Generac Generator Valve Replacement - Generac 4000XL 

I just fuxed a 10000exl that I got for $150. They said all the oil seals were bad. It was actually the float stuck open from bad gas in the needle valve. It blew lots of smoke and ran terrible. New carb installed last night and it runs perfectly. Thank you James, you helped me get this little gem running!!!

I’m nominating you for the Mustie1 award for your work on engines and the Tesla award for your work on the coils.

Alittle trick when installing those two piece keepers is a dab of grease on the keepers to hold them in place while releasing the spring also give them a tap with soft mallet to insure their locked in place and well seated.

I use an old pressure washing wand I curved the last 5" of to pressure wash the inside of gas tanks with! They do fill up fast , but it cleans the crap out of them.

On tanks that are easy to remove, I toss in a carton of BBs and shake it around. Strain the BBs through an old colander to reuse. Works great.

Nice save on this one too, man! Two not running into two running AND making power is a win for sure. Glad you could get the valve kit to make it happen on this 2nd one. Keep em coming JC!

Never got a reply back from u about a question I had but, i kept at it and figured it out. I didn't want to do all that work so I found a replacement valve spring retainer that works ! I bought a valve kit from a different motor for $13. Or you can buy just the retainers for $10. Now I have a working generator ,without taking off the head .

You got 2 generators intending to use both to make one good one but end up with 2 good generators, awesome work James!

Another excellent example of being a good mechanic. Great job bringing it back

Mr. Condon, thank you for the continued videos. I think every diyer and some professional small engine techs can benefit from your work. Great hard work.

Glad that you could save both generators. You have a great understanding of how they work.

Thank you for another great video. Always enjoy watching you fix the generators and anything you fix. Great work as always. 😀🇨🇦

You really gotta love that rollock soft nylon bristle brush you use.

James rolls the dice with another Chineseum carb - and WINS🎉 I’m glad it worked out for you👍

Love these videos James! I have a myriad of small engines in my care. Thanks to these videos, I'm gaining confidence that I can keep them all running for a very long time. I've replaced many carburetors with success but now I'm itching to do a top end or complete rebuild. Love to build a high performance go-kart engine. Keep 'em coming!!

Great job james , was waiting to see what was repair for this next one

Another great repair James , I sure ENJOYED !! That one was well worth fixing..Thanks

So happy you changed that exhaust, looked like it got dug out of a swamp!

Many thanks for this. Paid a good-used price for a pressure washer using the same engine. Same problem. Looks to me like they used the same (or similar) keeper from the 6.5hp engine on the 7.8hp only to have this trouble all over the place. The upgrade kit uses split cone keepers just like a big kid engine. I will refer to this video when r/r the head on mine. Very clear and complete with torques.

gonna be another great video .I will watch after work!! I needed this model looked at too! Cheers!!!

I have a generator in storage for the last year. From your videos I can refurb the carb and make it run again.

Great learning program, i learn something every time, way to go Doc.

Great job as usual! A new lease on life for another genset!

Hi James well you did it mate You got the second one to run as well nice to see this old model with a oil filter it will last for another 20 years a good class to sit in today James thank you

Nice fix again James👍👍👍

These cylinder head rebuild / cleaning videos are always the most satisfying

Vinegar might be a better solution for removing rust from that plastic tank, Jim. I recently cleaned up a mower wheel with vinegar in a bucket, then soaked it in baking soda and water for a bit to neutralize it. I then dried it and primered it with rust converter just to make sure it will hold up.

Hi James, Generac are great units if taken care of. I have an 7750 EXL, which purchased in July 2004. Still working great, get's a monthly test run with load. Kept in an out door enclosure. I look forward to you weekly video's. The unit has been maintained as per manual. You are the Master at generator repairs.

Another two for one deal👍👍😎😎. That's awesome that you got it up and running just in time for hurricane season. Great deal for sure. I loved how everything cleaned up and that the clone carb worked so well. Great tip on how to test the oil sensor switch.

Finality and completeness are traits found in people with OCD. Great job on fixing them both….I feel your pain lol

As always great job, couldn't help but notice the nut rounder on the drain plug, and that's fine with me, if you turn the wrench around it will load the tool so it's less likely too damage the drive surface of the plug, either way I know it's you doing it and if you did damage it you would likely replace it

desde Cuba saludos, mi generador eléctrico de 4 tiempos estaba trabajando y se me apagó por completo, verifiqué si era pérdida de combustible pero no, aún así le eche más combustible y luego no me encendía, lo dejé reposar y cuando volví a encenderlo hizo un sonido fuerte que venía del carburador, y un pequeño humo blanco por el sistema de respiracion del generador, y cuando me di cuenta habían gotas de aceite en el perno que sujeta la Cuba del carburador, y entonces cuando lo enciendo no genera bien las revoluciones y se apaga, ese generador no tiene sensor de aceite así que puedo descartar esa opción, limpié el carburador, limpié las bujías, abrí el departamento de las válvulas y estaban llenas de aceite, en resumen amigo el generador no me dura encendido ni 10 segundos, y compresión tiene el generador, usted cree que el sobre lleno de aceite haya dañado al motor, o a las válvulas? Cuál es su punto de vista.. mi generador es de 2000watts le agradecería mucho su ayuda.

