Your portable generator represents a significant investment and, more importantly, a promise of reliable power when you need it most. Whether it's keeping the lights on during a bushfire-season blackout or powering your campsite in the outback, a well-maintained generator delivers when called upon. A neglected one might leave you in the dark at the worst possible moment.
The good news is that generator maintenance isn't complicated. With a basic understanding of your machine and a commitment to regular care, you can dramatically extend its lifespan and ensure reliable performance for years to come. This guide covers everything Australian generator owners need to know about keeping their equipment in top condition.
Understanding Your Generator's Needs
Generators are essentially small engines connected to alternators. Like any internal combustion engine, they require regular attention to fuel systems, lubrication, air filtration, and electrical components. The key to effective maintenance is understanding that prevention is far easier and cheaper than repair.
Most generator problems stem from one of three causes: stale fuel, insufficient oil, or dirt contamination. Address these fundamentals, and you'll prevent the majority of issues that plague neglected generators.
Fuel System Care: The Most Critical Factor
Fuel-related problems are the number one cause of generator starting issues and poor performance. Modern petrol is particularly problematic because it degrades quickly and can damage carburetors and fuel lines.
Using Fresh Fuel
Always use fresh, high-quality unleaded petrol. Fuel begins degrading within 30 days and can cause significant problems after 90 days. For generators used infrequently, this timeline creates real challenges.
⚠️ Ethanol Warning
Many Australian petrol stations now sell E10 fuel containing 10% ethanol. While some generators tolerate E10, ethanol attracts moisture and accelerates fuel degradation. Check your generator's manual—many manufacturers recommend using regular unleaded (91) without ethanol for small engines.
Fuel Stabiliser: Your Best Friend
Fuel stabiliser is an inexpensive additive that dramatically extends fuel life. When added to fresh petrol, quality stabilisers can keep fuel viable for 12-24 months. For any generator that isn't used weekly, fuel stabiliser should be standard practice.
Add stabiliser according to package directions whenever you fill the tank. Run the engine for a few minutes to ensure treated fuel reaches the carburetor. This simple habit prevents countless starting problems.
Long-Term Storage Protocol
If storing your generator for more than a month, you have two options:
- Store with treated fuel: Fill the tank with stabilised fuel and run the engine until treated fuel reaches all fuel system components.
- Store dry: Run the generator until it stops from fuel starvation, then drain any remaining fuel from the tank. This prevents stale fuel from gumming up the carburetor.
Many experienced users prefer storing dry for extended periods, as it eliminates fuel degradation concerns entirely.
Oil: The Lifeblood of Your Engine
Regular oil changes are essential for engine longevity. Oil lubricates moving parts, reduces friction and heat, and carries away contaminants. Neglecting oil changes leads to accelerated wear and eventual engine failure.
Oil Change Intervals
For most portable generators, change the oil:
- After the first 20-25 hours of operation (break-in period)
- Every 50-100 hours of operation thereafter
- At least annually, even if hours haven't accumulated
- More frequently in dusty conditions
Checking Oil Level
Before every use, check the oil level with the engine off and generator on a level surface. Remove the dipstick, wipe it clean, reinsert fully, and check the level. Oil should be between the minimum and maximum marks. Never operate with low oil—many generators have low-oil shutoffs, but don't rely solely on this protection.
💡 Choosing the Right Oil
Use oil specified in your generator's manual. Most recommend SAE 10W-30 for general use or SAE 30 for warmer climates. Synthetic oils offer superior protection in extreme temperatures but aren't required for most applications. Never use automotive oil additives or treatments unless specifically approved.
Air Filter Maintenance
The air filter prevents dust, dirt, and debris from entering the engine. A clogged filter restricts airflow, reducing performance and fuel efficiency. A damaged filter allows contaminants to cause rapid engine wear.
Inspection and Cleaning
Check the air filter before each use and clean it every 25-50 hours of operation, more frequently in dusty conditions. Most generators use foam or paper element filters:
- Foam filters: Wash in warm soapy water, rinse thoroughly, squeeze dry (don't wring), then apply a few drops of clean engine oil and squeeze to distribute evenly.
- Paper filters: Tap gently to dislodge loose dirt. Replace if visibly dirty, damaged, or according to the manual's schedule.
Never run a generator without the air filter in place—even a few minutes of operation can cause significant internal damage from dust ingestion.
Spark Plug Care
The spark plug ignites the fuel-air mixture in the engine. A fouled or worn spark plug causes hard starting, rough running, and poor fuel efficiency.
Inspection and Replacement
Inspect the spark plug every 100 hours or annually. Remove it with the correct socket (usually 13/16" or 21mm) and examine the electrode:
- Light tan or grey coating indicates proper operation
- Black, sooty deposits suggest rich fuel mixture or incomplete combustion
- White, blistered deposits indicate overheating
- Oil-fouled plugs may indicate engine wear
Clean light deposits with a wire brush. Replace the plug if the electrode is worn, damaged, or heavily fouled. Always gap new plugs according to specifications (typically 0.7-0.8mm) before installation.
Cooling System Maintenance
Generators rely on air cooling, and blocked cooling fins cause overheating. Before each use, inspect the engine and remove any accumulated grass, leaves, or debris. Pay particular attention to the flywheel fins and cylinder cooling fins.
Avoid operating generators in enclosed spaces, not only for carbon monoxide safety but also to ensure adequate cooling airflow. In hot Australian conditions, consider providing shade for extended operation.
Electrical System Checks
Periodically inspect all electrical connections for corrosion, looseness, or damage. Check outlet receptacles for cracks or burn marks. Test the circuit breakers by pressing the reset buttons. If your generator has an electric start, ensure the battery is charged and terminals are clean.
✅ Exercise Your Generator
Generators that sit unused for extended periods often develop problems. Run your generator under load for 30-60 minutes every month to keep seals lubricated, prevent fuel system issues, and verify everything works. This "exercise" is particularly important for emergency backup generators.
Seasonal Maintenance Checklist
Before peak usage seasons (storm season, camping trips), perform a comprehensive check:
- Check and change oil if due
- Inspect and clean or replace air filter
- Examine spark plug condition
- Drain old fuel and refill with fresh, treated fuel
- Inspect fuel lines for cracks or deterioration
- Check all bolts and fasteners for tightness
- Clean exterior and cooling fins
- Test run under load for at least 30 minutes
When to Seek Professional Help
While basic maintenance is within reach of most owners, some issues require professional attention:
- Persistent starting problems despite fresh fuel and good spark
- Unusual engine noises or vibrations
- Visible oil leaks or excessive oil consumption
- Power output problems or fluctuating voltage
- Carburetor cleaning or rebuilding
- Any safety-related concerns
Invest time in regular maintenance now, and your generator will reliably serve you for decades. It's a small price to pay for peace of mind when the power goes out or you're enjoying the Australian wilderness miles from the nearest outlet.