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Should I be wrorried about the rusty exhaust pipe..

3269 Views 199 Replies 10 Participants Last post by  speedy2019, 
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I have just noticed this but Im not sure why its so rusty as the actual exhaust isn't very rusty at all. Im thinkinng the rusty pipe will break before long?
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Also I dont think its a issue as it doesn't look tobe doing much but the rubber has split around the spark plug connector, Im guessing due to the cold weather as the generator is outside 24/7 with a weather proof cover over it. Its odd how only some parts of the generator are going rusty as you can see patches around the spark plug has rust too, but the spark plug isnt fully covered when its connected as you can see in the 2nd pic from my previous message...


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GenKnot
speedy2019 said:
I have just noticed this but Im not sure why its so rusty as the actual exhaust isn't very rusty at all. Im thinkinng the rusty pipe will break before long?
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That is the exhaust header going from the engine cylinder head over to the muffler. It is one of the hottest parts of the entire generator and it is hard to keep paint on it. You can get high temp header spray paint if you like, or just ignore it. You will likely never take it apart very easy now as the nuts are pretty much locked in place by the corrosion. And, you will likely not need to take it apart anyway.

speedy2019 said:
the rubber has split around the spark plug connector
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You can get a replacement spark plug boot with wire...they are cheap.

As for the rusting, one of the things I did when I stored my other gen is to put a little bit of oil on rusting areas with a rag. It will create a little smoke off the muffler for awhile on the next run, but it does cut down on the speed with which the rust eats the metal while in storage.

As for the plug boot, it helps to use silicone grease on the plug's ceramic insulator so that water does not travel up inside the boot. The slight rust on the outside of the plug will not cause an issue for now. At some point you need to get rid of that Torch plug and get an NGK Iridium.
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Do yourself a favor. Loosen those nuts and apply some antisieze to the threads. If you ever need to pull the muffler you'll thank yourself.
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GenKnot
flopshot said:
Do yourself a favor. Loosen those nuts and apply some antisieze to the threads. If you ever need to pull the muffler you'll thank yourself.
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Yes indeed, if you can get them off now without breaking them off in the cylinder head.
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Im guessing the nuts will be well rusted on and if I tried Id prob round the nuts off knowing my luck,,, I might get someone with a blowtouch to get the nuts off for me as they should come off quite easy if heated up?... My only concern is, if the pipe breaks due to the rust as its quite rusty, but I can get a new exhaust for it though, so its not the end of the world if it breaks, and you never know it might last years without breaking
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Colt Carson
Ahhh…. that’s the thing, finding the happy balance between being conscientious and leaving well enough alone. I would replace that bad spark plug wire though. Every engine I've seen had rusty exhaust manifolds directly off the engine, unless they had some high quality special coating on them.
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sledman8002002
speedy2019 said:
Im not sure why its so rusty as the actual exhaust isn't very rusty at all.
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speedy2019 said:
the generator is outside 24/7 with a weather proof cover over it.
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Just curious, does the cover have any vents allowing it to breathe?
speedy2019 said:
the rubber has split around the spark plug connector
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You 'might' be able to find the rubber seal by itself from a small engine, OPE or motorcycle shop. A mechanic could have a couple in a tool box drawer. He'd likely just hand you one.
Regardless, once replaced smear some die-electric grease over & inside it.

Like mentioned, I would for sure replace that torch plug with an NGK or Champion.

Concerning the 2 rusted nuts, you could apply some penetrating fluid every few days before attempting to remove them. Stuff a rag in behind to catch any excess overspray.
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My last watherproof cover was really bad as it was thick so I guess not very breathable and the gen was always damp when taking off the cover, so maybe thats whats done the damage.. But Ive since changed to this real thin weatherproof cover now and been using it for about 2 yrs and and the gen is always nice and dry when I take off the cover even when its really cold and wet.

I think I will leave the exhaust pipe that connect to the engine well alone,, but might smear some kind of grease on the nuts to stop them rusting anymore,, but what kind of grease do you recommend as I dont want it to set on fire?