Nice job as always

Given the track record of clone carbs, I have to say the ones you used on these Generacs work really, really well.

Very nice job once again! That thing under a load is giving you more voltage than we are getting from our power company right now. I noticed everything slowing down so I checked with my Fluke and we’re getting a consistent 100 volts sometimes dipping to 99!

Love the videos! Reminds me oh Bob Ross when I was a kid!

That Fram filter reminded me of a parts house that discontinued a bunch of small filters. I was able to get the bunch dirt cheap. I gave a bunch to a church camp and they were able to use them on a Deere mower they had recently (at the time) bought. Some were for motorcycles, but he said the thing that mattered was the microns and the fit. The filters were a good name brand, too.

Great Job as always...

As a subscriber and a fellow RU-vid mechanic, I would like to recommend that you grab a can of Sea Foam Deep Creep and use it in the place of PB Blaster. It is an amazing and more efficient penetrating lubricant. I found it through watching Project Farm on RU-vid and can attest that it is a truly great product.

The female end of a 3/8 drive extension may fit that square oil drain plug. A hex or rod coupling nut makes an adapter so a socket on the male end of the extension can be turned with a ratchet and another socket. Thanks for your videos, I have learned a lot from them.

Another great video, I really like the tips and tricks you add in... Thx. Could you at some point show how you built your alternative fuel source for testing?

Another thing I have found good for removing film deposits from any container is a fine gravel in soapy water, and shake it up well.

9:00 those suction cups for the lapping, can be fitted to a socket bit on a drill, and can make a quick job of lapping the valves. I've done this a few times on my small engine motorcycles.

This is what I enjoy doing and rebuilding engines I AllWAYS tap valve to make sure keeps are in place

Watching your videos reminds me of when I was a kid and we would go down to the local car garage. The owner would let us go back into the work bays and watch the mechanic work. He would tell us what he was doing and why and also answer all the questions our young minds could think of. Of course, that was over sixty years ago, before all of the liability concerns and OSHA rules and regulations.

👍 Danke fürs Hochladen! 👍 Thanks for uploading! 👍 Very good and beautiful, thank you! 👍 Sehr gut und schön, danke!

Being an Aussie, I've never heard anything bad about Fram until I just searched after you said 'yes I used a Fram'. I only thought they had the one quality (the Fram Filters we get over here are all Orange & ridiculously expensive) I have used them on my Drag & Oval Track cars for over 30 years without incident!

My favourite channel

Keep em coming and now it’s time to start another small motor….(lawnmower).

Informative and interesting. Thanks for the video. I hope I do not need to replace valves on my 7000EXL, but good information if this is needed in the future. The new valve retainer with keepers is a lot better design than the original. The fuel tank had an amazing amount of rust from the small amount of steel in the float. The generator was obviously left out in the rain for extended period of time. The crack in the cap can let in a lot of water over time. Dave.

Great job man...Only bad thing...Fram !!! LOL.

I've started cleaning those up and I paint the exhaust muffler and pipe with a high temperature primer paint seems to stay on keeps them from rusting!

Magnific 😊

James Condon, the Generator Wizzard extraordinaire...!

There is a poetic justice in this video, in that the poor old scruffy dog, after being robbed of essential parts, is rewarded with brand new replacements to bring it back to life again. All it needs now is a new handle and a pair of wheels to make it mobile again. - Turned out well in the end! Now, we need to get our stash opened up and take a look at some of the machines stored away in there.

on cleaning those gas tanks, you may want to use the andrew camarada method of after you drain the last of the cleaning liquid, throw in a rag or two and blow in the fill hole with compressed air. the ramdom activity of the rags seems to get to every nook and crannie of the tank.

i did not watch this one, boy where was my mind. oh wait i had no power on that day, but been looking in-to Generators.

AWESOME!!!!!!!!!

I do the samething using fram oil filters. Cheaper than oem and they work just as good

THKS

I wish I had a generator. Then I could break it and fix it. A clone carb for under $20 is why people don't bother repairing things. I don't blame them one bit. As you said, the needle is probably $10 which is crazy.

A day early!? Must be going on vaca soon. We'll be at the beach next week. Busy with work this morning, but will catch up on this one this evening.

Really need a small sand blaster to clean up flywheel and engine blocks

Fram filters make great targets to shoot at the range. :) The orange color makes them easier to sight in. They are total junk to use on any engine.

Wheels and handles and it's ready to serve a new owner.

It is a deep and philosophical conundrum to consider.........is a Fram filter.......better than nothing? Boy, did that genset sound good with the new carb )) I was working on a Keihin FCR-39 flat slide (not a clone) today on a dirt bike.......and unbelievably the Air/Fuel screw was never correctly installed from new.......it was stuck in the lower float bowl housing, since the hole for the screw had never been drilled out to the proper size.

The XL's are good Generators Ive owned quite few and worked on a few as well . That one sounds like it may need a Spark plug it has a little hitch in its giddy up .

