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I don't have a clue what is making it sound the way it does so that is the plan. Run it till something breaks and then fix it.

Back together and load tested! Runs fine, but with a slight note to the exhaust that doesn't sound normal. Almost sounds like a baffle going in the muffler, but muffler is brand new. I had 11k on it to load test it and when I disconnected to load it made a slight sound almost like a little...

Guy I will back that mag pickup off just a touch then

This was sitting on the ground. I have ran a dozen other 803s in the same location. If it was the first one I had worked on I may have thought it was normal, but after working on a bunch you get a feel for what is right. It is right next to a ground rod I have for testing purposes so I know it...

Got it back together! I ended up pulling the rotor and flywheel again. I couldn't find anything that would make it off, but after reinstalling it I didn't find any runout like I did before. I adjusted the mag pickup to 3.16 volts. It has to be only 1/4 to 1/2 turn out to achieve that. I may take...

Sensor shows a little wear on the end. It's been rubbing while running I'd say. Only 14 hours on this. Sensor did work because starter disengaged and it produced voltage. Condition matches hour meter. Pulls 11k load and all exhaust shows it was all firing

Also, I have some corrosion in the exciter and stator. Minor, but should it be cleaned off? If so, how, without damaging either?

Ok reading on how easy it was to open these gen head up I went ahead and did it this morning. It helped that way have a ton of snow so no work today. I took the stator off. I slid it on blocks then picked it up by hand and set it aside as my cherry picker was buried in another building with...

I figured the throttle cable would go. The whole governor is not right anyway so I want to start over with that and get it adjusted properly. It seems to run right how they have it rigged, how it does I have no idea. This might be a project that takes a month given the amount of time I have...

Any tips on taking the stator off without damage? Looks like the TM says it can come out the back with the load panel and two doors removed. How do you slide the stator off without making contact on the rotor? Supporting the engine will be easy enough with a couple blocks.

Autopsy of the gauge shows burn mark on the rear of face. No other sign of arcing or burn marks.

If I'm reading the -24TM right it looks like the whole generator end needs to come out to rotate the rotor? Any way to just spin it without complete removal? Also, how do you stop the rotor from contacting the stator and damaging one or both? I've not had to open any up this far yet. I still...

The way this thing vibrates I'm surprised not more stuff came loose. Hz changed even with it locked down. With it sitting in a limestone driveway I feel it running in about a 5 foot circle around it.

Now why didn't I think of measuring the voltage at the back of the meter?? It went down to zero when shut off. Maybe the vibration in this thing knocked something loose. Spinning the rotor sounds like a complete PITA. But that will need to be done to attempt to make this unit right. I haven't...

I have one extra gauge on a parts unit. I don't want to install it and fry it as well though. Freak thing? Chance of frying a new one? I could see if something arced inside and killed it completely. Is there something inside that would let go and show half voltage? I guess I will be tearing that...

Just saw it out of the corner of my eye. I was watching load as I flipped breaker to load the unit. I think it was from the gauge but not 100% sure. I had it running with just a halogen light on it a week and a half ago and it worked fine then.

I was looking that up at the shop this afternoon but ran out of time to actually do anything with it. I can't figure out why someone monkeyed with it so badly, and how it runs in spec with it being so far off.

Ok I guess I'm not clear on how to attach a video! It does work if you open it though