Generator Hard to Pull Start? Check These 5 Things to Fix!

Published 2022-01-07
This video covers 5 common reasons that a generator might be hard to pull start.

Video on how to fix a recoil start assembly:    • How to Fix a Recoil Start Assembly an...  

The most common reason a generator is hard to pull start is hydrolock, which is where liquid gas or oil is sitting on top of the piston and cannot be compressed when you try to pull the cord.

Removing the spark plug, pulling the cord a few times, and replacing the spark plug should clear this problem up.

As a general rule, a generator will be hard to pull start due to hydrolock in the cylinder, a malfunctioning recoil start assembly, a damaged flywheel or flywheel keys, the piston is seized, or the compression release is broken.

All Comments (21)
  • 100% best Generater.Systems I have used. A test for hurricane prep here in Louisiana: three AC units, 5000, 5000 & 8000, 3 fridges, 2 device power setups, 4 flat screens....AND I had 40% of the power meter to spare.
  • WOW!! Your intelligence is very attractive, and your video helped start my generator when I thought there wasn't any chance of it ever starting again....Thanks
  • @VTchalk
    Thanks for the video. Your hydrolock diagnosis and tip quickly solved what I thought was a big problem.
  • @brentablett7845
    Great video. For the possibly partially seized cylinder (corroded) I have found putting in a little oil as suggested and then using a screwdriver in the pull start slotted cup (remove recall starter), I could work that gently round clockwise + counter until it became more free. Once free-ed up sufficiently it was easy to start. You are right that once started that oil with produce some smoke for a short time!
  • Thank you so very much all very well worded. Definitely had hydralock. All fixed now
  • @hilham89
    Alright, so I have an almost new westinghouse generator that I usually turn the gas off and let the gas run out to kill the generator not leaving any gas set besides the tank. While doing this one day I had a backfire and every since it's been hard to pull start it. Figured gas might be leaking into it even though I had the gas turned off so I pulled the plug and gave it a few pulls in case but when I put the spark plug back in it when straight back to hard pull. This generator can't have but maybe 20 hours if that. I use it just about every weekend since I got it for a hour sometimes maybe 5 hours at the most. To run my camper just until I get my power plug put in. Any ideas?
  • @JoshMiller-lg8mx
    Thanks learn something everyday would over never figured out hydrolock
  • @Anpk24
    Thank you so much for explaining the remedies to starting issues. I have a Duramax 4000 generator from 2019 with a 208CC engine that starts so much easier than my auger with a 52CC engine. Is there a better recoil starter in the generator? Will I be able to replace the older recoil on the auger with an easy start recoil?
  • @gregoryjones9454
    Thanks I had a hydro lock for some reason I have to turn off my fuel it keeps dripping idk
  • I recently acquired six generators for free. Three of them are now operating properly and I only put a total of $1.99 for parts. One of them I have not finished the diagnosis yet but two identical duromax xp13000eh units were both impossible to pull start and even the electric starter was not able to turn the engine with a fully charged battery and jumper cables attached from my pickup truck. Only tried that with one of the POS duromax generators. Then I removed the cylinder head and found that the exhaust valve broke and ended up in the piston sideways. Then took the cylinder head off the second durocrap and found the same thing. I'm happy they were both free lol. After attempting to contact the manufacturer by email to get replacement parts, never got a response. I have found a suitable replacement valve that is for an automotive engine and am going to attempt to repair the hole in the piston with an oxyacetylene torch and some aluminum stick welding rod. If it works out, that would be cool as whale shit. If not, I don't really have much to lose other than some time. Either way it should be a good learning experience. So the point is that a broken valve jammed into the piston could be another reason why a generator would not pull start, and in my opinion, duromax generators are fucking junk. The strange thing is that one of the duromax engines looked like it had many many hours of run time, but the other one looked as if it was almost brand new. For a company that touts how great their products are and how they are so proud of them being engineered and supposedly manufactured in the USA, I find that extremely difficult to believe. Looks like some Chinese junk to me. From the lack of response to my email and no availability of parts that I could find online I am certainly glad that I am not the original purchaser of those generators and hope that the people who did pay money for those were refunded or supplied new products from a different manufacturer.
  • @waltzb7548
    Thank you for this video. I have a pulsar 6500 dual fuel which is a few years old with under 50 hours on it. Few weeks ago had a hard pull couldn't get the flywheel to move without coaxing it as soon as I got a turn it started right up. Same thing just happened again after a few weeks. Would appreciate any thoughts or advice. Thank you again!
  • I have a eu3000is that is very hard to tryband pull the recoil even with the plug removed. The valves are moving fine and the piston isn't seized.. it ran great a few months ago when I serviced it for the customer but he said it started smoking and then quit. They had put too much oil in it and the gas is bad but even after changing the oil and removing the spark plug it is still way too hard to pull start and the electric starter can baring turn it over
  • @hawkhawk5072
    Some times a small mouse makes a nest in the exhaust muffler which also can cause a hard start