No Power - Broken Rotor Wire Repair

I found this Generac GP5500 generator outside covered in mud. The owner gave this generator away for free. He listed it for parts or scrap and did not state what was wrong with it or if repair was possible. The price was right. Lets see if we can get this Generac GP5500 running and making power again.

Generator Model: GP5500 (0059390)
Fuel Gauge: 0H9005A

This is a common failure on the GP series generator. Last weekend I did a live repair on another GP5500 that Ken brought over. It had the exact same issue. See it live and uncut: https://www.youtube.com/live/mqmOSbA_gOA?si=XmEsgH3OkEJ0-oc8

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#Generac #GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #howto

AVR, Alternator, Automatic Voltage Regulator, Broken Rotor Wire, Broken Wire, Carburetor Clean, Critter, Dirty Carburetor, Fixed, Fuel Gauge Replacement, Generator, Hack, Hertz, High Voltage, How To, How-To, Insulation Failure, Load Test Fail, Load Test, Low Oil, Magic Smoke, No Oil, No Power, Ohms, Open Circuit, Parts or Repair, Parts, Power Quality, Repair, Resistance Test, Rust in Gas Tank, Rusted Tank, Scrap, Small Engine, Speed Adjustment, THD, Torch Spark Plug, Total Harmonic Distortion, Troubleshooting, Valve Adjustment, Voltage Control, Voltage Regulator, Water in Fuel, Will Not Start, Won't Run

0:00 Introduction
1:42 Triage
5:02 Valve Adjustment
11:00 Fuel is Always an Issue
25:45 First Start
27:06 Finding the Generator Fault
35:03 Stator Removal
40:33 Locating the Break
42:33 Rotor Repair?
54:59 Evicting the Critter
56:56 Stator Installation
1:01:35 Testing the Band-Aid
1:02:17 Speed Adjustment
1:03:44 Getting it Together
1:07:12 Fuel Tank Repair
1:22:59 Load Test Attempt
1:24:34 Over Voltage
1:25:16 Voltage Regulator Swap
1:26:42 I Let the Magic Smoke Out
1:27:09 Switching Back the AVR
1:29:14 Is It Dead?
1:31:20 Full Load Test
1:34:35 Speed Adjustment
1:35:23 Conclusion