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Sportsman Dual Fuel Inverter Generator Will NOT Start

James Condon 471,438 3 months ago
Video Not Working? Fix It Now

A subscriber picked up this Sportsman inverter generator in non working condition. There was water in the engine and the recoil would not move. It freed up with little work, but the compression was low and no spark. After lapping the valves and replacing the ignition coil it still would not start. He has taken it apart several times and decided to donate it to the channel to see if we can get it running again. Will this Yamaha MZ80 clone run again? And can I find parts for it? Visit My Amazon Store: https://www.amazon.com/shop/jamescondon Generator Model: GEN2200DFI Engine Model: 148f (Yamaha MZ80 Clone) Gasket Kit: https://amzn.to/3YsokxX Piston: https://amzn.to/3AfzcqM Yamaha Short Block: 7DX-E5111-00-00 Yamaha Bearing: 93306-204YY-00 Yamaha Oil Seal: 93102-20802-00 Yamaha Lifter: 7DX-E2153-00-00 Yamaha Valve Cover Gasket: 7DX-E1351-00-00 Yamaha Valve Stem Seal: 7DX-E2119-01-00 Yamaha Head Gasket: 7DX-E1181-10-00 Yamaha Piston: 7DX-E1635-00-00 Yamaha Rings: 7DX-E1610-00-00 3 Jaw Puller: https://amzn.to/4aY2TJu 3-Pound Hammer (ESTWING MRF3LB): https://amzn.to/3vWQFSB 3M Roloc Bristle Disc: https://amzn.to/4dXJdb5 Amprobe ACDC-52NAV (THD Meter): https://amzn.to/3vRgRy7 Assembly Lube (Permatex 81950): https://amzn.to/4cVaKsb Ball Joint Puller: https://amzn.to/3UtlG9R Compression Tester (Mityvac MV5530): https://amzn.to/3Qxld4E Cylinder Hone: https://amzn.to/4f3AEvm Evapo-Rust (ER012): https://amzn.to/4aadkZS Feeler Gauge (Lisle 68100): https://amzn.to/4aY3gnm Fluid Extractor (OEM 24937) https://amzn.to/4ff72v2 Kill A Watt: https://amzn.to/3Ui8WTU Leak Down Tester (Lang CLT-2): https://amzn.to/40nwIRC Oscilloscope: https://amzn.to/3UkttqL Piston Ring Grinder: https://amzn.to/3YESyiq Simple Green PRO HD: https://amzn.to/3UqsXGu Spark Tester (PET4000EC): https://amzn.to/3UjpavN Squeeze Bottle: https://amzn.to/4cW0GjF Test Tank: https://amzn.to/3wi6DXG If you want to donate to the channel, you can use the YouTube "Super Thanks" feature or via PayPal: https://www.paypal.com/paypalme/jamescondonYT Carburetor: 88.8 in-lbs (7.4 ft-lbs) Connecting Rod: 79.2 in-lbs (6.6 ft-lbs) Crankcase Cover: 86.4 in-lbs (7.2 ft-lbs, 10Nm) Flywheel: 29.4 ft-lbs (40 Nm) Generator Rotor: 29.4 ft-lbs (40 Nm) Head: 97.2 in-lbs (8.1 ft-lbs, 11Nm) Muffler Bolt: 57.6 in-lbs (4.8 ft-lbs) Stator Housing: 57.6 in-lbs (4.8 ft-lbs, 6.5Nm) Valve Cover: 97.2 in-lbs (8.1 ft-lbs, 11Nm) Intake and Exhaust Clearance: 0.004" +- 0.001" (0.07mm - 0.12mm) I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors. Recently I have been using Simple Green PRO HD with good results. #GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #howto 79cc, 80cc, Alternator, Back Firing, Broken Flywheel, Compression Test, Cylinder Damage, Damaged Bore, Duel Fuel, Evap-o-rust, Fixed, GEN2200, GEN2200DFI, Generator, Hertz, Hone, How To, How-To, Ignition Coil, Impulse Generator, Leak Down, Leaking Fuel Tank, Leaking Gas Tank, Load Test, MZ80, No spark, Pickup Coil, Power Quality, Propane, Puller, Pulse Generator, Rebuild, Recoil Rope, Repair, Resistance Test, Small Engine, Spark Test, Sportsman, Stalling, Stuck Ring, Stuck Rings, THD, Teardown, Tri-Fuel, Troubleshooting, Valve Clearance, Valve Clearance, Water Damage, Wiring Issue, Yamaha, Yamaha Clone 00:00 Intro 02:03 Oil 03:29 Spark Test 04:14 Compression Test 07:13 Peeling the Onion 09:51 Ignition Troubleshooting 22:45 Fist Start? 26:21 Maybe a Valve Problem? 28:26 A Big Clue 31:09 Another Start Attempt, w/Oil in Cylinder 32:14 More Peeling 38:54 Rotor Removal Attempt 43:22 Leakdown Test 47:16 Head Removal and Cylinder Inspection 49:48 Rotor Removal 53:20 Where is the Flywheel? 58:14 Engine Teardown 1:00:05 The Internals 1:02:15 Cylinder Cleanup 1:03:23 Plan "B" 1:04:41 Checking Fitment 1:12:23 Ball Bearing Install 1:13:50 Oil Seal 1:14:58 Engine Assembly 1:23:43 Leakdown Test 1:24:52 Updates 1:25:54 Finishing the Build 1:41:24 First Start 1:45:19 Carb Clean 1:52:52 Testing the Clean Carb 1:53:54 Fuel Tank Setback 1:55:24 Finishing It Up 1:58:33 Breaking the Engine In or Just Breaking It? 02:02:02 Possible Inverter Failure 02:05:45 Propane Test 02:09:12 Ignition Problems 02:11:00 New NGK Plug Test 02:13:36 Ignition Wiring Repair 02:17:10 Ignition Wiring Test 02:18:14 Spark Test 02:19:37 The Smoking Gun 02:20:42 The Fix 02:22:58 Is It Fixed? 02:26:20 Load Test 02:34:52 Outro

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