Generator Only Runs at Half Choke

[locke_n_load]

Bought a 3200/4000 Watt Generator from Harbor Freight in May. I am still on the original tank of gas (which has fuel stabilizer in it) and I run it every 1-2 months for 30 minutes just to keep things clean. I also always turn the fuel to off and run it till it dies. I have not had a problem with it till yesterday - if I tried to move it from about half choke to run (no choke), it would start to sputter like it's running out of gas. I have a hard time believing that the carb could be dirty after using it for 7-8 months with stabilizer in it. What else could it be? I have contacted HF to see what I can try. Youtube video here: https://youtu.be/23MhHaX1gaA

 

[Younggun]

That issue is almost always caused by a dirty carb.

Usually fixed by running it to break down any varnish, or running with an additive like seafoam.


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[Younggun]

Also, check the fuel filter if it has one and dump the gas for fresh gas. The temp swings will cause a ton of condensation in the tank.


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[BRD@66]

Sea Foam!

 

[locke_n_load]

Y'all think the carb could get that dirty in 7 months?

I will put some seafoam in the tank and run some carb cleaner through the intake (harder to do without a real throttle).

Really think I should dump the 7 month old gas with stabil in it for new gas? I guess it can't hurt. What do I do with 2.5 gallons of old gas?

 

[Vaquero]

Y'all think the carb could get that dirty in 7 months?

I will put some seafoam in the tank and run some carb cleaner through the intake (harder to do without a real throttle).

Really think I should dump the 7 month old gas with stabil in it for new gas? I guess it can't hurt. What do I do with 2.5 gallons of old gas?

I dump the old gas in my farm truck gas tank and drive it.
The EFI doesn't seem to care.

 

[TheDan]

Y'all think the carb could get that dirty in 7 months?

Could have been crud in the tank from the factory.

 

[locke_n_load]

I dump the old gas in my farm truck gas tank and drive it.
The EFI doesn't seem to care.

I guess 2 gallons mixed with 34 gallons in my truck wouldn't hurt.

Well I'll try to clean everything out short of taking off and cleaning the carb.

 

[grasshopperglock]

My guess is the fuel jet is being blocked by trash of some sort. Depending on the carb, you might be able to get to them without totally pulling the carb. If you can see them, computer duster and a long straw. Blow them out.


Next guess is the gas tank cap isn't venting. It's sucking fuel against a vacuum.

 

[Shotgun Jeremy]

Check your fuel filter and for any cracks in your lines. Don't rely too heavily on carb clean. It doesn't work very well on films.

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[Dawico]

I always run premium gas in small engines.

You can check the pick up tube too. Most have a screen on them and can get glogged.

 

[locke_n_load]

So order of events:
Got it warmed up
Removed air filter
Shot carb cleaner in intake - no white smoke - gave it several good bursts just for good measure though
Ensured all accessible carb bolts were tight
Drained gas
Replaced with new gas
Ran again
Ran without gas cap
Removed spark plug - immaculate
Reinstalled plug
Ran again
adjusted idle screw
put idle screw back into original location

Nothin. Still only runs at half choke, and dies when I load it with the same tools (near max capacity) as when I first bought it. Would still probably work for my fridge and 6,000 btu a/c, but won't run full load, which really bothers me. I guess I could try some seafoam.
Or the only other thing would be to rebuild the carb, but with only 8-10 hours on it, gas always had stabilizer, gas always ran out of carb, I just find a dirty carb hard to be the culprit, but I can't imagine what else it would be.

ETA: no fuel filter, just a screen at the top of the gas tank.

 

[Vaquero]

Dang.
I hope HF gives you a replacement then.
I've got the same gen set and haven't had a bit of trouble in 10 months.
Keep us posted on developments.

 

[locke_n_load]

Dang.
I hope HF gives you a replacement then.
I've got the same gen set and haven't had a bit of trouble in 10 months.
Keep us posted on developments.

Hopefully. Unfortunately I did not get the extended warranty, but with under 10 hours on the genny and 7 months old, I would hope they would make it right. I sent them an email Sunday night with no response today (just asking for tech support, nothing else). Fingers crossed. If I get a replacement I will run it every month for sure. I know they say 3 months, but it definitely wouldn't hurt anything. Will keep you posted.

 

[Vec]

main jet clogged

 

[Recoil45]

Y'all think the carb could get that dirty in 7 months?

I will put some seafoam in the tank and run some carb cleaner through the intake (harder to do without a real throttle).

Really think I should dump the 7 month old gas with stabil in it for new gas? I guess it can't hurt. What do I do with 2.5 gallons of old gas?

Yes because it does not happen all at once.

I'd clean the carb and run it on fresh gas. If the old gas doesn't look cloudy use it 50/50 with fresh gas. Once you know it's fixed.


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[ed308]

Before you rebuild it, pickup a bottle a Mechanic in a Bottle at Home Depot. They sell it around the lawn equipment. I've used it on mowers and lawn equipment that wouldn't start or ran rough after sitting over winter. On engines that won't start, you drain the gas and put it in at full strength then let it sit over night after cranking the engine to get the product in the carb. The stuff works too. I had a pressure washer that wouldn't start after sitting 5 years with gas in it. Also had a edger that would start for 3 years. Both work great today.

 

[TheDan]

Or the only other thing would be to rebuild the carb, but with only 8-10 hours on it, gas always had stabilizer, gas always ran out of carb, I just find a dirty carb hard to be the culprit, but I can't imagine what else it would be.

You just need to clean the jets. It probably had crud in the tank or lines from the factory.

 

[Chirpy]

main jet clogged

This. It can happen from sitting, I've switched over to Marine Stabil as the regular stuff isn't really formulated for gasohol, and it evaporates quick, leaving behind all kinds of nasty sticky stuff that looks for all the world just like varnish.

One way to help is to always turn the gas off and let the genny run until it sucks the carb dry, then there is less to evaporate. If you pull the float bowl you can usually use some brake cleaner or something to get the worst of it off, and then slap some seafoam around and then put it back together.

I've got way too much experience doing this with my pressure washer.

 

[locke_n_load]

Gonna try seafoam for 1-2 hours tonight, in a very strong concentration (half bottle to 1 gallon of gas).

This. It can happen from sitting, I've switched over to Marine Stabil as the regular stuff isn't really formulated for gasohol, and it evaporates quick, leaving behind all kinds of nasty sticky stuff that looks for all the world just like varnish.

One way to help is to always turn the gas off and let the genny run until it sucks the carb dry, then there is less to evaporate. If you pull the float bowl you can usually use some brake cleaner or something to get the worst of it off, and then slap some seafoam around and then put it back together.

I've got way too much experience doing this with my pressure washer.

I run it dry every time! Float bowl is just the half cylinder on bottom of carb? Take it off, clean everything I see? Am I going to need a gasket?


If I decide to disassemble the carb for cleaning, am I going to need gaskets? I imagine they are hard to find for Harbor Freight engines.
Is anything in there adjustable that I could screw up? I am mechanically inclined, but I have never cleaned a carb other than running carb cleaner through one while running.