Generac Power Systems 2500 Diagnostic Repair Manual page 25

3. Set DMM to measure resistance.
4. Connect one meter test lead to the previously
disconnect wire coming from the oil level switch.
Connect the other meter test lead to frame ground.
INFINITY should be measured.
Results
A reading of CONTINUITY indicates that the switch is no
longer functioning and will need to be replaced.
Test 49 – Test Recoil Function
Procedure
Attempt to pull start the engine and make the following
observations while doing so.
•
Does the cord pull easily and smoothly?
•
Does the cord return with no assistance?
•
Does the engine turn over as the cord is pulled?
Results
If the recoil does not perform properly, possible problems
are:
•
The engine could be seized.
•
The recoil could be detached from the flywheel.
•
The recoil mechanism could be broken and not
properly retracting into the engine.
Test 49A – Replace a Recoil Starter
Rope
Tools Required
•
Safety glasses
•
New rope
•
Screwdriver
•
Locking pliers
Procedure
1. Remove the recoil starter from the engine. Look for
the knot where the old rope is secured. Some
ropes will have metal fitted on the end.
2. Pull the old rope all the way out of the recoil starter.
3. Prevent the rope sheave from rewinding. If the
sheave has a hole in it, insert a pin or nail through it
and lock it to the housing. No hole present, then
use a pair of locking pliers, but be careful not to
damage the sheave.
4. Obtain 6 feet (1.82 m) of rope that matches the
diameter of the existing rope. Braided nylon is a
durable choice with a lower risk of fraying.
5. Run the rope through the guided hole in the
housing into the sheave and through the knot hole.
Tie off. Tie handle to the other end.
Diagnostic Repair Manual
Section 2 Engine Troubleshooting
6. There is a coiled spring under the recoil assembly.
Turn the recoil assembly clockwise seven or eight
times. Stop when it feels tight, then back off to line
the rope up with the holes. On some housings
there are arrows cast into the recoil starter that
align with marks on the rope sheave.
7. Adjust the handle length for a comfortable pull.
Tips and Warnings
WARNING
Vision loss. Eye protection is required when
servicing unit. Failure to do so could result in
vision loss or serious injury.
Safety glasses must be worn and can reduce the risk of
eye damage. Use a screwdriver to hold the coiled spring
in place.
Test 50 – Test Engine Function
Procedure
1. Remove the recoil and front cover assembly.
2. Remove the spark plug from the unit.
3. Remove the pump assembly from the engine.
Refer to Section 4 Disassembly.
4. Attempt to turn the engine over by hand.
Results
1. If the engine can not turn over freely with the spark
plug and pump assembly removed, the engine has
suffered some type of internal failure that has
seized it and is inhibiting it from running.
2. Refer back to flow chart.
Test 51 – Verify Engine Running at
Rated Speed at No Load
Procedure
1. Turn on the water to the pump.
NOTE: Water must be hooked up to the pump and
turned on. DO NOT pull trigger on pressure washer
wand, this will engage pump and this will come up with a
false reading.
2. Start the engine and pull the throttle to the high
"rabbit" position.
3. See Figure 2-25. Place the sirometer firmly
against the crankcase of the engine.
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