Wow, after watching the first video, in my mind I said "well, this 2nd genny is going to wind up a parts machine" .... never shoulda doubted your ability to resurrect the dead. Nice going there James. Got a question and please forgive me b/c I know it's been asked before but I've watch so many videos that I don't remember which one. But ...... where did you get your temporary fuel bottle? I've looked and looked online and all I've been able to come up with are 2-stroke mixing bottles. I'd like to find something like or similar to what you've got but have had no luck. Thanks @James Condon, another interesting video. Appreciate it.

Enjoy the video as always, you make me feel like I’m sitting in a classroom. One question, what grit lapping compound do you use for your valve lapping?

Wow great and clean work awesome 👍... recently I dismantled my 5kva generator and I replaced the timing gear and now I'm gonna replace the both valves but I have one doubt which is what type of that red color lubricant that u have used on the valves and what if I use an engine oil instead of that?? My regards

Why aren't small engines designed like this anymore? That head has an optimal bolt pattern and a domed combustion chamber. The casting is really clean.

I have one with the exact problem, retainer broke in half on the intake valve, I found a chinese retainer from another engine, it was a little sloppy and worn center, that lasted a month or two, and the stem worked its way through the center, So I dug around in the shed and found some honda valves the retainer was slightly larger where the spring went around it, but a slight pressure and twist it went right on, and the stem seemed to fit perfectly, but it has a cup cap on it, so I am going to put the cup cap on and set the clearance, looks like it is more robust than the original. we will see.

I wonder if maybe soaking some of the rusty chrome parts in vinegar may bring them back to usable shape?

That's the same valve spring retainer as on my predator 3500. That retainer is common and under different part numbers. I linked a place to purchase it but I guess my post was removed?

Nice work, James, buddy I have one exactly like those generators, only one problem one of the 120v outlets dies not produce 120v, been that I am in Nicaragua and I live in a farm do not have access to a tone to fix it for me, what can I do? Any ideas?, love your videos man and you are so inspiring 👍👍👍👍

Try a little woke a cola and wadded up tin foil on that rusty valve cover James. Nice job as usual.

the oil filter.wooooow men

Great video on these Generac's. After listening to your comments about the oil filters on these units I double checked my free 4000xl and discovered it does not have an oil filter or a provision for one. Do you know if I can update my generator for an oil filter. I got it running very well after some work and would like to keep it running that way. Thanks Bill White

Being that the retainer is superceded to a kit with different vlv retainers, it's probably a good thing and won't break again..

Where did you find the air filter housing? I need to get one but can't locate. Thanks James!

I see you primed the filter I do that as well but I was always wondering if that’s what you’re supposed to do I don’t ever see anyone else doing it on RU-vid you’re the only one that I’ve seen to do that so is priming the filter a good thing?

James - Thanks for your excellent videos. Would recommend converting a gasoline generator to propane?

Hey James. I have the same generator can't find parts either . All I need is 1 valve spring retainer. I can't seem to find anyone that sells it . I did see u bought a kit . There are a few incorrect part numbers online I was wondering if you knew which one is the correct one that I would need without having to buy the whole kit.

hey you ever try evapo rust rust remover? The valve cover and exhaust cover could really use it.

James great video nice job on saving the generator....I have the same exact generator the idle control doesn't work on mine, how would you troubleshoot the idle control circuit? When I turn the switch on the idle stays the same is it possible motor on top is bad?

Hi James , I’m at a lost end and was winding if you could share some wisdom ! I have a makita dpc 6200 and I need a new carb adjustment screw or new carb (may be the simple option) It I can’t find one for the life of me ! Any ideas where to look ?

What made the new valves not compatible with the engine? I bet you have quite an extensive library of manuals and documentations. Excellent video. Are you going to put a wheel & handle kit on it?

Another save from Mr Generator! Nice work. How much was the valve kit? Will you find a handle and wheels for this unit?

I have an 17 or 18 hp engine on a riding mower where I changed the oil and apparently the oil plug vibrated out without my noticing then a while later the engine abruptly stopped. Is that repairable or will I need to get a new engine. I don't remember if it's a Briggs and Stratton or a kholer.

Must be getting chilly where you are. Not used to seeing you with sleeves lol

Those suction cup thingies for lapping valves have been around for a hundred years.... Isn't there a tool you can chuck into a drill to do that now? Or is the back-and-forth motion important?

what tools and cream do you use on putting new valves in please Kevin Jones

Hi James , I could supply you with lots of Briggs parts .ive lots of blown up engines stripped and all serviceable parts kept . But I'm in Scotland

Morning Sir, may I ask what the compound you use to grind the valves ? Is it a graphite compound.

On and unknown engine I would have pulled the oil filter first and checked it for metal before I did any more work!

Fram fters are good. Not the cheapo orange ones but you get what you pay for.

Nothing wrong with fram filters, I used them when I ran a mobile auto service and repair business in the '90's and on all my own vehicles. I would expect that the quality of all components has gone down somewhat, certainly this is my experience.

Just curious would vinegar have worked better in the fuel tank than denatured alcohol?

I always said that you do miracles

It looks to me that it would be easier to clean the tin when the parts are off the motor.