Generator attempts to start multiple times but fails and then shuts down with 'Overcrank' displayed on the controller.

Safety first: Turn the generator to OFF on the control panel and open the main service disconnect. Shut off the gas supply before touching fuel components. Allow the engine to cool.

Step-by-step checks:

• Verify fuel supply: Confirm the LP tank is not empty or the natural gas service is active. Check the tank gauge (for LP) and ensure the main gas cock to the generator is fully open.
• Inspect gas line and regulator: Look at the Honeywell/Generac-style fuel regulator at the generator for icing, damage, or loose fittings. Listen for gas flow when the unit attempts to start (you may smell gas briefly). If there is no gas flow, the regulator or upstream valve may be faulty.
• Check air filter and intake: Remove the air filter cover and inspect the filter. Replace if heavily clogged, as restricted air can prevent starting.
• Inspect spark plug and ignition: Remove the spark plug boot, pull the plug, and inspect for fouling, heavy carbon, or damage. Clean or replace with the correct Honeywell-specified plug and verify the gap per the service manual.
• Clear the fault and retry: After correcting any issues, turn the controller to OFF for 30 seconds, then back to AUTO. Initiate a manual test. If Overcrank returns, further diagnosis of the ignition coil, fuel solenoid, or engine compression is required and a technician should be contacted.