Troy-Bilt Generator Engine Runs Well But Doesn't Put Out Power 

This is better than Netflix or Amazon Prime TV or movies. I love his patience, cleaning, his methodical step by step, always takes carb apart and cleans it with ultrasonic, checks spark, buys broken parts, changes oil, even splits the engine to fix timing gone bad. Watching these some of us learn better maintenance requirements. James should sell these videos or get them put on PBS, likeThis Old House. James would be famous as everyone has small engine machines that are not running as they should or could. I have learned to apply many good tech ideas, Thank You, James

I picked up the same generator last week with a blown motor... I got it for a steal... $25.00.... So this video will be priceless when I get the time to fix it... Thanks James

I've never had a problem yet with any of my generators but somehow got addicted to this channel full of broken ones😀 Good work here!

Who knew generator repair could be so entertaining? The production is done well and the instruction is also. I've only watched three or four to date but I know more hours are about to be spent on your channel. Thanks

James, you are my go-to when researching about generators. I recently brought home a Troy Bilt 6200 watt machine that had been stashed away in a shed for several years because my cousin said it never gave her any power. Finally, she couldn't even get it to start. It was filthy so I cleaned it thoroughly and made it look almost like new. The plastic tank was easy to clean out, but the carb was a mess inside. Put a new carb on it and it fired right up. After cleaning it up I pulled the cover off the end of the power head and looked at it closely. Everything looked great, but it did have a very different regulator in it from most that you show us. No voltage adjustment. I also removed it and the brushes and the brushes looked really nice, almost like new. The rings also looked almost new, but I did scotch-brite them to be sure. HOWEVER, I only get a rotor resistance reading of 6.8 ohms. That's right! Six point eight ohms! I checked it maybe a dozen times to be sure. Used two different meters, one was a Fluke 77. So, I figured it was shot. NOT SO FAST, THERE COWBOY! I finished installing the new carb and put it all back together and it fired right up as expected. But, what wasn't expected is that it showed 115 volts on my meter so I plugged in my grinder and it worked! My question is, are there some power heads that do have lower resistance rotors and a totally different regulator to work with them? Must be, because mine is working just fine! My power head is exactly like the Storm Responder one you show in this video. Everything on mine looks exactly like the Storm Responder machine you are showing. Exact engine, too. Just wondering why my rotor resistance is so low since most are supposed to be 40-70 ohms. I almost junked the whole unit because of that, but decided to just try it anyway. Glad I did! It's a nice running unit now. No load voltage of 115.6 volts with 60.1Hz. Loaded (750 watt fan loading) it goes to exactly 60.0 Hz at 114.0 volts.

Nicely done James you are very professional and meticulous in your diagnosis. You make it easy to understand the workings of the genarator. Thanks for another great video.

Another save from Condon’s House of Power!

I do this myself as a hobby, best video this man has done, a very true and honest guy, just love watching other people doing this and this guy beats them all, want to see more, and more from this man. I need to subscribe kind regards colin from croydon surrey England 👍 👏 ❤

Great video as always. I like the way you you figured out the wiring. It shows you totally understand how it works. A wiring diagram wasn’t required. Good job.

The screw that was missing might have fallen out and been thrown into the windings, but if that were the case, you should have found the screw. Unless someone had opened the end, and removed it. Always liked a good mystery. Great video.

Very impressive as always, James. Love your content. Very detailed and flawless. Love and blessings from Ontario Canada!

Hey, I just realized something, there are always no advertisements on these videos. Does that mean that they are not monetized? If so, hats off to you. Although, what you do and the videos that you post are valuable. I would be willing to watch some ads so you can get paid for this.

Great video, I learned a lot. I tuned my old generator and lapped the valves but have not checked the output yet.

Love your content, and your detail, add to my Knowledge every day, and motivated me to get out and repair some small Engines.

Congratulations James, your eye for detail lived up to your usual high standard. Well done.

Nicely done as usual. Impressive experience and knowledge to be able to correlate the different wiring schemes to get it to function without issue. 👍 👍

I just did a slight mod on my microlite 2800, picked up for free, tuned up, oil change and replaced coil spring for choke, adjusted governor response to load applied .. voltage unloaded 125 at 61 hz, loaded 50% or 1500 watts, 118v at 59.8 hz . Quite a drop for half load. Its primary use was an RV but ATT had it in a service van, used it til it would not run steady.. My company purchased the van as a swap when the other hvac vehicles were in for repairs.. I pulled genny out and kept it til the time was right. Now I have emergency power to feed one leg on house panel for essentials.. heat, fridge and basic lighting. Made a frame, wheels and a three gallon tank with a draw fuel line since the unit has its own fuel pump, electric start .

