Champion 458cc Engine Rebuild - Duel Fuel Generator

I recently swapped a Honda GX390 engine onto this Champion generator after the original engine dropped a valve destroying the engine after just over a year from new. Although the Honda runs well, it has limited horse power an not able to pull the 8000 rated watts that this generator is rated at. It was the best option at the time since I could not locate all the parts needed to rebuild the original engine. Today I am going to change that. A Champion dealer reached out and helped me secure the parts needed. In last weeks video I started the rebuild after the Powermate generator I was working on ended up being a quick fix. This week we will finish the build and restore the generator to full power.

If you missed last weeks video here is a link. The champion rebuild started at 15:50 mark. Here is the link:    • Like New 80s Powermate Found in Garage  

Champion Rebuild Video Series:
Champion Generator Engine Locked Up After 1 Year - Fixed (part 1):    • Champion Generator Engine Locked Up A...  
Like New 80s Powermate Found in Garage part 2):    • Like New 80s Powermate Found in Garage  
Champion Duel Fuel Generator Engine Rebuild (part 3): (this video)

Generator Model: 201035
Engine (458cc): R460N-VP

Torque Specs:
Connecting Rod: 156 in-lbs
Crankcase: 204 in-lbs
Head: 29 ft-lbs
Flywheel Nut: 85 ft-lbs
Muffler: 216 in-lbs

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13010-Z6B0210-00A0 Connecting Rod Assembly
13121-Z100110-00A0 Pin, Piston
13122-Z100110-0000 Circlip Ø21 × Ø1
13111-Z6B0210-00A0 Piston
13200-Z0J0110-00A0 Rings
12140-Z6B0210-0BA0 Head
12121-Z6B0110-0000 Exhaust Valve
12111-Z0D0210-0000 Intake Valve
12131-Z6B0110-00A0 Head Gasket
12109-Z0D0110-00A0 Keepers (Valve Lock Clamp)

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I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors. Recently I have been using Simple Green PRO HD with good results.

#GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo

389cc, 420cc, 458cc, Alternator, Assembly, Break-in, Breakin, Champion, Connecting Rod, Conrod, Dual Fuel, End Gap. Engine Rebuilt, Engine Test, Fixed, GX390, Generator Engine, Generator Installation, Generator, Governor Droop, Governor Reset, Head Bolts, Hertz, Honda Clone, Hone Cylinder, How To, How-To, Ignition Coil, Keepers, Load Test, Metal in Oil, Metallic Oil, New Rings, Piston, Poor Governor Response, Power Quality, Propane, Push Rod, Repair, Slow Engine Speed, Small Engine, THD, Troubleshooting, Valve Clearance

00:00 Introduction
01:39 Block Cleanup and Prep
03:40 The Piston and Rings
11:11 The Crankshaft
12:59 Counterbalance Weight and Camshaft
16:04 Closing Up the Bottom End
17:10 New Valve Stem Seal
21:30 Bolting the Head Down
26:34 Valve Clearance
30:34 Flywheel
32:09 Don't Forget the Oil
33:56 Ignition
35:16 Cooling
36:09 The Carburetor
38:56 Test Stand Mounting
39:50 Wiring and Starter Test
41:45 Exhaust
42:07 First Start
44:49 Rebuild Complete
45:32 Removing Engine From Test Frame
46:32 Removing Honda Engine From the Champion Generator
54:26 Back to Full Power
1:06:04 Smoke Test
1:08:31 Engine Break-In Round 1
1:11:35 Engine Break-In Round 2
1:14:24 Engine Break-In Round 3
1:18:20 Excessive Governor Droop
1:22:55 Governor Sensitivity
1:26:11 Load Test - Gasoline (Petrol)
1:30:29 Load Test - Propane
1:35:08 Conclusion