Service parts for the GP5500
Grouped by system, with how many of each the parts manual calls for.
Oil system
1 requiredIgnition
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
| Fuel | gasoline |
|---|---|
| Frequency | 60.0 Hz |
| Prime power | 5.5 kW |
| Emissions | 49-State |
| Oil capacity | 1.1 L |
| Voltage options | 120/240 V |
| Rated current | 45.8 A |
| Circuit breaker | 20/25 A |
| Dimensions (L×W×H) | 692×687×638 mm |
| Dry weight | 81 kg |
| Fuel tank | 27.3 L |
| Tank runtime | 10 hr |
Maintenance & consumables
for the Generac OHV| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | 2-stage (paper, foam element) | — | 200 hr | ||
| Fuel filter | In-line fuel filter | — | |||
| Oil filter | Spin on full flow vertically mounted | — | |||
| Oil | 5W30 | 1.5 quart | 0J00620106 | 100 hr | Amazon eBay $35.00 NAPA $2.82 FridayParts $32.07 |
| Spark plug | Champion RC14YC; gap 0.030" (0.76mm) | 0J00620106 | Amazon eBay $35.00 NAPA $2.82 FridayParts $32.07 |
Service intervals
1| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Engine oil | Change | 100 hr | First service — every 100 hours of run time thereafter |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Flywheel magnet attraction distance (screwdriver test) | 3/4 (19mm) | inch | |
| Gap | Spark plug gap (GP1800/GP3250/GP5000/GP5500/GP6500) | 0.028"-0.031" (0.7-0.8mm) | inch | |
| Gap | Spark plug gap (GP7000/GP8000) | 0.030" (0.76mm) | inch | |
| Other | 1.5 Amp fuse rating | 1.5 | Amp | |
| Other | AC output load test - frequency should not drop below | 59 | Hertz | load applied |
| Other | Capacitor rating - Alternator Configuration A | 47 | µf (440 VAC) | |
| Other | Capacitor rating - Alternator Configuration B | 28 | µf | |
| Other | Capacitor test tolerance | ± 5 | µf | |
| Other | Cylinder leak down - normally acceptable leakage | 20 | percent | |
| Other | Nominal amp draw of starter in generator | 60 | amps | |
| Other | Product Dimensions | 14.5 x 11.5 x 3.5 | in (368 x 292 x 89 mm) | |
| Other | Product Dimensions | 18 x 18 x 4 | in (457 x 457 x 102 mm) | |
| Other | Product Dimensions | 9 x 6 x 5 | in (229 x 152 x 127 mm) | |
| Other | Product Weight | 23 | lbs (10.5 kg) | |
| Other | Product Weight | 24 | lbs (11 kg) | |
| Other | Product Weight | 26 | lbs (11.75 kg) | |
| Other | Product Weight | 5 | lbs (2.25 kg) | |
| Other | Starter motor maximum amps | 50 | Amps | performance test |
| Pressure | Cylinder leak down - minimum air source | 90 | psi | |
| Pressure | Cylinder leak down - regulated test pressure | 80 | psi | |
| Pressure | Engine oil pressure - shut down threshold | below about 10 | psi | engine running |
| Pressure | Minimum allowable compression pressure | 60 | psi | cold engine |
| Pressure | Normal engine oil pressure | 35-40 | psi | engine running |
| Pressure | Oil pressure switch rating | 10 | psi | single cylinder engines |
| Resistance | Brushless DPE winding resistance (Wire 2 to Wire 6) | 0.97 and 1.13 | Ohms | |
| Resistance | Brushless stator winding resistance (11-22, 33-44) | 0.12-0.14 | Ohms | |
| Resistance | Exciter Windings - GP1800 (alt 0H8255/0J0819) | 2.53 | Ohms | |
| Resistance | Exciter Windings - GP3250 (alt 0H2626/0H3578) | 1.72 | Ohms | |
| Resistance | Exciter Windings - GP5500/GP/LP5500 (alt 0G9769/0J8363) | 2.81 | Ohms | |
| Resistance | Exciter Windings - GP6500E (alt 0H9920/0K1291) | 2.9 ± 10% | Ohms | |
| Resistance | Exciter Windings - GP7500E DF-CO (alt A0001920613/A0000121536) | 1.928 | Ohms | |
| Resistance | Exciter Windings - GP8000E COSTCO (alt 0J8438/0K9791) | 1.626 | Ohms | |
| Resistance | Exciter Windings - LP3250 (alt 0J2561/0J6032) | 2 | Ohms | |
| Resistance | Power Windings - GP1800 (alt 0H8255/0J0819) | 0.798 | Ohms | |
| Resistance | Power Windings - GP3250 (alt 0H2626/0H3578) | 0.62 | Ohms | |
| Resistance | Power Windings - GP5500/GP/LP5500 (alt 0G9769/0J8363) | 0.681 | Ohms | |
| Resistance | Power Windings - GP6500E (alt 0H9920/0K1291) | 0.6 ± 10% | Ohms | |
| Resistance | Power Windings - GP7500E (alt 0J1927/0K8981) | 1.62 | Ohms | |
| Resistance | Power Windings - GP7500E DF-CO (alt A0001920613/A0000121536) | 0.491 | Ohms | |
| Resistance | Power Windings - GP8000E COSTCO (alt 0J8438/0K9791) | 0.471 | Ohms | |
| Resistance | Power Windings - LP3250 (alt 0J2561/0J6032) | 0.63 | Ohms | |
| Resistance | Receptacle panel / stator winding continuity | 0.01 and 0.02 | Ohms | |
| Resistance | Rotor Windings - GP1800 (alt 0H8255/0J0819) | 29.4 | Ohms | |
| Resistance | Rotor Windings - GP3250 (alt 0H2626/0H3578) | 31 | Ohms | |
| Resistance | Rotor Windings - GP5500/GP/LP5500 (alt 0G9769/0J8363) | 61.48 | Ohms | |
