nobody realizes that THIS more than anything else is what is destroying our planet. Perhaps in the future carbon credits will trickle down to the consumer, and things like this will earn months of carbon credits because right now nearly everyone would just toss that engine in the trash convinced that the time and money required to rebuild it simply isn't worth it. We need more guys like you willing to breathe new life into old things. No doubt that generator was rode hard and put up wet, and the skills you demonstrated aren't just for generators or even small engine repair. They translate into just about every mechanical setting. And your stubbornness to not let missing service data or unavailable parts deter you is beyond laudable. I wish I lived in your area because I would buy one of your rebuilt generators in a heartbeat. I can't wait for Part 3 to hear this generator roar to life!

@jcondon1 2 года назад

Thanks. I agree completely. Too much waste in this world. Wish manufacturers were required to supply parts and make quality equipment.

@scottfirman 2 года назад

Most people are not willing to pay for that type of repair any more. I have a hard time justifying a repair like that myself any more. Not that I don't because I purchased a non running generator last summer and found the timing was off. I had to totally disassemble everything to fix it. A paying customer would simply go buy a new one. Even repairing a carburetor is not worth the time and effort over a replacement now days. If it has any corrosion at all any more, I just replace it. 99% of the time, they never run right again anyways. Yes, we live in a disposable society, but you have to look at how we got there in the first place.

@garrydonnelly6433 2 года назад

Your comment Bill is just so accurate. Well said.l

@lordjaashin 2 года назад

that is why right to repair movement is very important

@YukonHawk1 2 года назад

Well said.

@jeremydewolfe8026 2 года назад

Well James, this is exactly the content I was looking for! I had to be patient because I really wanted you to dig into that crankshaft issue at the end of the last episode but you went above and beyond on this episode even so far as to thinking ahead and realizing that we all wanted to see it at least fire so I appreciate the scramble effort at the end to get it to run for a second. I was enthralled for one hour and two minutes. You should get a RU-vid raise :)

@lv_woodturner3899 2 года назад

Wow, a lot of things needed to be fixed. A lot to learn from this video. I can imagine the frustration of having to wait for the parts delivery. Glad that the engine finally runs. Dave.

@vettepicking 2 года назад

Couple things to look at. First was maybe lapp the head on some 320grit paper on a flat surface to rid the chance of a warp. Next dont use a abrasive brush or pad after the piston is installed your making a lapping oil that runs into and coats the cylinder and rings before start up. Great vid

@petertothpete6518 2 года назад

Kinda stunned on that one myself. Always do all de-carboning/cleaning before final assembly.

@gremlin1396 2 года назад

I totally agree I would have cleaned the piston before installing it into the cylinder that way there's nothing on the rings.

@markyoung7470 2 года назад

James You are not crazy to try and start an engine with a defective compression release believe me it hurts like all get out when it pulls the pull grip out of your hand and if you not wearing gloves it will remove skin from your hand which really burns and takes forever to heal up. I look forward to all of your video's VERY informative and well done we need more people in this world teaching like yourself well done!

@francisbailey3831 2 года назад

Good morning, James. A very enjoyable and interesting video. As usual you are the master in small engine repair. I see that you love a challenge to solve and bring an engine back to life. 👍👍👍👍. I have watched part 1 & 2. Very much looking forward to Part 3. To watch the generator come roaring back to life, and to be able to put back into service.

@brewster3987 2 года назад

Am loving this series, sir... great tenacity! Not many channels that I will even start watching a 1-hour video, but yours never disappoint! One comment for consideration... torquing the crankshaft nut against a variable resistance (rope in the piston - slightly compressible) may give you some error in the actual applied torque. In this application it probably doesn't make a difference worth worrying over. If you want an absolute rotation lock on the crank, you might consider a piston stop installed in the spark plug hole. Love the channel and I'm always happy when I see a new video come out!

@jcondon1 2 года назад

Thanks. I agree, its not exact and neither is my torque wrench. Have considered using a piston stop, but the idea of putting that force on the spark plugs threads doesn't sound great, although I know a lot of people do it without issue.

@jamesws3 2 года назад

@@jcondon1 Agree. Always thought a rope not gives some cushion, but spreads the load over greater surface area.

