Honda EX1000 Disassembled 20 Years Ago - Will It Run and Make Power Again?

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A subscriber sent me his Honda EX1000 Generator. 20 years ago, it stopped making power. He brought it to the local Honda dealer who disassembled the powerhead and told him it needed a new stator. They told him it would be cheaper to buy new. He declined to have it repaired and instead took it home in parts and stored it for 20 years. He sent it to me as a parts machine. But before stealing parts from it, lets double check the diagnosis. Will it run and make power again?
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#HondaGenerator #EX1000
Bad Stator, Basket Case, Broken Spark Plug, Carburetor Clean, EX100, Fixed, Generator, Governor Droop, Governor Spring, Governor, Honda EX1000, Honda Generator, Honda, How To, How-To, Ignition Test, Insulation Failure, Load Test, No Power Output, No Power, Powerhead Installation, Set Engine Speed, Small Engine, Spark Test, Stator Installation, Stator, Troubleshooting, Ultrasonic Cleaner

Опубликовано:

27 апр 2022

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Комментарии : 337

@Dstromb232 Год назад

I have one of these that my dad had bought just in case we lost power at our country home that was never used. Since the passing of my parents, we sold the home, and I took this generator with me and still never have used it. Looks brand new. I think he bought this unit in the early 90's. I thought about selling it, but this is the only thing that remines me about the past.;

@mattyal9347 Год назад

It was a inspirational letter at the end of this restoration video.

@sunbeam8866 Год назад

So,the Honda dealer wanted to do Jim a big favor by 'disposing' of it. Then threw a fit when he said "no"! (I read the letter too) As if somehow it became THEIR property. Fascinating!

@richardbenson4048 Год назад

Most people would figure it won't provide enough juice to be of value. The chop saw proves it had enough to be of great value when needed. It's an inanimate object but I'm glad you have given it a new life.

@kilroy294 Год назад

i am a self taught small engine tech and your videos are well informed. i thank you.

@marknasia5293 2 года назад

i wanted to share with you that watching your videos on generator repair helped me fix a single cylinder 5kw generator that had thrown a rod, and then the camshaft needle bearing went out. The video you showed on how to remove a stator from the engine housing, threaded bearing etc was priceless as I had been stuck on repairing the generator. I had bought a new diesel engine and had no idea how to get the stator off and mounted back to the new replacement engine. Thank you so much, I am in SE Asia and power goes out regularly, so a generator is a must to keep things in the refrigerator from going bad.

@chriss5956 2 года назад

I have a EX 1000, been my little work horse for 20 years, wouldn't give it up for anything!

@gwinters6847 Год назад

The message at the end was a tad touching . knowing that the Honda 1000 was responsible for saving lives.. nice ending James, very nice.

@RANGUIDRY Год назад

What a great history that little Honda has. Almost deserves to be in a museum.

@jeromekurtzsr878 2 года назад

I watch every single video you put out and absolutely love them, You have so much knowledge and trust me I use it everyday when I’m working on small engine’s in my garage, You have 100% Patients and you never flip out because it’s giving you problems…Always looking for a new video from you everyday.

@jcondon1 2 года назад

Thanks

@kriswright1022 2 года назад

I'm with ya on James's videos, never miss a chance to see him work his magic!

@alext8828 Год назад

A man with infinite patience; or should we call it perseverance. I stay glued here for my mental health. He is unwavering. I don't know what his life is about, but he is a rock when it comes to success or defeat. I'm not like him. I wish I were. Maybe my life will improve if I hang in there. Keep watching. Is he a high priest? I don't know. Reminds me of Zen and the Art by Rob't Pirsig. If I tell you not to go there, will you???

@Conservator. Год назад

@@jcondon1 Hi James, Watching this video, I’m wondering why the Honda dealer had disassembled that generator. Do you have any idea? Thank you for your videos. I just love to watch you explaining what you do to troubleshoot these machines and then, most of the time, repairing them.

@wjodf8067 2 года назад

Got a lawn mower running that had been stored over winter under a porch with fuel in it. Got it apart remembering all your lessons and it started on first pull ...son in law was in awe when it took off Thanks for all the practical knowledge and great videos

@jcondon1 2 года назад

Very nice...