| Resistance | Rotor Windings - GP6500E (alt 0H9920/0K1291) | 69 ± 10% | Ohms | |
| Resistance | Rotor Windings - GP7500E (alt 0J1927/0K8981) | 58.8 | Ohms | |
| Resistance | Rotor Windings - GP7500E DF-CO (alt A0001920613/A0000121536) | 52.42 | Ohms | |
| Resistance | Rotor Windings - GP8000E COSTCO (alt 0J8438/0K9791) | 52.17 | Ohms | |
| Resistance | Rotor Windings - LP3250 (alt 0J2561/0J6032) | 58 | Ohms | |
| Speed | Acceptable running limits (389/206/163cc) | 59-61 | Hertz | running |
| Speed | Acceptable running limits (410cc) | 59-62 | Hertz | running |
| Speed | Load frequency limit (minimum) | 59 | Hertz | rated load applied |
| Speed | Minimum engine cranking speed for spark test | 350 | rpm | cranking |
| Speed | No-load AC frequency | 62.0-62.5 | hertz | running adjustment, no-load |
| Speed | No-load AC frequency | 62.5 – 62.0 | HZ | no-load |
| Speed | No-load frequency (389/206/163cc governor adjust) | 62.0 - 62.5 | hertz | no-load |
| Speed | No-load frequency (410cc governor adjust) | 62.5 | Hz | no-load |
| Speed | Starter motor minimum rpm | 4500 | rpm | performance test |
| Torque | Governor Lever Clamp Bolt | 110 | in-lbs (12.4 Nm) |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Engine oil | 10W-30 | Oil will need to be purchased separately based upon the recommendations listed. | |||
| Engine oil | 5W30 | 0.6 liter | GP1800/GP3250 oil capacity 0.634 quart (0.6 liter) | ||
| Engine oil | SAE 30 | Oil will need to be purchased separately based upon the recommendations listed. | |||
| Engine oil | Synthetic 5W-30 | Oil will need to be purchased separately based upon the recommendations listed. | |||
| Engine oil | synthetic 5W-30 | Below 10°F | |||
| Fuel | gasoline | fresh, clean gasoline | Shelf life on gasoline is 30 days; a fuel stabilizer must be used at all times | ||
| Fuel | unleaded gasoline, minimum 85 octane | Do not use any gasoline with more than 10% added ethanol. Never use E85. Do not mix oil with gasoline. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
1| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| Red Short Flash | CO Module - Red Short Flash | Elevated level of CO in the area; module is functioning properly and protecting operators | Shutdown | Generator shuts down; module is functioning as intended |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Test 12 – Adjust Voltage Regulator adjustment
⚠ Ensure all material is clear of the alternator before proceeding.
Tools: VOM
- Remove cover from end of alternator assembly.
- Remove two screws holding down the voltage regulator (AVR).
- Leave AVR connected to stator and brushes.
- Set VOM to measure AC voltage.
- Connect VOM across a 240VAC socket.
- Set START-STOP-RUN switch to START.
- Turn adjustment screw clockwise to increase voltage, counterclockwise to lower.
Test 20 - Check Spark Plugs / Test 23 - Check Valve Adjustment adjustment
Tools: feeler gauge, crow foot wrench
- Adjust valve clearance with engine at room temperature
- Position piston at TDC of compression stroke (both valves closed), or set intake/exhaust valve fully open method
- Loosen rocker arm jam nut; turn pivot ball stud while checking clearance with a feeler gauge
- When clearance is correct, hold pivot ball stud and tighten rocker arm jam nut to specified torque with a crow foot wrench
- Recheck valve clearance to make sure it did not change
- Install rocker arm cover with a new gasket
Test 27 - Check / Adjust Governor adjustment
Tools: AC frequency meter
- Loosen governor clamp bolt
- Hold governor lever at wide open throttle position
- Rotate governor shaft counterclockwise (389/208/196cc) or clockwise (410cc) as far as it will go
- Tighten governor lever clamp bolt to 110 in-lbs (389/208/196cc) or 70 in-lbs (410cc)
- Turn speed adjustment screw counterclockwise three full turns to avoid overspeed
- Start engine and let warm up under no-load
- Connect AC frequency meter; no-load frequency should be 62.0-62.5 hertz
- Turn speed adjust screw until frequency/RPM is within limits
- Apply removable Loctite (Loctite 241) to speed adjust screw threads
Test 33 – Check Valve Adjustment adjustment
⚠ Use a new rocker arm cover gasket.
Tools: feeler gauge, allen wrench, crow's foot
- Adjust valve clearance with engine at room temperature.
- Position piston at TDC of compression stroke (both valves closed).
- Loosen the rocker arm jam nut.
- Turn pivot ball stud while checking clearance with a feeler gauge.
- Hold stud with allen wrench and tighten jam nut to specified torque with a crow's foot.
- Recheck valve clearance after tightening.