Good vid! I have to be careful watching your videos, I usually stick with lawn equipment but you make me think I can use your videos to get up to speed and expand out to generators.

Great video. Thanks for taking the time to make it.

Really nice job James. Lucky you had a spare power head. Thanks for the video.

Love all your helpful videos and your wood ramps with side guides. Yes, I saw you invert one of the neutral ring terminals so they fit better back to back on the stud. Not your first rodeo. :-)

That black tie wrap with the screw eyelet is pretty cool. 👍 I got to get some of those, handy to have!

WOW , That one really burnt up James ! They blow like a light bulb to man FAST .. glad you had the parts to make a nice generator out of it ! ENJOYED ..

If I was doing this, it died at the point I disconnected the wires... there'd be more hope of Napoleon coming back & re-connecting them properly than me doing it. I do love watching people who really know their stuff, do stuff. Great vid. :-)

Hi James great sitting in your class today mate This gene looks like new very big burnout on this one easy to find the problem which is a bonus good job on the electrics James thank you for sharing your knowledge with us

James another informative video lesson. The biggest compliment I personally can offer you is, I would definitely buy a refurbished generator from you…. Take care.

Great video great explanation. I especially liked when you cleaned it up warmed my heart.

Another great video Jim. Thanks for what you do.

I also appreciate the careful and methodical approach. Very informative. I would buy a machine from you anytime.

A-PLUS! I was with you about the starting and stopping, especially the stopping. The 1st time it seemed to wind down a lot faster than usual but it was fine on the 2nd. Everything getting seated in I guess. Happy weekend and GBWYall!

I have watch many of your videos and learned a lot, all for free! Something I've noticed is so many of the machines like this one look like new. Finding a good generator is like going to the casino.

another nice repair job; nice to have the needed spare parts on hand.....!

nice repair! I am learning a lot.

It's a shame the powerhead failed but at least you had spare ones on hand to fix it up, nice work James! I just picked up my first portable generator off marketplace for $50, it's a vintage Sears 3000 watt with 230v output too. Looks like it might even have 12V DC output too because it has a positive and negative terminal on top of the powerhead, anyway I got the engine running and it powered up and makes power too! Will have to do a load test on it now.

Nice job Doc., that will make someone a great backup generator.

Also love the Condon cleanup and wipe down⭐️⭐️⭐️⭐️⭐️

Another informative video James,thank you for your all your info as always .

Thank you for all the great videos and all the effort you put into making them. Tony, in the land of 230/400V 50Hz (UK)

Always informative. Thank you.

As always you do not disappoint! as an observer, what would think about the missing AVR screw falling out and just rattling around inside the housing until it shorted the winding to the housing?

Thanks for the good content James. Keep it up man

Good stuff and pays to have parts on hand. Good insight on moving the end housing over. Cleaned up really nice and is a Hoss at 8200 watts. If you guys get the storms you, Ken or Gary just posted about it will surely go to good use.

It’s cool how you build the loading rack for vehicles Very neat to have it ready to pickup a item if time is limited

Your videos are great. Very informative

Nice video, I noted that the fuel in the jug went down very little. Seems fairly efficient for that high a load.

A mighty fine unit there, seems to perform better on every run cycle. It is such a pretty red also.

Keep up the awesome content. Trust me I’ve learned a lot from your videos 👍👍👍

Very nice job and well narrated, for todays prize for being attentive , I think you missed the second fastener on the brush mount assem. On the Troy Built. Thanks for teaching us ! Tom~

Another great video, at least you could see it without a lot of looking . that was a fast and a good one.

Jim, Another good video. I like the ramps you made to get the generators in and out but looks like it can be difficult and even dangerous at times by yourself. Have you thought about getting a small riding lawnmower size trailer with a gate? congratulations on passing 70,000 subscribers.

This was quite interesting...Thanks Jim!

Excellent, I learn a lot with your videos, also the way you make them is very unique and I like it, the other day a friend of mine had a problem with his Honda EU20IS , so I check it out, carb issue, fix it right away and he said, you know a lot about this , me: no, I just watch James Condon channel, i learn everything about generators there, that and messing around with mine xD thank you

Another great video. Thanks for the description.

Excellent analysis and diagnosis. Great testing to make sure of the correct wiring. Fixed another one. Off hand how many generators do you think you have fixed and or repaired. Thanks for the videos and information.

Outro is great. As well as all of your videos.

Fine work as always. The top mystery is why did the stator fail in the first place? I'm assuming if someone was overloading it that could happen...

Good job James loved it ! John from the UK

6.3.22 Another fine video James. I like the comment about the bonded and floating ground if going to connect to the house for power.

