Generator runs rough: Common Causes & How to Fix
1Generator Carburetor
Most Common Solution
Repair Instructions:
Your carburetor could be blocked. This often happens when fuel stays in the generator for a long while. As time goes by, parts of the fuel can disappear and leave a sticky, thicker material behind. This sticky material can block the carburetor and stop the engine from starting. If your carburetor is blocked, try using a carburetor cleaning product. If it still doesn't work well after cleaning, you might need to rebuild or replace the whole carburetor.
How to Replace Generator Carburetor
- Disconnect the battery. Always disconnect the negative terminal first to prevent sparks.
- Drain the fuel. Use an approved container to drain gas from the carburetor bowl and fuel tank.
- Remove air filter housing. Detach the air filter assembly to access the carburetor.
- Disconnect fuel line. Loosen the fuel line clamp and detach the line from the carburetor. Plug line to stop fuel flow.
- Remove carburetor. Take out the carburetor mounting bolts and detach the throttle linkage. Carefully remove the carburetor.
- Install new carburetor. Carefully mount the new carburetor, attaching throttle linkage and mounting bolts.
- Connect fuel line. Attach the fuel line to the carburetor inlet and tighten the clamp securely.
- Reattach air filter housing. Reinstall the air filter assembly and inspect for proper fit.
- Refill fuel. Add fresh gasoline back into the fuel tank.
- Check for leaks. Inspect the fuel line connection and seals before starting the engine.
- Reconnect battery. Reconnect the negative battery cable once all checks are complete.
2Generator Carburetor Repair Kit
Most Common Solution
Repair Instructions:
The generator carburetor may be blocked. This often happens when fuel is left in the generator for too long. As time passes, parts of the fuel can evaporate and leave a thick, sticky material behind. This can block the carburetor and stop the generator's engine from starting. If you think the carburetor is blocked, try cleaning it with a special cleaner. If it still doesn't work after cleaning, you may need to rebuild or replace the entire carburetor.
How to Replace Generator Carburetor Repair Kit
- Disconnect the spark plug wire from the spark plug to prevent accidental starting.
- Drain the gasoline from the carburetor bowl into an approved container.
- Remove air filter cover and air filter to access the carburetor.
- Detach fuel line connecting carburetor to fuel tank.
- Remove carburetor from generator by unscrewing mounting bolts.
- Disassemble carburetor and remove old gaskets, diaphragms, o-rings, etc.
- Install new parts from repair kit, replacing all gaskets, diaphragms, o-rings, etc.
- Reassemble carburetor with new components per kit instructions.
- Reinstall carburetor using mounting bolts, ensuring proper alignment.
- Reattach fuel line to carburetor inlet.
- Replace air filter and tighten air filter cover.
- Add fresh gasoline to fuel tank.
- Reconnect spark plug wire.
- Test run generator to ensure proper performance. Make adjustments as needed.
3Generator Spark Plug
Common Solution
Repair Instructions:
Check the spark plug to see if it's worn out or damaged. If the white ceramic part is cracked, or the metal part is burned or damaged, or if there's a lot of black carbon build up on the metal part, you need a new spark plug. Use a spark plug tester to check if the spark plug isn't working right. When the engine is trying to start, you should see a bright spark between the parts of the tester. If there's no spark, it means the spark plug isn't working the way it should, and you should get a new one.
How to Replace Generator Spark Plug
- Disconnect the battery. Always disconnect the negative terminal first to prevent sparks.
- Locate the spark plug. The spark plug is threaded into the engine block. Refer to the manual for exact location.
- Clean the area. Use a wire brush to clear dirt and debris around the spark plug.
- Remove the plug. Use the appropriate spark plug socket to unthread the old plug from the block.
- Inspect the plug. Check the old plug for wear and fouling. This can indicate issues.
- Gap the new plug. Use a spark plug gap tool to set the gap on the new plug to the manual spec.
- Install the new plug. Carefully thread in the new properly gapped spark plug by hand.
- Torque the plug. Tighten spark plug to specified torque in foot-pounds using a torque wrench.
- Reconnect battery. Once the new plug is securely installed, reconnect the negative battery cable.
- Test operation. Start the generator and check for proper performance.
4Generator Fuel Filter
Common Solution
Repair Instructions:
The problem could be that the fuel filter is blocked. This often happens because old fuel was left in the generator. Over time, some of the chemicals in the fuel can evaporate. This leaves a thick, sticky substance. This sticky material can get stuck in the fuel filter. When the filter gets clogged, it stops the engine from starting properly. If you left old fuel in the generator, first drain it out of the fuel tank. Then replace the fuel filter. This should allow fresh fuel to flow correctly again so the engine will start up.
How to Replace Generator Fuel Filter
- Shut off the generator and let it cool down. Make sure the generator is turned off and has had time to cool before servicing to avoid burns.
- Locate the fuel filter. The fuel filter is usually located along the fuel line between the fuel tank and carburetor. Consult your owner's manual for the exact location.
- Clamp the fuel lines. Use hose clamps on both sides of the fuel filter to prevent fuel from leaking out when you remove the filter.
- Remove the old filter. Loosen the clamps holding the filter in place and pull it off the fuel lines. Catch any dripping fuel with a rag.
- Inspect the fuel lines and clamps. Check for cracks or damage and replace any worn parts.
- Install the new filter. Slide the new filter into place between the fuel lines and secure it with the clamps. Make sure it is installed in the proper direction of fuel flow.
- Remove the fuel line clamps. Take off the hamps you used to close the fuel lines when removing the old filter.
- Check for leaks. Turn on the fuel valve and check for any leaks at the filter connections before starting the generator. Tighten clamps if needed.
- Restart the generator. Once you have confirmed there are no leaks, restart the generator and let it run for a few minutes to circulate the fuel through the new filter.
- Properly dispose of the old filter. Drain any excess fuel from the old filter into an approved container. Place the old filter in a sealed plastic bag before throwing it away.