@joesinakandid528 2 года назад

Lets be clear here, James, I would happily watch a 3 hour video of yours - back-to-back with a 4 hour one! Your videos are the equivalent to many, many trips to the knowledge bar - and that is a seriously good thing. OH - I usually, for myself, use ATF instead of WD-40 - better lubrication in my way of seeing it. Then again, that's just me. Patiently waiting for Part 3! - Joe -

@robertpeters9438 2 года назад

Try Lucas oil extender!

@phillipmckinney7906 2 года назад

Love the old school Rope trick as it always works with a bit of elbow grease as i saw done back in the day with dad doing fixes on Oil pumping machines in the oil fields

@ghettsumm7949 2 года назад

I like the fact that you rarely show your face in your Vlogs,... It reminds me of the friendly, neighbor " WILSON " next door. 😊

@RickP654 2 года назад

Hey James, I'm not real sure but, I thought you missed getting it in perfect timing on the first set of gears. By it firing back through the intake supports my suspicion even more. I'm not sure how it would effect the engine in the long run. My experiences with the old v8's would prove out a hotter running engine. You do a fine job working on these little engines and other projects as well. I hope you never quit putting these fine videos out for the public to learn from. God bless.

@jcondon1 2 года назад

Thanks. Timing was my initial thought. A bad coil behaves in a similar way. Especially on small engines because the coil sparks a second time on the exhaust stroke igniting the fuel when both valves are open that did not ignite under compression.

@merlepatterson 2 года назад

Never seen the water in the rotor through bolt hole removal trick, but that's pretty slick and good to know.

@deangentles4966 2 года назад

Hi James great sitting in your class today mate nice to see you are sharing all your knowledge with us looking forward to part 3

@jcondon1 2 года назад

Thanks Dean

@Exit26B 11 месяцев назад

I absolutely am fascinated by your videos, Mr. Condon. Your technique, your logic, your methods, your follow through and conclusions and reasonings and the way you tell it to me in your soothing voice convinces me you are more than an expert in what you do. I envy you. Thank you for the many hours I have watched your great camera work and editing! Aloha from Hawai’i.

@stazeII 2 года назад

I might have filed a bit off the crank case just for piece of mind. The thought of that little clearance when something is spinning at 3600rpm makes me think it’s gonna close that gap. But I’m likely just paranoid. :) Great work sir! And awesome luck on that $18 rod. :)

@checkonetwo9155 2 года назад

yep..i would bet if you checked both rod big ends they would be in the ballpark range the same , and the crank is where the problem is as it was slightly oversized incorrectly. If this is the case it will make the new rod do the same thing again when its ran for extending period of time .i would of sanded a half a thou off the crank ....do the chi nese sabotage some of these engines to make ameri cans buy more on assembly line for a reason and make tolerances real tight so when the engine gets hot from running it ,its seized . I say its likely,is it done on purpose to get in our wallet or just chi nese error, and why is there no tolerance specs on anything anywhere on these engines to be found~ so they are just thrown away and a new one purchased same game and plan.?

@stevenlilly 2 года назад

I'm excited to see you troubleshoot the compression release.. You mention it on about all of your repairs but I have no idea how that system works.. Glad you didn't try pull starting.. You would have been in for a wild ride!

@jesterr7133 2 года назад

This engine had a very unusual set of issues. This was very interesting. I learned a new way for an engine to fail, and I definitely would have missed this one. You are very good at what you do.

@kenmitchell3784 2 года назад

Setting here drinking my morning coffee watching James work, almost makes me think about coming out of retirement. Good job can't wait to see part 3

@rayshutsa6690 2 года назад

Thank you for the great video on rebuilding a high compression engine for a genarator. When the engine turned over and jumped I can see why you did not use the pull cord.

@freddyrosenberg9288 2 года назад

Paint stripper works very well at removing carbon build up. I use it on heads and pistons. Apply with a brush, let it sit for 10 minutes and wipe off. Repeat as needed.

@robertpeters9438 2 года назад

What type of paint stripper

@haneyoakie14 2 года назад

I thought I would watch 5 minutes, an hour later I realized an hour went by. Great work. Every detail you showed is important and interesting.

@LostDeadSoul 2 года назад

I was thinking that the connecting rod would never fit. It's a shot in the dark. But damn, that was a well educated guess.