Test 40 – Check / Adjust Governor (389/206/163cc Engines) adjustment
⚠ Do not apply excessive torque to the governor shaft.
Tools: frequency meter
- Loosen the governor lever clamp bolt.
- Hold governor lever at full INC RPM; rotate governor shaft counterclockwise fully.
- Tighten governor lever clamp bolt to 110 inch-pounds.
- Turn speed adjustment screw counterclockwise three full turns.
- Start engine and let it warm up and stabilize at no-load.
- Connect frequency meter; set no-load frequency 62.0-62.5 hertz.
- Add a drop of Loctite 241 to the speed adjust screw threads.
Test 41 – Check / Adjust Governor (410cc Engine) adjustment
Tools: frequency meter
- Loosen the governor clamp bolt.
- Hold governor lever at wide open throttle; rotate governor shaft clockwise fully.
- Tighten governor lever clamp bolt to 70 inch-pounds (8 Nm).
- Start generator; let it stabilize and warm up at no-load.
- Connect frequency meter across generator AC output leads.
- Turn the primary adjust screw to obtain a frequency of 62.5 Hz.
Test 1 – Check No-Load Voltage and Frequency diagnostic
Tools: VOM, AC frequency meter
- Disconnect or turn OFF all electrical loads connected to the generator.
- Set a VOM to measure AC voltage.
- Reset all circuit breakers to the ON position.
- Start engine and let it stabilize and warm up.
- Place meter test leads into an outlet.
- Read AC voltage; connect frequency meter and read frequency.
Test 23 – Check Start-Run-Stop Switch diagnostic
Tools: voltmeter (resistance)
- Set a voltmeter to measure resistance.
- Remove all wires from the START-RUN-STOP Switch.
- Check terminal 2 to 1: CONTINUITY in START, INFINITY in STOP.
- Check terminal 2 to 3: CONTINUITY in STOP, INFINITY in START.
- Reconnect all wires to the switch.
Test 25 – Testing Starter Motor Performance diagnostic
⚠ DO NOT rotate engine with electric starter with spark plugs removed.
Tools: clamp-on ammeter, tachometer P/N 042223, 12 volt battery, starter test bracket
- Remove starter motor and assemble to test bracket; clamp in vise.
- Connect a fully charged 12 volt battery and clamp-on ammeter.
- Activate the starter (jump terminal on Starter Contactor).
- Note reading on clamp-on ammeter and tachometer.
- Take readings after ammeter and tachometer stabilize (2-4 seconds).
Test 36 – Cylinder Leak Down / Compression Test diagnostic
Tools: cylinder leak down tester, compression gauge
- Remove the spark plug.
- Gain access to the flywheel and remove the valve cover.
- Rotate crankshaft until piston reaches TDC (both valves closed).
- Lock the flywheel at top dead center.
- Attach leak down tester adapter to spark plug hole.
- Connect an air source of at least 90 psi.
- Adjust regulated pressure to 80 psi.
- Read right hand gauge; 20 percent leakage is normally acceptable.
Test 41 - CO Module Verification Test diagnostic
⚠ Do NOT insert the drill bit into the LED holes; damage to the LEDs will occur
Tools: 3/64 inch drill bit
- Do not install CO badging (decal) prior to performing this test
- Run generator under normal operation with no CO module notifications for a minimum of 65 seconds
- With generator running, insert blunt end of a 3/64 inch drill bit into test switch hole
- Hold the drill bit against the mounting panel until notification LEDs appear and generator shuts off
- Successful pin test shows both LEDs on solid (not blinking)
Test 49 – Test Recoil Function diagnostic
- Attempt to pull start the engine and observe.
- Check whether the cord pulls easily and smoothly.
- Check whether the cord returns with no assistance.
- Check whether the engine turns over as the cord is pulled.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 120/240 | Single | L14-30 (models 6852-6854) | 30 Amp inlet for 6852-6854; CS6377 inlet for 9854-9855 (50 Amp) |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
Which engine powers the Generac GP5500?
The Generac GP5500 is powered by the Generac OHV engine.
What fuel does the Generac GP5500 use?
The Generac GP5500 runs on gasoline.
What is the oil capacity of the Generac GP5500?
The Generac OHV engine in the Generac GP5500 has an oil capacity of 1.0 liters.
What is the dry weight of the Generac GP5500?
The Generac GP5500 has a dry weight of 81 kg (179 lb).
What size fuel tank does the Generac GP5500 have?
The Generac GP5500 has a 27.3 liter (7 US gallon) fuel tank, giving about 10 hours of runtime.
What voltages is the Generac GP5500 available in?
The Generac GP5500 is offered in 120/240 V.
