Manual for 68525 - Troubleshooting and error codes + PDF Download

Manual for 68525 - Troubleshooting and error codes + PDF Download

Brand: Predator

Category: Portable Generator

Manual Type:

Language:

Uploaded: April 8, 2025, 1:56 p.m.

Warranty Summary

This Predator 68525 generator has a 90-day limited warranty for product defects and a 2-year warranty for the emission control system.
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Basic Operation Summary:

  • Pre-Start Checks: Inspect generator and engine, check oil and fuel levels.
  • Starting the Engine: Follow choke instructions for cold or warm starts, use manual recoil or electric start. Allow engine to warm up.
  • Connecting Loads: Calculate wattage, connect higher wattage items first, avoid overloading.
  • Stopping the Engine: Turn off electrical loads before stopping, turn engine switch to OFF, close fuel valve.

Troubleshooting and error codes

Problem Possible Causes Probable Solutions
Engine will not start FUEL RELATED:
  1. No fuel in tank or fuel valve closed.
  2. Choke not in CHOKE position, cold engine.
  3. Gasoline with more than 10% ethanol used. (E15, E20, E85, etc.)
  4. Low quality or deteriorated, old gasoline.
  5. Carburetor not primed.
  6. Dirty fuel passageways.
  7. Carburetor needle stuck. Fuel can be smelled in the air.
  8. Too much fuel in chamber. This can be caused by the carburetor needle sticking.
  9. Clogged Fuel Filter.
IGNITION (SPARK) RELATED:
  1. Spark plug cap not connected securely.
  2. Spark plug electrode wet or dirty.
  3. Incorrect spark plug gap.
  4. Spark plug cap broken.
  5. Circuit breaker tripped (electric start models only).
  6. Incorrect spark timing or faulty ignition system.
COMPRESSION RELATED:
  1. Cylinder not lubricated. Problem after long storage periods.
  2. Loose or broken spark plug. (Hissing noise will occur when trying to start.)
  3. Loose cylinder head or damaged head gasket. (Hissing noise will occur when trying to start.)
  4. Engine valves or tappets mis-adjusted or stuck.
 FUEL RELATED:
  1. Fill fuel tank and open fuel valve.
  2. Move Choke to CHOKE position.
  3. Clean out ethanol rich gasoline from fuel system. Replace components damaged by ethanol. Use fresh 87+ octane unleaded gasoline only. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  4. Use fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  5. Pull on Starter Handle to prime.
  6. Clean out passageways using fuel additive. Heavy deposits may require further cleaning.
  7. Gently tap side of carburetor float chamber with screwdriver handle.
  8. Turn Choke to RUN position. Remove spark plug and pull the start handle several times to air out the chamber. Reinstall spark plug and set Choke to CHOKE position.
  9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
  1. Connect spark plug cap properly.
  2. Clean spark plug.
  3. Correct spark plug gap.
  4. Replace spark plug cap.
  5. Reset circuit breaker. Check wiring and starter motor if breaker continues to trip.
  6. Have qualified technician diagnose/repair ignition system.
COMPRESSION RELATED:
  1. Pour tablespoon of oil into spark plug hole. Crank engine a few times and try to start again.
  2. Tighten spark plug. If that does not work, replace spark plug. If problem persists, may have head gasket problem, see #3.
  3. Tighten head . If that does not remedy problem, replace head gasket.
  4. Have qualified technician diagnose/repair ignition system.
Engine misfires
  1. Spark plug cap loose.
  2. Incorrect spark plug gap or damaged spark plug.
  3. Defective spark plug cap.
  4. Old or low quality gasoline.
  5. Incorrect compression.
  1. Check wire connections.
  2. Re-gap or replace spark plug.
  3. Replace spark plug cap.
  4. Use only fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  5. Diagnose and repair compression. (Use Engine will not start: COMPRESSION RELATED section.)
Engine stops suddenly
  1. Low oil shutdown.
  2. Fuel tank empty or full of impure or low quality gasoline.
  3. Defective fuel tank cap creating vacuum, preventing proper fuel flow.
  4. Faulty magneto.
  5. Disconnected or improperly connected spark plug cap.
  1. Fill engine oil to proper level. Check engine oil before EVERY use.
  2. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  3. Test/replace fuel tank cap.
  4. Have qualified technician service magneto.
  5. Secure spark plug cap.
Engine stops when under heavy load
  1. Dirty air filter.
  2. Engine running cold.
  1. Clean or replace element.
  2. Allow engine to warm up prior to operating equipment.
Engine knocks
  1. Old or low quality gasoline.
  2. Engine overloaded.
  3. Incorrect spark timing, deposit buildup, worn engine, or other mechanical problems.
  1. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  2. Do not exceed equipment's load rating.
  3. Have qualified technician diagnose and service engine.
Engine backfires
  1. Impure or low quality gasoline.
  2. Engine too cold.
  3. Intake valve stuck or overheated engine.
  4. Incorrect timing.
  1. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  2. Use cold weather fuel and oil additives to prevent backfiring.
  3. Have qualified technician diagnose and service engine.
  4. Check engine timing.
Product doesn't have power.
  1. Product not plugged in properly.
  2. Circuit Breaker tripped.
  3. Product needs service.
  1. Turn off and unplug the product, then plug it back in again and turn on.
  2. Turn off and unplug product, Reset Circuit Breaker. Plug in product and turn on.
  3. Have product repaired.
Product begins to operate abnormally.
  1. Problem with appliance.
  2. Rated load capacity exceeded.
  1. Immediately unplug appliance. Have appliance repaired by a qualified technician, or replace appliance.
  2. Lower the number of items plugged into the generator to stay within the rated capacity, or use a more powerful generator.