@ScottSellsSoCal 2 месяца назад

Dawn power wash……. Amazing stuff. I’m thinking you need a parts washer to help you out! Loveeee your content and style James! Thank you

@g2theb584 2 года назад

Hey James, I've watched you fix so many gennies and I am 100% confident if I ever had to repair mine, I could do it without any issues. Love the videos.

@HobbyMotorDK 2 года назад

Great video James I enjoyed it very much - your T-shirt should read: Tenacity.

@bobcarry4820 2 года назад

I wish you would mention "added oil". I was concerned watching you try to start it and I have watched so many of your videos that I knew you added oil but you were in a hurry. Waiting patiently for video 3. I have learned a lot from your videos. Thanks.

@jantsbenzproaudio2953 2 года назад

I thought part 2 will took too long to be posted but it's not. Great work!!

@AntonioClaudioMichael 2 года назад

Vicegripgarage would be very proud you did an amazing job on the engine rebuild and the vise grips are a good touch @James Condon

@jcondon1 2 года назад

Thanks

@iantyler4045 2 года назад

I've had small motors kick back so hard that they've broken the pull handle and almost my fingers so I do understand your reluctance to pull start this one.

@Gfthce3426 2 месяца назад

When you use the side of a grind stone like that they can sometimes just up and let go of a chunk of stone fast enough to cause great owie or even sleep . 😮 Really enjoying your videos. Thanks

@jayyoung5423 2 года назад

Nice job James and the shout out to Derek at VGG was priceless.

@RC-fu6hg 2 года назад

Great video! I just enjoy following along as you troubleshoot and bring life to these generators. 👍

@danmackintosh6325 2 года назад

After that nod to Derek with the battery rigging, all it needed when you added fuel was "waaaayyyy too much... Perfect"...

@vmaxride06 2 года назад

Great series here Professor , cant wait for part 3. Best channel hands down

@ernmeister54 2 года назад

Great attention to detail on the rod bolt and push rod guides. I will keep that in mind for my next rebuild. Really good job on troubleshooting that cranky engine!

@timsiefer4387 2 года назад

Great video with perfect detail. I always look forward to your postings.

@bsdiceman 2 года назад

Takes resilience to keep going in the face of obstacles. Thanks for making this video for me.

@guataco 2 года назад

The Lifan adventure, miniserie in three episodes (we hope). I have no generators, nor small engines, but I love to watch your videos. Thank you.

@davidcampbel 2 года назад

Another excellent video, thank you. I learn a great deal from you with every video you offer.

@greghanlon2235 2 года назад

Nice diagnostic work James. Now hopefully people can understand why Chinese clones are always cheaper but cost more in the long run.

@chavescrave 2 года назад

As always James great video - cheers from Melbourne Australia.

@wjodf8067 2 года назад

Oh Lordy each one of the little jobs on that Jonah of a generator has a great big job just waiting for you...

@mjg263 2 года назад

Nicely done, can’t wait for pt 3!

@jaystradinger4352 2 года назад

One last comment on engine build practices, lube all threads as well as under the heads. Motor oil is fine. Results in about 10% greater squeeze with no change in bolt elongation. A good thing.

@gbsbill 2 года назад

James I found this video facinating I just could not stop watching you. The things you did to the connecting rod. But the choice to make sure it runs before reconnecting the generator head was brilliant. Thanks for this I hope I never encounter one in this shape.

@chucktrotter9699 2 года назад

1.20.22 Great video James. Learned alot from this engine. Can't wait for part 3. Thanks

@3jeepsdeep768 2 года назад

Connecting Rod box says "Beware of Imitations" - funniest thing I've seen all day!

@wildefox1478 2 года назад

Nice work James, looking forward to part 3!

@piconano 2 года назад

This channel is like a fun condensed course in small engine repair, for smarter people that don't need everything explained to them. Thanks for the free knowledge my Jedi generator whisperer 😉

@billsuess6243 2 года назад

I just wanted to reach out and say how much I enjoy your Channel. I enjoy the chase down of the problem the best.

@brngrofdeth 2 года назад

Excellent job as always! Love and blessings from Ontario Canada!

@scottjamison1602 2 года назад

I use spray carburetor cleaner and a brush to remove the carbon buildup, it’s amazing how well it removes even heavy buildup.

@Jameson4327 2 года назад

I truly wish you could include a break down of what you spend on the complete build? Once again you have proven that you are one of best! Keep up the great videos!

