Seized up generator crankshaft?

[ctilsie242]

I have had a 3000 watt generator for a while now, and it has at least 3000+ hours on it. Maintenance has been changing the oil out and the other basic stuff, including cleaning the carb.

It has worked perfectly until last weekend where when I tried to start it via electric start, the solenoid clicked, nothing happened. Tried pulling on the rope, it snapped.

I'm pretty sure it has given up the ghost, but I've never seen a generator actually seize up like this. Usually it might run a bit then just die, but this is the first time I've seen a generator hard-sieze where the camshaft couldn't be turned at all.

This is a head scratcher. Guess it is beyond my expertise, because it probably may require a valve job. Any ideas where to look?

[ctilsie242]

I let an engine specialist crack the thing open, because the camshaft just would not turn whatsoever. However, from what was relayed to me secondhand, the engine was warped due to overheating. Hopefully I will have more details including pics and such.

At the minimum, it will be something for this forum on what not to do.

Bike Bandit does carry parts for the generator, so hopefully I can get a list of what is trashed and add up what can be replaced.

[j-d]

Ah, Friends...

Price that engine, somebody here replaced the engine in an ONAN 4KY and I'm sure it was less expensive than $1100. I know they're different brands and all that, but still, check.

And of course, evaluate carefully first. If "friends" at least kept the oil close to full, I doubt it seized.

[ctilsie242]

I know this is a necro thread, but I did find what happened to the generator. When it was in storage, it appears to have been "borrowed" (and returned) by some former friends, who I gave permission to use it, provided it get its care and feeding (synthetic oil, new air filters, the spark arrester cleaned... basic stuff.) Only problem was that no maintenance was done while I was gone.

The good thing is that I can buy a complete engine assembly from Yamaha as a replacement. The bad thing, it likely will cost more than a Champion model 100263 which is $1100, and which is likely going to be what I spring for eventually.

[ctilsie242]

I did try changing the oil -- the oil was dirty, but no metal shavings in it.

Since it is a Yamaha generator, I'm probably looking at a bigger cost to replace the engine than buying a new one, so unless it is something odd like the pull rope breaking, a fault with the starter, and the low oil mechanism all triggering at once, it may be toast. Worst case, I put it away until I can take it to a service place that might be able to get it going again.

[Rvpapa]

Take the head off and clean the carbon out.
Art.

[theoldwizard1]

If nothing came flying out of the crankcase, it MIGHT be rebuildable !

Biggest issue is disconnecting the generator head from the engine. There are a couple of bolts but the problem is disconnecting the crankshaft for the generator rotor. Check YouTube, There are several good video showing how to do this.

Then you can pull the cover off of the engine and see what happened inside.

[j-d]

There's also the outside chance the engine stopped with the piston at exactly top or bottom dead center. Especially if there's anything sticky on rings, etc. it can be very hard to pull the engine over with the rope starter. Wrench on the crankshaft should get it to where it'd pull again. Given of course nothing's actually wrong.

[nineoaks2004]

I worked n a lawn mower engine awhile back, seems the carb float had stuck and the
engine crank case had filled up with gas, I drained everything, refilled the oil, gas etc. cleaned the carb and checked the float (which was the problem) It started right up and still runs good. Also the electric starter motor could be jammed there are quite a few things that could cause the problem you describe. I would take the time to give it a good check over before declaring it dead in the water. Could be something really simple and either free or cheap to fix..

[horton333]

Unless you are real strong the rope must have been badly worn, perhaps ready to break. Fix it before saying the motor is seized, or at least try the suggestion to try turning it directly before assuming that it's a write off

[MrWizard]

I HAD a pull rope break, it was worn a few inches inside, where it rubbed on the housing , a few inches of slack between the front panel and the pull cover allowed for the rope to move from engine vibration

if the engine is seized, you might get a universal replacement at harbor freight
but, its probably buy a complete new generator for near the same price

[midnightsadie]

could be starter jammed on fly wheel .

[SAR_Tracker]

Pull the spark plug, and try to turn it over by putting a socket on the end of the crankshaft.

[DrewE]

Will it turn if you take out the spark plug? It's a bit of a long shot, but maybe there's some oil or water or something that got in the cylinder and is causing hydrolock.

It may also be that the starter cord was getting weak with age, and a new one would turn the engine over without breaking. It could, of course, also have the engine seized for some reason.