@BruceBoschek 3 месяца назад

Congratulations a year later. 🙂

@joegutierrez2019 2 года назад

Such a cool story for the little generator that would not quit 😀. Nice to see it back on the line.

@michaeltarasenkoop2389 Год назад

James ! What is great about your show is that you get a troubled generator and have to diagnose the problem let alone fix the problem with your knowledge! Love the show ! Spent all day watching I think I’ve seen all the shows or close to it !

@johnclarke6647 2 года назад

I had a problem with my EX1000. The exciter capacitor had failed. One of the wires had broken off the capacitor after getting wet and rusting in the rain. Honda wanted over a $100 for this 13 ufd capacitor. I bought a 15 ufd capacitor off EBay, which fit the form factor as close as possible to the original. It worked fine. I used it for several years but finally sold it after close to twenty years of service.

@Bri-tg6xr 2 года назад

The note at the end was pretty cool, nice to see that machine was actually used well in its life.

@FeralPreacher 2 года назад

A new silk purse from a sows ear. Well done James.

@tubemember21 2 года назад

Great work! I was so happy to see the engine turn over after 20 years. These old Honda suitcase generators are remarkable machines. My family has had an EX800 for going on 40 years now for our off-grid property. Only oil changes and the occasional new spark plug and it's running perfectly with thousands of hours on it. I'll be sure to double check the air filter now that I know they can turn to dust!

@Rev-D1963 2 года назад

It's so cool to watch someone, like me with that "never say never" mentality, to bring back a parts machine to life. I did that with many old Rossi revolvers when I first started practicing gunsmithing. It was fun to see them roar back to life (.38 Specials). Thanks again James for the great videos, and the work you do. God bless. Rev. D.

@YukonHawk1 2 года назад

That's one tough generator. So cool to see it going again. Great letter from the owner you posted at the end. Great job. Also, you showed how the windings were "cemented" in place to keep them from moving around. I never knew that tidbit and that's why Hondas last as long as they do. Premium workmanship.

@brianallen9810 Год назад

After watching these I'm really tempted to get an ultra sonic cleaner.

@tubeDude48 2 года назад

I watch all of your rebuilds, and have learned a lot, and it help me get mine in better operating order. Your definitely a Generator GURU!!

@BKD70 2 года назад

Wow, I'm impressed that you had all of the hardware except for those 2-3 screws. That's amazing!! I've had success shortening a slightly stretched spring by putting a "Z" bend in the long leg of the spring with a pair of needle nose pliers. Something to try anyway. Great video as always!!! Love the backstory on that little genny!

@poprawa Год назад

Getting parts in worse condition but closer to specification via field fixes is owner job, not paid technician

@tomg721 2 года назад

It's a Honda.. Of course it will start. Being 20 years old, the carb never saw fuel with ethanol.

@MitchEllis-dn9lf 2 месяца назад

Amazing 20 PLUS year old fuel lines from Japan that are still in good shape.

@xcalibre222 2 года назад

You can spray the aluminum with silicone spray like Tire Shine. It will stop that white powdery oxidation. This protects the aluminum plus it looks much better. I do it every year on my aluminum engine car parts and they look Great. Thanks for the Vids Jim. :)

@aboveaveragejoe6291 2 года назад

Good tip, thanks man!

@user-uo7th1ly8k Год назад

😅 ‏‪20:23‬‏ 😅😢

@user-uo7th1ly8k Год назад

זשז😮 ‏‪40:23‬‏ רשששששש😊

@user-uo7th1ly8k Год назад

@davidblake6889 2 года назад

If I had a piece of kit broken down for 20 minutes, I would lose half of it, even in an empty locked room! To lose only a couple of screws 20 years after teardown is absolutely amazing. To bring it back to life after all that time is even more amazing. Thanks, James for all your videos. Your patient perseverance is a life lesson to us all.

@johncourtneidge Год назад

Entirely, yes!

@Landrew0 25 дней назад

I was impressed with these "suitcase" generators when they came out about 40 years ago. But nowadays I wouldn't want anything but an inverter generator.

@dimitarmladenski1367 2 года назад

I allways wanted EX1000, just like how it looks, but I can't spend 500 usd on it. Great video

@newdawn8477 2 года назад

I wind springs every so often and the one that is bad looks fairly easy to reproduce if you ever want to go down that path. I do it to replace springs in locks for a friend of mine, He's a locksmith so I get lots of random spring designs.

