Generator Rebuild

The generator was having a problem handling the load.  In other words, it would run great when I would start it, but as soon as I would turn on the air conditioner or push the slide out, it would turn off.  So I took it to a mechanic to check it out.  He said I may have a bent valve.  I drove home, did some research, and decided to do the work myself.

Here is a picture of the generator with its plastic green cover off.  It also shows the valve cover removed to the right side of the picture.

Here is a close up of what is under the valve cover.  As you can see there is some discolor of the bolt head on the right side, and the left side looks fine.  What that means is that the valve seal is leaking exhaust through the top of the valve and burning the bolt head and the parts around it.  That needed to be repaired.

 The next challenge was figuring out how to remove the generator from the RV to work on it.  I went to "Harbor Freight" tool store and purchased this cool tool.  It is a hydraulic lift table.  My plan was to roll this under the RV, jack it up to the generator, unbolt the generator, then lower the generator and wheel it out from underneath the RV.

Here are the very important 8 bolts holding the generator in the RV.

Here is the lowering of the generator.  The table only went so low, so I had to use the RV jacks to jack up the RV so I could roll out the generator.

 Here is the generator rolled out!

I rolled it right into the garage and took my time to rebuild it.  As you can see the table lifts up so it is easy to work on the generator.

Another picture if the generator's home for about 2 months.

This is the generator with the green cover, exhaust pipe, carburetor, engine head and throttle linkage removed.

 This was the problem.  See the black stuff in the middle... that is deposits built up on the valves and engine head.

 This is the other side of the engine head.  It is the burnt spot that needed to be repaired from the original assumption of the bent valve.

 Here is the same engine head when I just got it back from the machine shop.  They installed new valves and seals and repaired the seats.  Look at the distinct difference in the cleanliness of the rebuilt engine head.

Here is a picture of the other side of the engine head.  No more burnt spot!  It was ready to be put back together with all new gaskets.

Here is the generator put back together.  I wanted to test the generator before spending time installing it back in the RV if it needed more work.  So I extended the wires and the fuel line.  It ran great!

So I installed it back in the RV.  Everything works great!  I used the generator for the slide out on Labor day and I tested the air conditioner with it and it runs great!  I now run it every week for about an hour.