I have the next version up from this one. Aside from the 15hp single piston Briggs engine sounding like it wants to scatter itself at any moment, the unit has operated pretty well.

Very impressive video I like them all very informative I'm slowly learning about them

Interesting work. Nice video, well presented. Thank you.

nice job ..... thanks for taking the time to make this video

Great job Janes. Thanks for sharing

Great repair video. I was motivated and bought a cheap $99 Walmart generator. It arrived broken. I guess I have something to fix.

Much better than I thought it would be... thanks.

Definitely a better machine than those offerings of last week! The part I don't get, is why it's always the windings at the bottom of the stator that seem to fail, never at the top. This looks like another classic overload situation, only this time, it never got the chance of a 'run down' to cool off before stopping. It never ceases to amaze me that people know the limitations of the machine, but still insist on demanding that little bit more than it was meant to give. Even with the bigger machines that we used to get, when my dad was still with us, it was almost always the same story, just bigger and more expensive! I must admit, I'm developing a soft spot for these Troy-Bilt generators - Familiar engines, familiar gen-ends and familiar AVR. Perhaps not for industrial use, but at the better end of the domestic brands.

Thanks for the video Jim 👍

I learned a lot as usual thanks James. Ed

Super vidéo , bon sauvetage , toujours un plaisir a regardé vos vidéo , bonne journée .

I really enjoy your videos and I admittedly have a weakness with understanding generators I would like to suggest that with your approach doing very basic from the beginning generators 101 as though you were telling it to someone in 6th grade who knows nothing about generators a complete video on that would be I am sure one of the most popular leave no stone unturned explain all the parts all the resistance has everything and it would be such a winner

Great job, your videos are edited well and you stay on the point of why I was watching the video and easy to understand. 5******

James for President,good job.

Helo from P.R.! Good job and professional.I learned a lots.Thankyou.

That was one nasty blown winding. I got a little worried when the head wouldn't fully insert. But you got it. Nice job.👍👍

Great video. Thanks

++++++++++++++++++++ One learns something everyday ! "Powerhead " ......I wondered what the Hell you were referring to as the "powerhead " I suspect that the term is usual to the small power generator market, because generators used to supply tens of kilowatts do not use the term. Your series of generator videos are truly excellent, & your descriptions of what you are doing & why must be a boon to the private owners & DIY crowd. I commend you on your great camera work, your locution while explaining what you are doing, & the audio on the channel is superb. Thank you for your efforts, rest assured they do not go unappreciated.

Very nice James 👍

Great job as usual. Interesting video.

I’m impressed with your temporary fuel setup. (The bottle, stand, filter and valve) would you be willing to make a video describing it? I’d like to make my own. Thank you!

Another fine job.. 👍

Interesting. Thank you.

As always very good job. 👍

How do you find replacement stators? Enjoy your videos! Learning a lot!

Nice Fix for a troubled Job just doesnt get much better video than this one

Looking at the arc marks I would say that the bolt came out and shorted out on the copper wiring.

Hope you have help loading your generators, makes my back hurt, Thanks and keep up the great videos. They are so helpful.

You know your stuff, no doubt about it.👍🏻

Awesome! You did lose me on the wiring but im no electrician either!

36:17 You smelled burnt plastic. I thought you were going to find a short circuit/flopping around metal in the black box housing all the plugs that is above the stater. Great video so far!

👍Good repair. (I always put a bit of nail polish on that “POT”) 👍

Excellent video

Best video seen yet. Please do one on honda gx270 9 hp generator. Pull start, not battery electric please. Havent found one yet.

nice job. any thoughts on what may have caused that stator burnout?

Well James it is a wet and cold night here in South Aussie land and I put you up on the big screen in the lounge and as usual I enjoyed your show , not as good as Top Gun 2 but great thanks 👍

Great job you make it so easy very explain may be you make a video on generac gp 2200i wish you well here in Nicaragua thanks

It is nice to meet you

I love it when a plan works out smoothly,,,= easy money

James, I'm about 80 years old and 50 years ago I was in a shop where they took these small engines and put them on go carts to race. They modified them to about 60 horse. But it's been many years, and I might be wrong. There's a forum for racing go-karts and mini bikes where they take a lot of predator engines and modify them to race. My point is you might look there for parts, they use predator engines because they're cheaper to buy and modified than USA made engines would be now. I was thinking about your valve seal on your himmie 402, I believe.

Great video James!

There is another youtuber (Linguoer), a young lady in China that manually rewinds generator heads & electric motors which makes for interesting viewing. It's remarkable to see something like that being repaired.