@somerandomguy3868 2 года назад

Honda never fails to amaze me, I did wonder what caused the original stator to fail, considering the duty it saw I'm satisfied that mystery is solved

@thecrow3380 4 месяца назад

Ah that's a nice story. A bit of love and care, along with a touch of OCD. Long may she run.

@TonyGingrich Год назад

If you still have this generator, go back to the pilot jet and lean it in about an 8th of a turn more. That should greatly reduce the engine sag under load. I restore antique outboards as a hobby. My ears have become very trained to the sound of an overly rich mixture, ha!

@kenmitchell3784 2 года назад

You must be proud of your end result, as I know that feeling I get from making something work that someone has given up on.Good job James keep the videos coming

@aboveaveragejoe6291 2 года назад

Very nice of you to troubleshoot that stator for the person that sent it, another great video James, thanks 👍

@wildefox1478 2 года назад

That was great you managed to get a new stator and brought that generator back to life, nice work James!

@andrewk8636 2 года назад

I bought a dixie chopper ztr a couple weeks ago and you small engine videos are helping me so much! The mower had a ton of parts missing like the voltage regulator, exhaust, engine pulley and oil coolers. Definitely a learning experience but with your videos it'd a lot less scary to dig in to the engine!

@buckstarchaser2376 Год назад

Thanks to AVE, I understand that mechanical frequency indicator. It's nice to see one in the wild. Also, I wonder if the mechanic shop was upset about returning the parts because they had to take down their ebay auctions. Ebay was the brand new craze at the time when that was said to have last been on the healing bench, and that's just the sort of oddball item that people were highly interested in digging up, as it was "amazing" that people could find a buyer for dang-near anything that you couldn't simply buy in a store for the first time.

@jonminer9891 2 года назад

Hi, James. It is wonderful that you have created a channel with so many great viewers. It reflects well on your presentation and thoroughness. What goes around comes around. Your viewers are the best. Thanks for sharing! Stay healthy! To everyone!

@butler386 2 года назад

I must say you sure generate some quality videos. I enjoy you not only getting the engine running well but you get the unit putting out the best quality electricity. Your knowledge, patience and skill is unmatched. Thanks for all the information and videos

@jcondon1 2 года назад

Thanks

@poprawa Год назад

Only loom part, that is able to touch grounded stuff is going to ground. This is neat

@capnchip Год назад

Very interesting.....I have one. Had it about 20 years. I use it frequently to power electric blower and small chainsaw. I change the oil and the filter and never use ethanol gas. FANTASTIC THING!

@ruenjou 2 года назад

If you want to start a portable generator repair business to compete with James, watch all his videos, lol. Seriously, this is top-notch educational material presented professionally.Thanks.

@jcondon1 2 года назад

Thanks

@Dave-yo9tt 2 года назад

20 yrs old and a good runner... I'd consider a soft restore for this one... Especially, how people LOVE them...

@rstephe Год назад

Excellent job James. As always. Loving seeing that little guy live on and be repurposed instead of becoming landfill. Jim from the Fresno, Cali area - thank you for sharing with us and giving a project for James to teach us more. At least we know now the repair shop was not lying to you. I'm sure selling used parts as new is much more profitable. Great backstory (letter at end) too. Yes, I have to watch James Videos all the way thru lest I miss something.

@bernardsantiqueengines3128 2 года назад

Wow James! Just goes to show there's always potential in every piece of equipment.

@chrismoore9997 Год назад

I watched a video yesterday of someone rewinding a generator. They pulled all the old wire out and put in all new wire. Worked like a champ after.

@andyhamilton8940 2 года назад

Just inherited a EM1600X James. I will have a head start on bringing it back to life. Thanks James!

@arthurbiringer5676 2 года назад

That’s a great backstory! You made Jim very happy!

@stevenholton438 Год назад

I have this model I'm currently working on and now you have equipped me with the tips I need to get it performing well again (I just gave it a decoke!).

@brettnielsen3103 8 месяцев назад

This video and your other one helped me fix my EX1000 that I brought back from my parents house. So many memories of it powering our camping trips. I do have one mystery problem with my generator. The petcock valve's lower black hose leaks out all the fuel. Unsure how to fix the valve short of replacing it, I assumed the that lower hose is some sort of air burp for the tank. I plugged the bottom of the tube with a left over ball bearing as a stop gap and doesn't seem to cause an issue running it for 15 minutes. I'll continue to search the internet for it's purpose. Great channel!