@jcondon1 2 года назад

Thought I could get away with an $18 connecting rod. Here are the part costs. Connecting Rod $26, Gasket Kit $28, Rotator Cap $10, Push Rod Retainer $8, Ignition Coil $15, Spring Retainer $33, Airbox $19

@Jameson4327 2 года назад

@@jcondon1 Thanks for the reply.

@ItllBurnOff 2 года назад

That was a great video as always I love the detail you go into. As to the last thing you say in your videos.... yes, I'm someone and that help. Thanks again as always.

@Lennyj24 2 года назад

Finally the 2nd part i been waiting for these, love your videos really helps me alot.

@kingwood4357 2 года назад

Excellent video and very interesting, anxious to see it running and hopefully the generator is OK

@RS-yj3gn 2 года назад

I keep watching most your videos with great interest. Thank you for making the effort. The best trick today was the journal clean up, followed by the rope in the chamber. As I said in the comments on one of your other videos, the LIFAN engines are pretty good, performing well and reliably for a knock-off.

@cliffmauck510 2 года назад

Great video, I learned a lot. I do not blame you for avoiding the pull cord with high compression.

@leadpelletinass 2 года назад

Interesting content. Lots of technical stuff to keep me informed on what to look and test for. 😁 Also keeps me entertained while I do laundry and clean up my kitchen at midnight. Thank You for all the effort to post it.

@jcondon1 2 года назад

Thanks

@JohnT248 2 года назад

I look forward to each new video. Though confident in engines, I have now fixed about 6 that I wouldn't have attempted looking at any generator internals w/o these videos. So far it has been obvious issues pointed out in your past show hows. Thank You

@adnacraigo6590 2 года назад

You are an exceptional troubleshooter and mechanic.

@jcondon1 2 года назад

Thanks

@arthurbiringer5676 2 года назад

Okay! You’ve got my attention as usual! Can’t wait to see part 3…..

@YukonHawk1 2 года назад

I can't think of enough accolades to say on part two. This is way above next level.👍👍👍👍👍👍

@jcondon1 2 года назад

Thanks Paul

@wingloading 2 года назад

I doubt I'll ever do teardown work but watch these for a better understanding and your methodical patience.

@andytheflyer 2 года назад

Nicely done. A pleasure to watch.

@kpdvw 2 года назад

I love it when James says "I bought it as a parts machine" and it winds up as a functional rebuild! As for the missing rotator cup; factory has been known to forget to install it....! The flat areas on the valve spring retainer need to point up so that the smallest part of the spring retainer on the valve stem is up and gravity can not drop it !

@kpdvw 2 года назад

Before you "give it a go" did you add oil to the crank case?

@aboveaveragejoe6291 2 года назад

Wow James that is a great idea doing the crankshaft journal with the sandpaper and rope, I actually learned something, Thanks.

@jcondon1 2 года назад

Thanks

@jimmeroniuk8266 2 года назад

Thanks James. Learned alot this time. Appreciate it

@Rev-D1963 2 года назад

Man, that generator is turning into a major project, being a real stinker! BTW, I've had kick-back from high-compression engines before too, so you weren't being a "baby" for using the electric start, you were just keeping from getting hurt. Nothing wrong with that! You'll win on the next one James! Thanks for the great videos as always. God bless. Rev. D.

@michaeloyekan9078 Год назад

Please how do you fix a kick back from a generator due to high compression? Even when the compression release on camshaft is absolutely fine?

@Rev-D1963 Год назад

@@michaeloyekan9078 Check the flywheel key to see if it's broken or sheared off. If so, the motor is out of time and definitely will cause kick-back. Remove the recoil starter and check the flywheel key. If it's loose or missing, it's broken.

@BenMitro 2 года назад

Attention to detail. Careful control of ones urges and thoughtful progression through the process. I hope my mechanic working on my engine takes as much care. Thanks - love your videos.

@jcondon1 2 года назад

Thanks

@docpalazola491 2 года назад

What a great video, James. Can't wait for Episode 3.

@jcondon1 2 года назад

Thanks

@Trump985 2 года назад

“I just finished cleaning the parts in the kitchen sink” boy I hope you aren’t married 🤣🤣🤣

@kd5byb 2 года назад

Around 22:50, as you had finished applying cleaner to the frame, I turned my attention to my other monitor to take care of a window that had popped up. While I was looking away, you started your pressure washer, and for split second I thought you had AN INVISIBLE ENGINE installed in the frame running that was making the noise! :) Another great video. I really appreciate how you take the time to do things right and don't just slap stuff back together.