I guessing I will need to take to old sparkplug to a shop so its the correct size?
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GenKnot
speedy2019 said:
might smear some kind of grease on the nuts to stop them rusting anymore
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I wouldn't put grease on them...just some motor oil. Grease is too heavy.

speedy2019 said:
take to old sparkplug to a shop so its the correct size
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What is the number on the Torch plug? I'll look up a replacement if you know that.
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GenKnot
If I were to guess, it would be a Torch F6RTC or F7RTC. The difference is the heat range. Both would be gapped at 0.7-0.8 mm (.028-.031 in.).

Torch F6RTC = NGK 6637 BPR6EIX Iridium
Torch F7RTC = NGK 4055 BPR7EIX Iridium
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So they have sent me 1 of these to get the plug out with, but its no good at all as the long lever is against the fuel tank when fitted over the plug, so I can't turn it at all and the exhaust heat guard is in the way if I have the lever facing the other side .. So I will see if pliers or moldgrips will do the job, or I will have to buy something proper to remove the plug.. That Chinese for you hey?

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iowagold
this is another example why a heat and cold protected generator shed or shack is a must.
storage of any equipment outside in the elements is a bad idea.
over time the elements will claim the prized equipment.

but speed as you have stated several times. this is a low cost generator.
so if it needs to be stored outside.
just replace it every 5-10 years.
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Colt Carson
speedy2019 said:
So they have sent me 1 of these to get the plug out with, but its no good at all as the long lever is against the fuel tank when fitted over the plug, so I can't turn it at all and the exhaust heat guard is in the way if I have the lever facing the other side .. So I will see if pliers or moldgrips will do the job, or I will have to buy something proper to remove the plug.. That Chinese for you hey?

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Sounds like maybe you need a universal joint and some extensions for a socket wrench.
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GenKnot
speedy2019 said:
but its no good at all as the long lever is against the fuel tank when fitted over the plug, so I can't turn it at all
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Do you have (or can borrow) a 13/16" (21mm) spark plug socket? Even a thin wall deep 13/16" socket will also work.
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iowagold said:
this is another example why a heat and cold protected generator shed or shack is a must.
storage of any equipment outside in the elements is a bad idea.
over time the elements will claim the prized equipment.

but speed as you have stated several times. this is a low cost generator.
so if it needs to be stored outside.
just replace it every 5-10 years.
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I couldn't keep it in a shed, as it would take far to long for me to take out, then setup, not to mention putting it away again after. So it might not get rusty in a shed, but it wouldn't get looked after at all.. I was thinking about having it in a plastic storage box/cupboard, but its not that easy as that, because you need fans and stuff to keep it cool.

GenKnot said:
Do you have (or can borrow) a 13/16" (21mm) spark plug socket? Even a thin wall deep 13/16" socket will also work.
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My sister might have something like that I can borrow as she couldn't get the plug out of her mower, so she bought something to get it out with..
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Colt Carson
I think the problem is that the cover is so close to the generator that you get no airflow. The engine in your car does fine, but there is room for airflow around it and it is protected on all sides.
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GenKnot
speedy2019 said:
My sister might have something like that I can borrow as she couldn't get the plug out of her mower
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Hopefully it is 13/16" too. Spark plugs do come in different sizes.
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Colt Carson said:
I think the problem is that the cover is so close to the generator that you get no airflow. The engine in your car does fine, but there is room for airflow around it and it is protected on all sides.
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Would somekind of a light weight box be better that I could lift off and on?
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Colt Carson
speedy2019 said:
Would somekind of a light weight box be better that I could lift off and on?
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Possibly. I guess ideally a box that has screen covered ventilation holes down low where you would get airflow but without the rain getting in. I keep my generator in the garage, but if I had to use it I have a 6'x6' instant-up canopy to protect it from the rain and sun. I would just leave the canopy lowered so blowing rain wouldn’t get to it. Only problem with a canopy long term is that it doesn’t keep out the critters.
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