@gwinters6847 Год назад

I've also tried rope but on these angled heads, I found that a squirt of sae30 in cylinder, then pressurizing cylinder with around 35 to 45 psi compressed air or nitrogen holds the piston at bdc, (4 stroker) and run the bolts in with impact, then final set torque. Gary in Mich

@Roy_Tellason 2 года назад

I'm with you 100% on the way that rotor was potted. They should all do that, and with the stator windings as well. I first ran across this in some video that was talking about power tools, and it only makes sense, considering the vibration that's going on the whole time this stuff is running. It might be worthwhile considering doing this to some of this stuff, but then you'd have balance issues (for rotors) and heat dissipation issues (for stators) to consider.

@rayshutsa6690 2 года назад

I love all your video's. You are very professional and meticulous gentleman. The way you explain things makes it easy to understand. Thank you for another awesome video. 😀❤🇨🇦

@er1073 2 года назад

James you always seem to be able to bring things back from oblivion I mean 20 years and this little air aspirated internal combustion 4 stoke engine still lives!!! And the new power head for $150.00 it doesn't seem like there was too much time spent on this project you probably worked on other machines. Thanks for your step by step know how on this and all of the videos you do. Ed

@SAMUEL7.3 2 года назад

You make me feeling like trying to start my craftsman lawn mower that i havent started in 7 years..😊

@lestergillis8171 Год назад

The stator might be bad, but it COULD still make a fine boat anchor. ⚓

@stevek5416 9 месяцев назад

You put the bowl back on the carb 180 degrees out. The screw is a drain screw and should be accessible from the side. This is the exact generator that my neighbor threw in the trash, because of fuel being left in the carb and really gumming things up. I rescued the unit, cleaned the carb and then sealed the tank with the POR sealant because of a huge rust problem, and now I have a nice, working little jewel of a generator. Watching further, I see that you caught your error and corrected it.

@RustyNail5856 2 года назад

Great job. it was great to hear it run after all those years. keep up the good work.

@jcondon1 2 года назад

Thanks

@mikesbarn1858 2 года назад

Any time I’m diving that deeply into an old engine with a lot of light years on it I like to check the valve lash before calling it good.

@piconano 2 года назад

I love Honda engines. They run forever. Great video. This generator is built like a tank the old school way, with all steel parts, including the gas tank. Can't find that anymore! All plastic crap that if you look at the wrong way, it'll brakes.

@jcondon1 2 года назад

It is a well built generator for sure. Surprisingly heavy for it’s size.

@fishyfool 2 года назад

Ever considered annealing the spring to do your mods, then retempering it? I did that with one of my mothers oven springs when it snapped off at the bend for the hook. Blew my dads mind, lol.

@jameshedrick6839 2 года назад

I've seen almost all your videos and was confident enough to rebuild the motor on my generator. I didn't pay attention to the air filter and it turned to dust and got sucked in. I since then rebuilt it and i put the air box off an old blown up lawnmower on it to where it uses a paper filter now

@watermanone7567 2 года назад

Excellent video James. Lots of time and work in that one.

@shawnmrfixitlee6478 2 года назад

One of your best shares James ! I love to save these machines from the landfill . Glad he did not throw it out . You saved it and for cheap .. NICE , ENJOYED !!

@jcondon1 2 года назад

Thanks Shawn!

@shawnmrfixitlee6478 2 года назад

@@jcondon1 Had a repair job years ago for a logging equipment watchman . He had one of those little Ex Honda generators that he bought new , Ran it for 5 years 10-12 Hours a day . He brought it to me and all it needed was rings , A rod and a valve job .. Ran like new again .. Super well built.. & tough generators if they are treated right !

@vernt4583 2 года назад

Very good video and nice little topping of the cake 🍰 with the original owner response!!

@KaldekBoch 2 года назад

Oh man I really needed this content right now. Awesome work again.

@gidderman Год назад

Just a little tip, i saw you used WD40 to lubricate the fuel hose when you attached it to the carb, thats not a great idea as WD40 (or any penatrent) is a solvent and will dry out the hose. The old trick we were taught in automotive school is to use a drip of engine oil to lube fuel hose connections as it wont hurt the hose!