Troubleshooting and error codes

Problem Possible Causes Probable Solutions
Engine will not start FUEL RELATED:
  1. No fuel in tank or fuel valve closed.
  2. Choke not in CHOKE position, cold engine.
  3. Gasoline with more than 10% ethanol used. (E15, E20, E85, etc.)
  4. Low quality or deteriorated, old gasoline.
  5. Carburetor not primed.
  6. Dirty fuel passageways.
  7. Carburetor needle stuck. Fuel can be smelled in the air.
  8. Too much fuel in chamber. This can be caused by the carburetor needle sticking.
  9. Clogged Fuel Filter.
IGNITION (SPARK) RELATED:
  1. Spark plug cap not connected securely.
  2. Spark plug electrode wet or dirty.
  3. Incorrect spark plug gap.
  4. Spark plug cap broken.
  5. Circuit breaker tripped (electric start models only).
  6. Incorrect spark timing or faulty ignition system.
COMPRESSION RELATED:
  1. Cylinder not lubricated. Problem after long storage periods.
  2. Loose or broken spark plug. (Hissing noise will occur when trying to start.)
  3. Loose cylinder head or damaged head gasket. (Hissing noise will occur when trying to start.)
  4. Engine valves or tappets mis-adjusted or stuck.
 FUEL RELATED:
  1. Fill fuel tank and open fuel valve.
  2. Move Choke to CHOKE position.
  3. Clean out ethanol rich gasoline from fuel system. Replace components damaged by ethanol. Use fresh 87+ octane unleaded gasoline only. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  4. Use fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  5. Pull on Starter Handle to prime.
  6. Clean out passageways using fuel additive. Heavy deposits may require further cleaning.
  7. Gently tap side of carburetor float chamber with screwdriver handle.
  8. Turn Choke to RUN position. Remove spark plug and pull the start handle several times to air out the chamber. Reinstall spark plug and set Choke to CHOKE position.
  9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
  1. Connect spark plug cap properly.
  2. Clean spark plug.
  3. Correct spark plug gap.
  4. Replace spark plug cap.
  5. Reset circuit breaker. Check wiring and starter motor if breaker continues to trip.
  6. Have qualified technician diagnose/repair ignition system.
COMPRESSION RELATED:
  1. Pour tablespoon of oil into spark plug hole. Crank engine a few times and try to start again.
  2. Tighten spark plug. If that does not work, replace spark plug. If problem persists, may have head gasket problem, see #3.
  3. Tighten head . If that does not remedy problem, replace head gasket.
  4. Have qualified technician diagnose/repair ignition system.
Engine misfires
  1. Spark plug cap loose.
  2. Incorrect spark plug gap or damaged spark plug.
  3. Defective spark plug cap.
  4. Old or low quality gasoline.
  5. Incorrect compression.
  1. Check wire connections.
  2. Re-gap or replace spark plug.
  3. Replace spark plug cap.
  4. Use only fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  5. Diagnose and repair compression. (Use Engine will not start: COMPRESSION RELATED section.)
Engine stops suddenly
  1. Low oil shutdown.
  2. Fuel tank empty or full of impure or low quality gasoline.
  3. Defective fuel tank cap creating vacuum, preventing proper fuel flow.
  4. Faulty magneto.
  5. Disconnected or improperly connected spark plug cap.
  1. Fill engine oil to proper level. Check engine oil before EVERY use.
  2. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  3. Test/replace fuel tank cap.
  4. Have qualified technician service magneto.
  5. Secure spark plug cap.
Engine stops when under heavy load
  1. Dirty air filter.
  2. Engine running cold.
  1. Clean or replace element.
  2. Allow engine to warm up prior to operating equipment.
Engine knocks
  1. Old or low quality gasoline.
  2. Engine overloaded.
  3. Incorrect spark timing, deposit buildup, worn engine, or other mechanical problems.
  1. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  2. Do not exceed equipment's load rating.
  3. Have qualified technician diagnose and service engine.
Engine backfires
  1. Impure or low quality gasoline.
  2. Engine too cold.
  3. Intake valve stuck or overheated engine.
  4. Incorrect timing.
  1. Fill fuel tank with fresh 87+ octane unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
  2. Use cold weather fuel and oil additives to prevent backfiring.
  3. Have qualified technician diagnose and service engine.
  4. Check engine timing.
Product doesn't have power.
  1. Product not plugged in properly.
  2. Circuit Breaker tripped.
  3. Product needs service.
  1. Turn off and unplug the product, then plug it back in again and turn on.
  2. Turn off and unplug product, Reset Circuit Breaker. Plug in product and turn on.
  3. Have product repaired.
Product begins to operate abnormally.
  1. Problem with appliance.
  2. Rated load capacity exceeded.
  1. Immediately unplug appliance. Have appliance repaired by a qualified technician, or replace appliance.
  2. Lower the number of items plugged into the generator to stay within the rated capacity, or use a more powerful generator.