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Not sure of the extent of the damage to the muffler but pretty sure it is toast. I'll pull it off after it has cooled down. How do I go about diagnosing this engine? Should I start it up without the muffler and see if any oil is coming out? The exhaust was only black when it was buckling...

Thanks. That muffler looks pretty used. I'd hate to get another restricted one. Let me know if you find that guy's number. Thanks. Is it possible for a motor running properly to wetstack this bad or is it likely I have an excess fuel issue?

Well the good news is I think I figured out the problem. Bad news is I almost burned my truck and house down. Muffler caught on fire and generator was in my truck bed. I was running a 2.7kw load with the governor set to full throttle. It was holding the load but more smoke than I wanted...

I installed a new fuel filter and changed oil to 10w30 and same problem. At 2.7kw it bogs down, blows black smoke and eventually trips the breaker. The only other piece of information I can add is that after I filled it with oil yesterday I couldn't get it to turn over. It would try to crank...

I'm guessing it has to be related to not being able to crank it. How hard is it to replace a broken piston ring? I have no experience overhauling engines but I'm a quick learn.

I installed a new fuel filter and changed oil to 10w30 and same problem. At 2.7kw it bogs down, blows black smoke and eventually trips the breaker. The only other piece of information I can add is that after I filled it with oil yesterday I couldn't get it to turn over. It would try to crank...

OK. Going to get a fuel filter and if that doesn't work I'll switch to 10W30 that Yanmar recommends for this engine. Chris I'm a big fan of the Rotella T synthetic and if I end up keeping this genset that's what I will use.

OK I have cracked the injector nuts while running. Both on top of the engine and on the front side where the hard fuel line goes into the engine. Diesel came squirting out so I'm pretty sure I don't have air in the lines. I changed the oil and made sure I had exactly 38.4 ounces. Also...

That would make sense since I ran the fuel pump some after I drained the fuel. What is the best way to bleed the fuel system. I'm not too sure my neighbors are happy with me running it for hours blowing smoke.

Yesterday my 831a was running fine at 110% even though it was blowing more white smoke than I would like. I drained oil and the fuel that was in it. Today I put in Rotella 15W40 and fresh diesel. Now I can't get it to run past 2.5 kw. It bogs down and blows black smoke. The only thing I...

Indy does the plastic return line tee screw into the top of the motor or does it connect to something that comes out of the motor? I won't be able to look at my genset for a few days. Also if I try to put a cut in the hose to make it easier to remove I guess I risk damaging one of the tees...

Thanks. I assume if I break a plastic tee then the lid has to come off. I think I read that the plastic tees are the same as sprinkler tees.

Thanks Indy. I just bought three feet of return line in Ebay. Did you slice the lines with a razor blade to get them off or just work them off with needle nose?

I picked up an MEP-831a today that I won on GL. It had the military 24v battery and it's in great shape. The genset had a full tank of fuel but the oil was partially drained. Go figure. Added some oil and it fired right up. I've changed the oil three times because there appeared to be water...

Thanks for the responses guys. I had a chance to look at my 803a today and indeed the return line on top of the motor is leaking. Seems like it is just oozing out of the fabric covered line between two of the nipples. How fragile are the return line nipples on top of the motor? I tried to...

Got the 803a I won fired up today. It runs great but it is weeping fuel around the head. I was only able to get it up to 60% with the heat guns and lights I had available. Going to use some space heaters to get it to 100% I have attached a photo of the fuel weeping. Is this likely to...

Got my wellnut installed today in my 803a. No leaks so far. Thanks for the all the great info!

Thanks. I will use the gas rated threaded tape on the wellnut threads. I'm fixing the drain line so no worry of it getting in the injectors.

Thanks but the military instructions he attached say the threads of the "straight adapter" should be coated with "sealing compound".

Thanks. Any recommendation on sealant for the threads? I'm having trouble finding Permatex with PTFE locally.