@alasdairhamilton1574 2 года назад

Nice back story to the old Generator 👍🏴󠁧󠁢󠁳󠁣󠁴󠁿

@shawnbenson979 2 года назад

Great vid ant the letter was spot on . respect

@marcelobraz4259 2 года назад

James, congrats again with cumpliments due to that sequential good history that comes from stator previous owner. A hello from Brazil’s audience. Best regards!

@bernardbush4199 2 года назад

Nicely done as usual James. Thank you.

@duaneclarke7411 2 года назад

James you are one clever fella and a pleasurer to watch, I'm looking forward to the next video thanks

@markwiley9516 2 года назад

James great job 👏 after 20 years of not working it sounds good 👍

@Roy_Tellason 2 года назад

Yeah, that motor was just purring...

@timg8138 2 года назад

I can believe it has been setting for 20 years. To think he had it setting on his shelf since 1982. Yep. 20 years ago was 1982.

@Rein_Ciarfella 2 года назад

Not sure if you’re using the new math or what, but 20 years ago is 2002, not 1982. 😉

@Bassguitarist1985 2 года назад

Way to go James! Another generator saved!

@johncourtneidge Год назад

Beautiful, as always! Thank-you!

@johncorlett3699 9 месяцев назад

just love the ultrasonic, makes a real nice job

@kerrygleeson4409 2 года назад

Great save James thanks for sharing your knowledge 🦘👍

@zodzod9378 2 года назад

Good job loved it ! a new lease of life ! John from the UK

@robertjennings397 2 года назад

I’m sure being an expert and owning it very personal. I’d feel contrite to know half of your skill.

@phillipmckinney7906 2 года назад

Really wish i had a teacher like you in School as id learned so much more and stayed in school as i quit in 8th grade as it was so boring and those are baked in a oven to cover the copper winding as i learned much later in life

@arthurbiringer5676 2 года назад

Another great job and resuscitation!

@aliwho 2 года назад

All all the best James keep them coming

@rickhartzell1708 Год назад

i just started watching your videos really enjoy watching thanks

@deangentles4966 2 года назад

Hi James as always with your amazing knowledge a great class to sit in to day mate Always look forward to your next video

@jcondon1 2 года назад

Thanks Dean!

@haneyoakie14 2 года назад

That is an extremely cool backstory and an excellent job getting it running well here in 2022. I enjoy your content because I like your explanations and that you explain your thoughts in detail. “I could do A, B, Or C. I chose B for reason X.” Great education for me. Thank you.

@jcondon1 2 года назад

Thanks

@KensSmallEngineRepair 2 года назад

Great video, super cool back story!

@andrewgrace4410 8 месяцев назад

Great fix and troubleshooting 😊

@davidtillwach5542 Год назад

@James Condon You can have new springs made at Stanley spring in Chicago Illinois. It's worth having more springs for the EX1000 from Honda

@redneckbryon 2 года назад

Personally I always try and fix something, to try and give it a new life as well. Nice story at the end.

@Tech-Dave 4 месяца назад

Great Video James. You have a great Channel

@bbrown9763 2 года назад

FYI, there's a stator & rotor on eBay right now for $105 including shipping if you want to nab a spare.

@orvjudd1383 2 года назад

Jim, you might try calling Curran Coil Spring in Wilsonville, Oregon. They specialize in all types of coil springs.

@gschaeffer8724 2 года назад

Good job dude, love you vids, learn a lot from you!

@gschaeffer8724 2 года назад

I want to add that the story at the end is very cool as well! Again very nice job!

@christophermarshall5765 2 года назад

Good job. Well worth fixing.

@nobbybrown8056 9 месяцев назад

Great video again, I like your style of presenting, very thorough. The update from the previous owner was very interesting, it would be kind of a nice thing to take it back to Kings Speedway for a revisit, I see it is still operating, maybe with the previous owner and do a bit of a history talk?

@Skynet-1 2 года назад

Another great video Jim, thanks for sharing! ⚡⚡⚡👍👍👍

@GuysPlayingWithTools 2 года назад

Good show! When I get a box of parts I always shake my head and hope for the best. Seems like there is always an air cover or handful of nuts/bolts missing in the box.