Generac 5500 parts diagram

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

Problems?

Questions?

Before 

taking 

your 

unit

back 

to the 

store,

call 

the generator 

helpline 

at 

1-800-270-1408

M-F 

8-5 CT

Model No. 9885-3  (5,500 Watt AC Generator) Part No. B2674  Revision 2 (6/28/2000)

Visit our Generac website: www.generac-portables.com

Portable Generator Owner’s Manual

DANGER!

This generator is designed for outdoor use only. Never use this generator inside any building

or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide

poisoning, fire and/or an explosion may result. No user performed modifications, including venting of

exhaust and/or cooling ventilation, will eliminate the danger. Always have at least two feet of clearance on

all sides of the generator while operating the unit outdoors.

DANGER!

You must isolate the generator from the electric utility by opening the electrical system’s main

circuit breaker or main switch if this unit is used for backup power. Failure to isolate the generator from

the power utility may result in injury or death to electric utility workers and damage to the

generator due to a backfeed of electrical energy.

The Emission Control System for this generator is warranted for standards set by the

Environmental Protection Agency. For warranty information refer to the engine owner’s manual.

5500XL

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Generac Portable Products 5500XL Extended Life Generator

13

Item Part #

Qty Description

1

A92070

1

Control Panel

2

23897

4

#10 (M5) Flat Washer

3

49226

4

M5 Lock Washer

4

91526

4

M5-0.8 x 12mm Screw

5825

38

1

Idle Control Switch

6

82881

4

7/16" Lock Washer

7

43181

4

M3-0.5 x 10mm Screw

8

43182

4

M3 Lock Washer

9

90418

1

12V DC Outlet

10

75207A

2

30A Circuit Breaker

11

75207D

2

15A Circuit Breaker

12

233656

#8 Shakeproof Washer

13

68868

1

120 Volt AC, 30 Amp Locking

Outlet

Item Part #

Qty Description

14

43437

1

120V/240V AC, 30A Locking

Outlet

1563025 1

120V AC, 15

A Duplex Outlet

16

43180

6

M4 Flat Washer

17

22264

6

#8 (M4) Lock Washer

18

51715

6

M4-0.7 Hex Nut

19

64526

8

#6-32 x 3/8" Screw

20

83970

1

System Control Board

21

64525

4

3/4" Hex Stand-Off

22

87962

1

12V, 10A Cir. Breaker (auto)

23

843351

Wire Harness Assembly

24

84134

1

Rubber Conn. Grommet

25B92069

1

Box, Control Panel

26

84028

1

Idle Control Transformer

EXPLODED VIEW AND PARTS LIST – CONTROL PANEL

My Generac Wheelhouse 5500 / 5550 generator (made by Briggs and Stratton) was sitting in my shed for years without seeing much action. I knew I had to test it every month but without any need, it was sort of forgotten and unused. So when it refused to start with Hurricane Sandy bearing down us, all I managed to do was flood the engine when I repeatedly pulled the starter rope.

Although I was fortunate enough to purchase a new Briggs and Stratton 5500 Storm Responder generator from Home Depot at 3 AM, I shudder at the thought of not having electricity with 2 young children (by the way, my electricity was out for 14 straight days).

While my new generator was up and running, I was able to get my Generac generator to up and running, thanks to Internet and some fine folks at DIYChatroom (thanks again guys!).

I wrote this article to capture what I learned in hoping that it might help someone else to get their generators up and running.

PROBLEM TYPES

There are 2 main problems you may face with a generator that has been sitting around:

1. Generator runs fine but there is no electrical output
2. Generator runs poorly or does not start at all
• Engine starts but quits after running for about 10-15 seconds;
• Engine does not start but gas leaks from the air filter
• Engine will only start for few seconds with a squirt of starter fluid
• Engine will run rough under full choke but dies when choke is opened
• Engine sputters, guzzles gas then dies

If there is no electricity, you may need to field flash your generator or troubleshoot the automatic voltage regulator (AVR). Please see my other post titled “Troubleshooting a Portable Generator with no Voltage Power Output” (LINK -TBD)

SCOPE

Briggs and Stratton engine found in Generac Wheelhouse 5500 / 5550 generator came with either a Walbro or Nikki carburetors.

Information in this post pertains to only Nikki because my particular Generac Wheelhouse generator came with it (B&S OEM part # 697978 G02523 4312 A).

CAUSES

Generator’s inability to start of remain running has lots to do with old, stale gasoline. Most research I’ve read indicates that the gasoline goes stale after only 30 days after it is manufactured. After 30 days t starts to form varnish that looks like red rust flakes.

Varnish tends to stick and clog internal components like a needle valve, emulsion tube, etc. where tiny holes are critical for the engine to properly work properly.

REPLACE OR OVERHAUL THE CARBURETOR?

BUY A NEW BRIGGS AND STRATTON CARBURETOR – PART # 591378

If you don’t have the time for an overhaul / rebuild (i.e. a storm is coming!), you will want to buy a replacement Briggs & Stratton Carburetor – Part # 591378.

Installing a replacement carburetor is basically a drop-in that takes less than 20 minutes. If you do buy one, you need re-use the choke handle bar because the new one is shorter than the original one (this involves simply removing a choke plate).

Nikki Carb Part #697879 has been discontinued and official replacement part is not available. Although the packaging on the new carburetor #591378 does not state that it can replace #697978, it works.

For about 15 bucks cheaper, you can also look at this replacement carb. I have personally not used this part though.

REPAIRING OR OVERHAULING THE OLD CARBURETOR

Overhauling a carburetor is more labor intensive process and may not be a good solution if you need to get the generator up and running and you need to do other things to get ready.

I am going to share my detailed step-by-step instructions with you so that if you have some spare time,

DECISION

I think you can agree with me that spending 100 bucks for a new Briggs & Stratton Carburetor Part # 591378 is far cheaper than buying a new generator

APPROACH

I had three choices in trying to solve my problem:

1. VARNISH REMOVAL – Costs may be $10 or under; least expensive route but may develop leaks if old gasket is damaged during cleaning process
2. OVERHAUL – Costs about $25 for an overhaul / rebuild kit
3. REPLACE – Costs about $100

I ultimately chose to go with option #2 because I felt confident that my generator will be working after the engine tuneup (replacing air filter, spark plug, oil change, etc.) + overhauling my carburetor.

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