Troubleshooting
119Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Generator produces zero voltage or residual voltage | Main circuit breaker tripped or bad | Reset to ON or replace if bad |
| Generator produces zero voltage or residual voltage | Receptacle panel continuity bad | Replace component as needed |
| Generator produces zero voltage or residual voltage | Alternator requires field flash | Field flash alternator |
| Generator produces zero voltage or residual voltage | Capacitor bad | Replace capacitor |
| Generator produces zero voltage or residual voltage | Brushless DPE winding bad | Replace alternator |
| Generator produces zero voltage or residual voltage | Brushless stator windings bad | Replace stator |
| Generator produces zero voltage or residual voltage | Stator shorted to ground | Replace stator |
| Voltage & frequency are both high or low | Engine governor out of adjustment (389cc engine) | Check & adjust engine governor, 389cc engine |
| Voltage & frequency are both high or low | Engine governor out of adjustment (410cc engine) | Check & adjust engine governor, 410cc engine |
| Voltage & frequency are both high or low | Capacitor bad | Replace capacitor |
| Voltage & frequency are both high or low | Alternator bad | Replace alternator |
| Excessive voltage/frequency droop when load is applied | Load voltage & frequency bad | Re-check voltage at receptacle panel |
| Excessive voltage/frequency droop when load is applied | Load watts & amperage overloaded | Reduce load |
| Excessive voltage/frequency droop when load is applied | Engine governor out of adjustment (389cc engine) | Check & adjust engine governor, 389cc engine |
| Excessive voltage/frequency droop when load is applied | Engine governor out of adjustment (410cc engine) | Check & adjust engine governor, 410cc engine |
| Generator produces high voltage at no-load | Frequency high | Check & adjust engine governor, 389cc engine; check & adjust engine governor, 410cc engine |
| Generator produces high voltage at no-load | Frequency O.K. but voltage high | Check capacitor; replace capacitor |
| Generator produces high voltage at no-load | Frequency O.K. but voltage still high | Replace alternator |
| Generator produces zero voltage or residual voltage (brushed excitation) | Main circuit breaker tripped or bad | Reset to ON or replace if bad |
| Generator produces zero voltage or residual voltage (brushed excitation) | Receptacle panel continuity bad | Replace component as needed |
| Generator produces zero voltage or residual voltage (brushed excitation) | Brushes bad | Replace brushes |
| Generator produces zero voltage or residual voltage (brushed excitation) | Automatic voltage regulator bad | Replace automatic voltage regulator |
| Generator produces zero voltage or residual voltage (brushed excitation) | Alternator bad | Replace alternator |
| Recoil cord will not pull | Obstruction causing binding of the recoil once installed | Visually inspect for obstructions that would cause binding of the recoil once installed; repair or replace |
| Recoil cord will not pull | Internal engine failure | Visually inspect external components for a failure that would cause the engine to be siezed; repair or replace |
| Engine starts hard and runs rough | Spark plug bad | Replace spark plug |
| Engine starts hard and runs rough | Low fuel | Replenish fuel supply |
| Engine starts hard and runs rough | Choke position and operation incorrect | Push in after starting |
| Engine starts hard and runs rough | Carburetion bad | Repair or replace as necessary |
| Engine starts hard and runs rough | Valve adjustment bad | Adjust valves and retest |
| Engine starts hard and runs rough | Flywheel key sheared | Replace flywheel key |
| Engine starts hard and runs rough | Engine/cylinder leak down or compression bad | Refer to engine service manual |
| Engine starts hard and runs rough | Governor out of adjustment | Check and adjust governor |
| Engine starts hard and runs rough | Flywheel bad | Replace flywheel |
| Engine starts hard and runs rough | Magneto bad | Replace magneto |
| Engine turns over but will not start | Fuel shutoff valve OFF | Turn ON |
| Engine turns over but will not start | Low fuel | Replenish fuel supply |
| Engine turns over but will not start | Spark plug bad | Replace spark plug |
| Engine turns over but will not start | No spark | Remove Wire 18 / shutdown lead; replace magneto |
| Engine turns over but will not start | Carburetion bad | Repair or replace as necessary |
| Engine turns over but will not start | Valve adjustment bad | Adjust valves and retest |
| Engine turns over but will not start | Flywheel key sheared | Replace flywheel key |
| Engine turns over but will not start | Engine/cylinder leak down or compression bad | Refer to engine service manual |
| Engine turns over but will not start | Oil level low | Replenish oil |
| Engine turns over but will not start | Oil level switch bad | Replace low oil alarm |
| Engine turns over but will not start | OFF-ON switch bad | Replace switch |
| Engine turns over but will not start | Flywheel bad | Replace flywheel |
| Engine "hunts" / erratic idle | Carburetion bad | Repair or replace |
| Engine "hunts" / erratic idle | Choke test bad | Repair or replace |
| Engine "hunts" / erratic idle | Spark plug bad | Replace |
| Engine "hunts" / erratic idle | Ignition spark bad | Replace magneto |
| Engine "hunts" / erratic idle | Flywheel bad | Replace |
| Engine "hunts" / erratic idle | Valve adjustment bad | Adjust / re-test |
| Engine "hunts" / erratic idle | Governor out of adjustment | Check and adjust governor |
| Engine will not crank | Battery or cables bad | Recharge or replace battery; clean, repair or replace bad cable(s) |
| Engine will not crank | Start-run-stop switch bad | Replace |
| Engine will not crank | No voltage measured at starter contactor | Replace |
| Engine will not crank | Starter motor defective | Replace starter motor if defective |
| Engine will not crank | Mechanical binding of the engine or rotor | Check for mechanical binding of the engine or rotor |
