Generac 5500XL with Governor Issues

This is the third Generator that Stanley donated to the channel. A friend of Stanley's picked this Generac 5500XL up from the dump. He fueled it up, pulled the cord and it started and made power! Things were looking good until the generator was pressure washed. It hasn't worked since. The generator was later given to Stanley. Stanley replaced the PCB (power control board) and reset the governor calibration, but has not tried to start the engine after the calibration. He was unsure of the adjustment he made on the governor and did not want to cause damage to the engine. This generator has now been discarded or given away by 3 different people. Lets get this poor generator fixed.

I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner.

Generator Model: 09778-3
Engine Model: GN360
Governor Spring: G073100

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5500 XL, Anti Lash Spring, Anti Surge Spring, Carburetor Clean, Carburetor, Droop, Engine Racing, Fixed, Fuel Tank Repair, Generac 5500XL, Generac, Generator, Governor Calibration, Governor Droop, Governor Reset, Governor Sensitivity, Governor Spring, Governor, Handle Install, High RPM, How To, How-To, PCB, Petrified Fuel Line, Small Engine, Tank Bushing, Tank Leaking, Troubleshooting, Ultrasonic Cleaner

[tonym]

I like the way you work James, very methodical, not rushing through your diagnosis and repair. Always learn something from your excellent vids, thanks! ⭐️⭐️⭐️⭐️⭐️

[spartanj]

Great powers of observation, and great thought process, my Auto mechanic instructor of 2 years from the 70's would be proud of you !!
As we all are.Thanks for sharing with us

[aboveaveragejoe]

What do you mean, see if I can, James you know you got this!

[Rev-D]

It's amazing how the littlest of things can cause the biggest of problems! Awesome detective work James, as usual; that took some doing! Great job on the outcome. And thanks for your videos. God bless. Rev. D.

[YukonHawk]

These models were well built back in the day. Components and materials were top notch. Great that you discovered the nut was in the way and raised the linkage out of the way. Another classic saved from the junk yard.

[oemytech]

Great video. The small things make a difference. A clean carb, correct springs and correct adjustments

[arthurbiringer]

Great job, great video! I’m surprised that you didn’t remove the valve cover, clean it up, paint it, and verify valve clearance while the paint dried! Keep up the great work, you batted 1, 000 with these three gensets.

[Ram]

It's a nice feeling to see something saved from the scrap yard when a little tinkering can make it useful. The engine seems to be in good shape as it runs great! Thanks James for the great video.

[deangentles]

Hi James always a pleasure sitting in your class mate Thank you for sharing your knowledge with us As always a good entertaining video

[kpdvw]

James is the wizard of Generators! Good job, excellent explanation odf issues! we all can learn a lot here!
Take the valve cover off and clean it on a wirewheel and then paint with silver paint and clear coat....!

[williamyorkolepossum]

Just love it. You are a good observer - an important skill for a repair fella....

[haneyoakie]

Nuance’s beyond my skill level, for sure. I had no idea, but now I do. Very educational Jim. This hour was well spent. Thank you

[iandennis]

Jim, I was actually holding my breath as you worked on that main

[lv_woodturner]

This video certainly may help me in the future. I have a Generac 7000EXL, so a bigger brother of this unit. I am the original owner. I purchased the generator around 2005. It is stored in the garage. I only open the garage doors to take something in or our, so normally closed. The machine has been a reliable unit when needed for power outages. This video has a lot of information in case my machine starts to give me issues.
The control panel faces a window in the garage. Sunlight does not fall on the panel, but over the years the paint has faded on the panel, but not the frame. So likely a different paint formulation on the panel.
I will have to check my output voltage and frequency, just for grins.
Thanks,
Dave.

[Craig]

Hi James, I just wanted to let you know how much I appreciate your videos. I have been watching for the past two years, and I have learned soo much. Your methods of disassembly, especially when things are old and cruddy are excellent. Thank You!

[tonyz]

That went in a completely different direction than I anticipated. I was thinking the governor linkage or linkage spring might have been dragging where it passes through the fan shroud. Nice job tracking down the problem!

[larrykelly]

Doc, great diagnostic video. Sometimes the obvious is hidden by the forest, that's my problem, something I'm looking for and can't find is right in front of me all the time.

[navvet]

I’m a huge fan of your gen repair videos. Here in hurricane alley, no one needs a generator until……. Generators are a premium price either new, used or non-running. I always look forward to your videos sir.

[johnallen]

After watching many of James videos I fancied a go at buying in something cheap to renovate myself.. I also have quite a lot of auto engine experience and feel quite confident that after gaining knowledge from these videos I could take on any issue..However that governer malarkey really SCARES me ! 😟

[jonminer]

Hello, James. More like poker than detective work this time. But you got the winning hand in the end. Good goin'! Thanks for sharing! Stay healthy!