Engine Will Not Run or Stops (Inverter Generators)

The information contained in our websites and in our videos are designed for assisting trained Repair Professionals as a guide only and does not replace professional training. By using our information you are agreeing to our T&Cs  and acknowledge that the advice given is a general guide.

This article is designed for Inverter Generators only. Please see our Repair Advice section for other types.

 

If your Engine will turn a full revolution by hand with no obstruction, please follow these tips. If there is an obstruction and the engine will not turn over with a sufficient amount of effort, please contact us.

 

Firstly, check whether you have a spark: Remove the spark plug from the engine and re-attach it to the Ignition HT Lead. Hold the end of the spark plug tip to a metal section of the engine, and turn over or crank the engine (you might need a friend to help you if your generator does not have electric start). If all is working correctly, you should see a strong spark, and the engine should run smoothly. If you do not have a spark, please continue below, if you do, please skip to Fuel System.

 

The “Ignition Controller" (sometimes called a CDI) provides fault warnings via the 3 lights on the control panel, and will determine if ignition should take place and if the inverter is functioning correctly. When you try to start the generator, take note of which of the lights illuminates. 

Low Oil Warning light comes on:

Check the oil level. Fill to the indicated point, not beyond. If the oil is at the correct level but the engine still won't start, disconnect the oil sensor wire (this can usually be found protruding from the base of the engine and has a 2-pin connector block to disconnect) and start the engine. If you now have a spark then you need to replace your “Ignition Controller CDI”.

If you still do not have a spark, then you need to test your "Ignition Coil" and "Spark Plug". Please contact us

Fuel System:

If you have a spark, then you need to work through your fuel system. 

Replace fuel with fresh fuel and check the tank does not contain any debris or rust, as this will eventually enter the cylinder head and begin to cause damage. Drain some fuel into a glass and inspect it for particles and/or (a small layer of) water. Replace rusted Fuel Tanks as soon as possible as the contaminants will damage your engine. Replace all the fuel (and flush the tank by swilling with a small quantity of fresh fuel) if you find water or contaminants.

Check if the fuel is getting to the head by checking if the spark plug is wet after cranking the engine. If the spark plug is dry: 

• If your unit has a Pump, check it is working correctly.
• Remove the Carburetor. Clean, replace and try starting the generator. 
• Rebuild it with a Carburetor Repair Kit (if available for your model).
• If this does not fix the problem you will need to replace the Carburetor. The high Ethanol content of fuel these days can eat away the Carburetor housing and turn into a "varnish" that blocks the internals of the fuel system.
• Check the Float Needle is moving freely (See video below).

Service the Generator. This should fix most running problems, you should service your generator regularly - as instructed in your manual. Change the oil, all filters and inspect the air filter closely. The foam of the filters has a tendency to break up and get pulled into the head. To give you an idea of how important regular servicing is, the standard is to service every year, or every 500 hours, whichever comes first. Full-Service Kits are available for most Generators.

If you have removed the Carburetor, or adjusted the settings on the Carburetor, then there are a few more things you need to check:

A) Be sure the Air Mixture Screw is set correctly. The air mixture screw is brass, with a spring behind it, on the side of the Carburetor. On the vast majority of modern units, it is usually set to "1.5 turns back from tight." but take note of the setting before changing incase the setting for your engine is different.

B) Check the Carburetor Gaskets are not pinched or split. This will also affect the Air/Fuel mixture. Replace if necessary. We sell these separately from the full Gasket Kits where possible. Look up "Carburetor Gaskets" on our parts system to see if we do it for your engine.

C) Check the Float Needle inside the Carburetor Bowl is moving freely.

Suitcase Inverter Generators do not have a gravity-fed fuel system due to the need to be compact. This means that fuel takes a more complicated route from the petcock to the fuel pump, then to the carburetor with the possible addition of a Primer Bulb Assembly after the fuel pymp. If none of the steps above have solved your issue, you need to work backwards through the fuel system from the carburettor to pinpoint the fault.

Ie, check whether fuel is reaching the carb by loosening the drain bolt, if fuel is not reaching the carb, check whether it is leaving the fuel pump, if not, check whether it is leaving the petcock and reaching the pump etc.

If you need any Parts we sell them on our website.

If you need any further assistance our Engineers are happy to help! Click here to open a support ticket with them.

Did you know...

We spend 1000's of hours every year providing Free Repair Advice. As you can imagine, this does not pay the bills! If you would like to buy us a coffee or leave us a review to say thanks, it will help us continue to be there for you in the future. And...  we would really appreciate it!