| Recoil cord will not pull (if so equipped) | Obstruction causing binding of the recoil once installed | Visually inspect for obstructions that would cause binding of the recoil once installed; repair or replace |
| Recoil cord will not pull (if so equipped) | Internal engine failure (possible compression release failure) | Visually inspect external components for a failure that would cause the engine to be siezed; consult engine service manual P/N 0C1103A for further engine service information |
| Engine cranks but will not start | Fuel shutoff valve OFF | Turn ON |
| Engine cranks but will not start | Low fuel | Replenish fuel supply |
| Engine cranks but will not start | Choke not pulled full out | Pull choke full out |
| Engine cranks but will not start | Start-run-stop switch bad | Replace |
| Engine cranks but will not start | Spark plug bad | Replace |
| Engine cranks but will not start | No spark | Remove Wire 18 / shutdown lead; replace magneto |
| Engine cranks but will not start | Carburetion bad | Repair or replace as necessary |
| Engine cranks but will not start | Valve adjustment bad | Adjust valves and retest |
| Engine cranks but will not start | Flywheel key sheared | Replace flywheel key |
| Engine cranks but will not start | Engine/cylinder leak down or compression bad | Refer to engine service manual P/N 0C1103A for further engine service information |
| Engine cranks but will not start | Flywheel bad | Replace |
| Engine starts hard and runs rough (410cc) | Spark plug bad | Replace spark plug |
| Engine starts hard and runs rough (410cc) | Low fuel | Replenish fuel supply |
| Engine starts hard and runs rough (410cc) | Choke position and operation incorrect | Push in after starting |
| Engine starts hard and runs rough (410cc) | Carburetion bad | Repair or replace as necessary |
| Engine starts hard and runs rough (410cc) | Valve adjustment bad | Adjust valves and retest |
| Engine starts hard and runs rough (410cc) | Flywheel key sheared | Replace flywheel key |
| Engine starts hard and runs rough (410cc) | Engine/cylinder leak down or compression bad | Refer to engine service manual P/N 0C1103A for further engine service information |
| Engine starts hard and runs rough (410cc) | Governor out of adjustment | Check and adjust governor |
| Engine starts hard and runs rough (410cc) | Flywheel bad | Replace |
| Engine starts hard and runs rough (410cc) | Magneto bad | Replace magneto |
| Engine starts then shuts down | Oil level low | Replenish oil |
| Engine starts then shuts down | Oil pressure switch bad | Replace oil pressure module |
| Engine starts then shuts down | Start-run-stop switch bad | Replace switch |
| Engine starts then shuts down | Flywheel bad | Replace |
| Engine starts then shuts down | Magneto bad | Replace magneto |
| Engine "hunts" / erratic idle (410cc) | Carburetion bad | Repair or replace |
| Engine "hunts" / erratic idle (410cc) | Choke test bad | Repair or replace |
| Engine "hunts" / erratic idle (410cc) | Spark plug bad | Replace |
| Engine "hunts" / erratic idle (410cc) | Ignition spark bad | Replace magneto |
| Engine "hunts" / erratic idle (410cc) | Flywheel bad | Replace |
| Engine "hunts" / erratic idle (410cc) | Valve adjustment bad | Adjust / re-test |
| Engine "hunts" / erratic idle (410cc) | Governor out of adjustment | Check and adjust governor |
| Battery will not charge | Battery charge socket connections bad | Check connections on battery charge socket |
| Battery will not charge | 1.5 amp fuse bad | Replace fuse |
| Battery will not charge | Battery charger bad | Replace battery charger |
| Engine starts hard or will not start | Physical damage to the AC generator; rotor contact with the stator | Check the rotor for contact with the stator |
| Engine starts hard or will not start | Starting under load | Make sure all loads are disconnected or turned off before attempting to crank and start the engine |
| Engine starts hard or will not start | Choke not working properly | Check that the choke is working properly |
| Engine surging | Carburetion problem; lean condition causing erratic RPM | Slowly pull the choke out to see if surging stops; if it does stop, carburetion should be checked |
| Engine runs rough, hard starting, lack of power | Improperly adjusted valves | Adjust valves to specification and retest; if problem continues, refer to flow chart |
| Compression loss | Air escapes at the carburetor | Check intake valve |
| Compression loss | Air escapes through the exhaust | Check exhaust valve |
| Compression loss | Air escapes through the breather | Check piston rings |
| Compression loss | Air escapes from the cylinder head | Replace the head gasket |
| Poor compression | Loose cylinder head bolts | |
| Poor compression | Failed cylinder head gasket | |
| Poor compression | Burned valves or valve seats | |
| Poor compression | Insufficient valve clearance | |
| Poor compression | Warped cylinder head | |
| Poor compression | Warped valve stem | |
| Poor compression | Worn or broken piston ring(s) | |
| Poor compression | Worn or damaged cylinder bore | |
| Poor compression | Broken connecting rod | |
| Poor compression | Worn valve seats or valves | |
| Poor compression | Worn valve guides | |
| Hard starting or failure to start | Flywheel key sheared or partially sheared, changing ignition timing | Check the flywheel key |
| No spark | Wire 18 has a short to ground | Trace Wire 18 back to the START-RUN-STOP switch and Oil Pressure Module (if so equipped) |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Repair guides
13- Determine what size generator you need
- Test 1 – Check No-Load Voltage and Frequency
- Test 12 – Adjust Voltage Regulator
- Test 23 – Check Start-Run-Stop Switch
- Test 25 – Testing Starter Motor Performance
- Test 33 – Check Valve Adjustment
- Test 36 – Cylinder Leak Down / Compression Test
- Test 4 – Field Flash Alternator (Configuration A Only)
- Test 40 – Check / Adjust Governor (389/206/163cc Engines)
- Test 41 – Check / Adjust Governor (410cc Engine)
- Test 49 – Test Recoil Function
- Test 50 – Test Engine Function
- Test 6 – Check Capacitor
Step-by-step procedures compiled from the Generac service manual for this model.