@KentuckyFriedFixes 2 года назад

Great video! I really enjoy the engine content!

@richardbaker3621 2 года назад

Thanks for another great video. Nice catch on the valve guide problem. Looking forward to see what the issue is with compression release.

@stevenn4393 2 года назад

Yay! Time to get out the popcorn….

@scrapbongo786 2 года назад

Love your detail and attention to the specifics, awesome /cheers ScrapBongo Liked

@neilspringer5530 Год назад

Friend gave me his old gen it would not crank I don't have a lot of mechanic skill but I was mesmerized by you skill I hope I can figure out why the crank is stuck, but it was fun just watching you work.

@kurtyoung6769 2 года назад

Excellent work!

@ShiversRSS 2 года назад

A wealth of information. I'd have been nervous pulling that cord as well

@dalee.mccombs8571 Год назад

James, I just worked on a 420cc Honda clone and there was a notch milled out of that small rib where your rod bolt was striking. So you cound have filed/ground a notch in the rib instead of grinding that rod bolt smaller. Hope this helps in your future rebuilds.

@Tom-In-Ga 2 года назад

Oh boy, part 2! Oh no, have to wait for part 3.

@DeadKoby 2 года назад

I actually discussed your situation with the mower techs locally. It does seem weird that it would be too tight, rather than too loose. The boss discussed how he would fix the existing connecting rod..... and that they have had a few of these shanghai special motors that were too tight from day 1........ they just filed warranty on the machine and let the OEM deal with it. In regards to the high compression, and not wanting to cord-start it....... Anything over 10hp, usually has electric start..... and I've had my fingers bruised by even 3.5-5hp motors.... a 15 could get your elbow or shoulder!

@jfjjjjfj 2 года назад

44:35 It looks like someone grinded the plate, with that grinding mark on top. Great video, I just watched part one and now away to part three 😺 So calm and peaceful video, with interesting tips and tricks! It makes me want to repair the same things 😺💕

@aymannabil9 2 года назад

Omg 😅 it took me 2 days to watch this video due to network connection issue in my place ...anyway I recently had this compression release problem and at last I found out that the spring which is attached to the timing gear was stuck then I had to replace the whole timing gear with new one then the problem was solved but in your case I don't know exactly what's happening and that's attracting me to see part 2 Can't wait to watch it 😅 Thanks a lot for the detailed explanation Mr. James ...👍

@AZVIDS 2 года назад

Great video, editing, detail etc👍👍👍👍

@shawnmrfixitlee6478 2 года назад

Glad that did not kick back and try to rip your hand off , Done that myself to many times ! Good call on the new rod .. Saved some real $ there .. Great work man , ENJOYED !

@jcondon1 2 года назад

Thanks Shawn

@edmnich8255 2 года назад

After all of the cleaning you did i was surprised to see you cleaning the piston in the clean engine.

@TaterPS 2 года назад

Great video as always. I wait in anticipation for the next episode of your videos like I used to wait for episodes of Breaking Bad. LOL!

@Big_Johns 2 года назад

Nice job James, looking forward to Part 3. 👍

@jcondon1 2 года назад

Thanks John

@Big_Johns 2 года назад

Anytime brother

@anthonysimonhough9691 2 года назад

Another great movie thanks a lot.

@AntonioClaudioMichael 2 года назад

I think your right the rotator cap came off and ended up Causing the Issue with the connecting rod good Find @James Condon

@lawnguru2344 2 года назад

Greatly appreciated james.. Tip for cleaning heads..get a brass bush .there's great on Aluminum heads.. and that high compression..Iam with you bother..had one nearly throw me face first to the floor !!! Be safe 🙏❤

@HillbillySailor 2 года назад

That pushrod plate is a definite upgrade. Lifan really cheaped out on that....

@AntonioClaudioMichael 2 года назад

That 110 psi compression makes that engine a Beastly runner @James Condon

@TheOriginalEviltech 2 года назад

Nice! I enjoyed the video alot! Good call not trying to start it by hand, that backfire can be quite painful. You can ask a friend of mine that tried to start my 92' DR650 like a 2 stroke... The kickstart kicked his shoe 15 meters away and he had to wear a cast for a month.