Parts
143| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 005819-0 | 26R Wet Cell Battery | Battery | Amazon eBay | |
| 048031B | CLAMP, HOSE, 09 | 4 | Clamp | Amazon eBay $2.89 |
| 070185B | OIL FILTER | 1 | Oil filter | Amazon eBay $26.99 NAPA $9.09 |
| 070264 | WASHER, FLAT, M10X4 | 1 | Washer | Amazon eBay |
| 073111 | FILTER, AIR | 1 | Air filter | Amazon eBay $16.95 |
| 0B1214 | BOLT, M8X45 | 5 | Bolt | Amazon eBay |
| 0D4968 | OUTLET 20A 120V DPLX | 2 | Outlet | Amazon eBay $22.45 |
| 0D4999 | PIN, COTTER | 2 | Pin | Amazon eBay $1.28 |
| 0E7585 | SPARK PLUG | 1 | Spark plug | Amazon eBay $12.77 NAPA $5.48 |
| 0E9470 | BOLT, M8X16 | 4 | Bolt | Amazon eBay $29.48 |
| 0E9507B | BOLT, M8X25 | 2 | Bolt | Amazon eBay $26.36 |
| 0E9507C | BOLT, M8X20 | 4 | Bolt | Amazon eBay $25.31 |
| 0G5442 | SnapButton | 1 | Button | Amazon eBay $29.48 |
| 0G8321 | METER, HOUR | 1 | Meter | Amazon eBay $24.99 |
| 0G8382 | SCREW, PAN, M5 X 16 | 8 | Bolt | Amazon eBay |
| 0G84420107 | NUT, M10 | 4 | Nut | Amazon eBay $25.16 |
| 0G84420194 | BOLT, M6X12 | 1 | Bolt | Amazon eBay $9.99 |
| 0G84420272 | NUT, M6 | 1 | Nut | Amazon eBay $24.78 |
| 0G8442C | ENGINE, 389cc | 1 | Engine | Amazon eBay $375.00 |
| 0G8442C113 | GRIP, HANDLE | 1 | Handle | Amazon eBay $35.48 |
| 0G8542 | BRACKET, MUFFLER | 1 | Bracket | Amazon eBay |
| 0G8758 | OUTLET 30A 120/250V SPCGR | 1 | Outlet | Amazon eBay $41.25 |
| 0G9028 | GASKET, EXH, CYLNDR | 1 | Gasket | Amazon eBay $16.95 |
| 0G9391 | COVER, OUTLET | 1 | Cover | Amazon eBay $49.17 |
| 0G9392 | COVER, OUTLET | 2 | Cover | Amazon eBay $38.81 |
| 0G9449 | Battery Type: Lead Acid (12V DC, 9Ah) | 1 | Battery | Amazon eBay $25.99 |
| 0G9756 | COVER, BACK PANEL | 1 | Cover | Amazon eBay |
| 0G9757A | HOSE, FUEL, 08X55 | 1 | Hose | Amazon eBay $28.75 |
| 0G9757B | HOSE, FUEL, 08X80 | 1 | Hose | Amazon eBay $22.00 |
| 0G9911 | SWITCH, ON/OFF RED-ROTARY | 1 | Switch | Amazon eBay $14.45 FridayParts $11.92 |
| 0G9914 | FILTER, FUEL | 1 | Filter | Amazon eBay $16.99 KuduParts $8.00 FridayParts $9.80 |
| 0H0204 | PIN, AXLE | 2 | Pin | Amazon eBay $20.00 |
| 0H0265C | BREAKER, CIRCUIT, 20A | 2 | Breaker | Amazon eBay $10.99 |
| 0H0265E | BREAKER, CIRCUIT, 30A | 2 | Breaker | Amazon eBay $33.69 |
| 0H0919 | BRUSH, ALTERNATOR | 1 | Brush | Amazon eBay $25.00 |
| 0H0958 | CAP, FUEL | 1 | Cap | Amazon eBay $14.98 |
| 0H12810104 | BOLT, M6X185 | 4 | Bolt | Amazon eBay $27.56 |
| 0H1326 | Fuel Filter | 1 | Fuel filter | Amazon eBay $7.99 KuduParts $6.00 FridayParts $8.66 |
| 0H1411B | RUBBER, FUEL TANK | 4 | Rubber | Amazon eBay $26.05 |
| 0H1610A | ANTI-CRUSH 10.8OD 9ID 10LG | 4 | Lining | Amazon eBay $25.01 |
| 0H1780 | BOLT, CURVED HEAD, M8X40 | 6 | Bolt | Amazon eBay $12.99 |
| 0H1781 | BOLT, CARRIAGE HEAD M8XX46 | 2 | Bolt | Amazon eBay |
| 0H1782 | CAP NUT M8-1.25 BLACK ZINC | 9 | Nut | Amazon eBay $17.60 |
| 0H1783 | MOUNT, RUBBER VIB | 4 | Mount | Amazon eBay $20.00 |
| 0H2579B | AVR 5.5-7.5KW VISION ALT | 1 | Avr | Amazon eBay $14.65 FridayParts $20.69 |
| 0H3049 | COVER ALTERNATOR INLET 5-7KW | 1 | Cover | Amazon eBay $20.00 |
| 0H43470112 | CUP, FUEL FILTER | 1 | Fuel filter | eBay |
| 0H43470123 | GASKET | 4 | Gasket | eBay |
| 0H43470140 | AIR CLEANER | 1 | Air filter | eBay |
| 0H43470143 | GASKET, CARBURETOR, (OUT B) | 1 | Gasket | eBay $10.00 |
| 0H43470145 | GASKET, CARBURETOR, (OUT A) | 1 | Gasket | eBay $0.99 |
| 0H43470147 | GASKET, CARBURATOR (IN) | 1 | Gasket | eBay $15.00 |
| 0H43470152 | AIR TUBE | 1 | Hose | eBay |
| 0H43470163 | SEAL, COVER | 1 | Seal | eBay |
| 0H43470174 | HOSE, OIL DISCHARGE | 1 | Hose | eBay |
| 0H43470176 | HOSE, FUEL PUMP OIL INJECTION A | 1 | Hose | eBay |
| 0H43470177 | O-RING | 1 | Seal | eBay $22.00 |
| 0H43470180 | FILTER, GAS | 1 | Fuel filter | eBay |
| 0H43470181 | HOSE, FUEL PUMP | 1 | Hose | eBay |
| 0H43470182 | HOSE, FUEL PUMP AIR | 1 | Hose | eBay |
| 0H43470183 | HOSE, FUEL PUMP OIL INJECTION B | 1 | Hose | eBay |
| 0H43470184 | FUEL PUMP ASSY. | 1 | Pump | eBay |
| 0H43470189 | GASKET, MUFFLER | 1 | Gasket | eBay |
| 0H43470192 | SEAL, EXHAUST COVER | 1 | Seal | eBay |
| 0H43470196 | O-RING, RUBBER | 1 | Seal | eBay |
| 0H43470203 | WASHER/ GASKET, HOOK | 2 | Gasket | eBay |
| 0H43470288 | GASKET, VALVE COVER | 1 | Gasket | eBay |
| 0H43470303 | OIL SEAL, CRANKSHAFT | 1 | Seal | eBay |
| 0H43470306 | SENSOR ASSY., OIL | 1 | Sensor | eBay |
| 0H43470309 | GASKET, EXHAUST PIPE | 1 | Gasket | eBay |
| 0H43470312 | GASKET, CAMSHAFT | 4 | Gasket | eBay |
| 0H7510A0SRV | TANK, FUEL, 7 GAL | 1 | Tank | Amazon eBay |
| 0H8096 | SPARK PLUG | 1 | Spark plug | eBay |
| 0H9005 | METER, FUEL | 1 | Meter | Amazon eBay $12.67 FridayParts $12.00 |
| 0H91980158 | BOLT, FLANGE, M5X220 | 2 | Bolt | Amazon eBay |
| 0H91980171 | HOUSING, REAR BEARING | 1 | Housing | Amazon eBay $49.99 |
| 0H9749AST03 | PANEL RAIL BACK | 1 | Panel | Amazon eBay |
| 0H97560ST15 | HANDLE | 1 | Handle | Amazon eBay $55.73 |
| 0H9760 | CAP, END | 1 | Cap | Amazon eBay |
| 0H9761 | ALTERNATOR SCROLL | 1 | Scroll | Amazon eBay |
| 0H9763A | MUFFLER | 1 | Muffler | Amazon eBay |
| 0H97670ST15 | BRACKET, HANDLE | 1 | Bracket | Amazon eBay $37.36 |
| 0H9775B | PANEL ASSY., CONTROL | 1 | Panel | Amazon eBay |
| 0J00620100 | BOLT, M5X10 | 1 | Bolt | Amazon eBay $24.85 |
| 0J00620106 | Spark Plug | 1 | Spark plug | Amazon eBay $35.00 NAPA $2.82 FridayParts $32.07 |
| 0J0974 | SHUT-OFF VALVE, FUEL | 1 | Valve | Amazon eBay $8.99 |
| 0J35220156 | BOLT, M6X20 | 1 | Bolt | Amazon eBay |
| 0J35220161 | NUT, M8 | 2 | Nut | Amazon eBay $4.59 |
| 0J35220173 | CLAMP, 012 | 1 | Clamp | Amazon eBay $26.73 |
| 0J35220174 | CLAMP, 010 | 1 | Clamp | Amazon eBay |
| 0J4535A | MANIFOLD, EXHAUST | 1 | Manifold | Amazon eBay $38.99 |
| 0J4536 | FACE PLATE, CNTRL PNL ASSY. | 1 | Plate | Amazon eBay |
| 0J4691 | GASKET, EXH., MUFFLER | 1 | Gasket | Amazon eBay $25.37 |
| 0J47870118 | WASHER, FLAT 6X0.8 | 1 | Washer | Amazon eBay $24.70 |
| 0J4967 | BOLT, M5X12 | 6 | Bolt | Amazon eBay $24.85 |
| 0J4968 | BOLT, M5X16 | 3 | Bolt | Amazon eBay |
| 0J6072 | TERMINAL | 1 | Terminal | Amazon eBay |
| 0J7921 | ROLL OVER VALVE | 1 | Valve | Amazon eBay $20.95 |
| 0J86620100 | FRAME | 1 | Frame | Amazon eBay $89.00 |
| 0J86620103 | BOLT, M10X275 | 1 | Bolt | Amazon eBay |
| 0J86620104 | BAFFLE | 1 | Baffle | Amazon eBay $26.05 |
| 0J86620108 | NUT, M4 | 6 | Nut | Amazon eBay |
| 0K0091 | HOSE FORMED ROV-AIRBOX | 1 | Hose | Amazon eBay $15.95 |
| 0K0092 | WIRE ASSY., GRND | 1 | Wire | Amazon eBay $29.12 |
| 0K0093 | WASHER, SPECIAL LOCK | 1 | Washer | Amazon eBay |
| 0K0094 | NUT, M6 | 1 | Nut | Amazon eBay |
| 0K0097 | FRAME, BENT FOOT | 2 | Frame | Amazon eBay |
| 0K0098 | NUT, M8 | 4 | Nut | Amazon eBay $25.68 |
| 0K0099 | FOOT, RUBBER | 2 | Foot | Amazon eBay |
| 0K0100 | BOLT, M6X28 | 2 | Bolt | Amazon eBay $25.31 |
| 0K0105 | NUT, M6 | 2 | Nut | Amazon eBay $5.49 |
| 0K1291 | ALTERNATOR ASSY. | 1 | Alternator | Amazon eBay |
| 0K6011 | WHEEL | 2 | Wheel | Amazon eBay $30.00 |
| 338-4086 | Genset to Pump Actuator | 1 | Pump | Amazon eBay |
| 338-4088 | For Oil Temperature Display from Sensor | 1 | Sensor | Amazon eBay |
| 005703-0 | Paint Kit | Service part / kit | Amazon eBay | |
| 005839-0 | Fascia Base Wrap Kit | Service part / kit | Amazon eBay | |
| 006004-0 | Scheduled Maintenance Kit | 2 | Service part / kit | Amazon eBay $25.20 |
| 006016-0 | 240V Conversion Kit | Service part / kit | Amazon eBay $55.00 | |
| 006806-0 | Scheduled Maintenance Kit | Service part / kit | Amazon eBay | |
| 022304 | WASHER FLAT 1/2 ZINC | 2 | Service part / kit | Amazon eBay |
| 067989 | NUT HEX FL WHIZ M8-1.25 | 4 | Service part / kit | Amazon eBay $6.00 |
| 0H43470136 | IGNITION COIL | 1 | Service part / kit | eBay $23.70 |
| 0H43470173 | VALVE, FUEL | 1 | Service part / kit | eBay $32.33 |
| 0H43470211 | DIODE, RECTIFIER | 1 | Service part / kit | eBay |
| 0H43470216 | BREAKER, DC CIRCUIT | 1 | Service part / kit | eBay |
| 0H43470299 | BEARING, BALL | 2 | Service part / kit | eBay |
| 0H43470310 | TAPPET, VALVE | 2 | Service part / kit | eBay |
| 0H43470316 | BEARING, OIL RETAINER | 2 | Service part / kit | eBay |
| 0H97480ST03 | FRAME, RAIL | 1 | Service part / kit | Amazon eBay $44.00 |
| 338-4084 | Harness, Switch (P2) (Includes Parts Marked @) | 1 | Service part / kit | Amazon eBay |
| 338-4085 | Genset to Battery | 1 | Service part / kit | Amazon eBay |
| 338-4087 | Lead Harness | 1 | Service part / kit | Amazon eBay |
| 338-4089 | For AC Display from Genset | 1 | Service part / kit | Amazon eBay |
| 696471068528 | Transfer Switch Model 6852 | Service part / kit | Amazon eBay | |
| 696471068535 | Transfer Switch Model 6853 | Service part / kit | Amazon eBay | |
| 696471071481 | Transfer Switch Model 9854 | Service part / kit | Amazon eBay | |
| 696471071498 | Transfer Switch Model 9855 | Service part / kit | Amazon eBay | |
| 7129-0 | UPC: 696471072716 (50-State/CSA) | 1 | Service part / kit | Amazon eBay |
| 7668-0 | Inverter Parallel Kit (sold separately) | 1 | Service part / kit | Amazon eBay |
| 96471068542 | Transfer Switch Model 6854 | Service part / kit | Amazon eBay | |
| A0001920610-B | Operator’s Manual for Power Washer | Service part / kit | Amazon eBay | |
| G006806-0 | Maintenance Kit | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Available documents
Spec sheet — 0180620SBY (Generac)Spec sheet — 0196610-a-gp5500 (Generac)Spec sheet — 0196610SBY GP5500 5939 5939 5975 5945(2) (Generac)Reference (Generac)Reference — 0179960SBY (Generac)Reference — 0180610SBY (Generac)Reference — 0180630SBY (Generac)Reference — 0180710SBY (Generac)Reference — 0189200SBY (Generac)Reference — 0189200sbygpseriesportabless newlowres (Generac)Reference — 0189270SBY (Generac)Reference — 0195040-B-GenTran-Switches-Model-6924-6925-6926 (Generac)Reference — 0196870-A-Flush-Mounting-Plate-Spec (Generac)Reference — 0196870SBY-A-Manual-Tswitches-1 (Generac)Reference — 0196880-A-Plugs-and-Connectors (Generac)Reference — Generac GP (Generac)Parts manual (Generac)Parts manual — 0198280-A-Portable-Maint-Kits (Generac)Service manual (Generac)Service manual — GP Series Service Manual (Generac)Service manual — Generac Portable Service Manual 0H0285 (Generac)
This page was generated from the 21 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.