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Certainly. Aluminum castings are easily welded. 4043 is the correct filler metal.

The first thing I noticed after swapping out the relay in the DH mod was the very loud click when it engaged. That is a good signal the relay is working so if you don't hear it, check that. The Bendix drive relay on the starter is the other issue that can go wrong. Best to pull the starter...

Change the transmission. There are threads here on retrofitting to 700R4, NV4500 manual and 4L80.

The harmonic balancer is PRESS FIT on the crankshaft. Interference fit, it will fight you both ways. Use your muscles and a tool. KD2291

You could look up the part number in the -24P parts manual and see...

I know it is going to another store to get the tool...NAPA sells a KD Tool puller which works great for both pulling and installing the harmonic damper. The pulling is easy enough to understand with the directions supplied, just use the correct bolts and it will eventually pull. You have to...

That which you pulled is the speed sensor, it senses every time a gear tooth passes by as it is a Hall Effect Sensor. Yes. there is a magnet in it, the gear tooth changes the magnetic field and it senses it. Counting the impulses over time is how the governor determines speed. It has nothing...

When you get over about 18mm, most metrics have a decent fit in 6 point sockets. 19 mm is 0.74803", give or take. Less than a sheet of paper difference.

Yes, T-handle near the PTO control handle.

For the light to be on constantly, the PTO and transfer case neutral safety switch must be on. Since all switches are double throw, it is possible someone has switched the wire to the NC (normally closed) where all should be on the normally open side.

Looks complete and unmolested. You need to work on the switches I've mentioned, the wires coming out of the PTO are for the speed sensor the governor uses to maintain 60 Hz frequency of the output from the generator. The PTO switch is on the PTO but has only one wire.

This wiring diagram should be on the inside of the front left door.

I too discovered this. Also, a 22 mm fits on the 1008/1010/1028/1031 singles. I thought it was 7/8" but 22mm is a better fit. Thankfully I have a full set of metric impact sockets.

The Bowden cable with the Tee handle is most definitely NOT stock. Yes, Muncie makes spare parts, that is not your problem. You have multiple issues. I doubt the governor is working properly. For the governor to work, three switches must be engaged, they are the PTO engaged, transfer case...

The original harness was in two pieces, the front light switch part which supplies the front and the rear which joins the front on the right side front fender liner. There are some modifications needed to run it with turn signals. Save as much of the old one to sort out the differences...

Rebuild it in place. If it had over 50k, swapping the pump might be warranted. As long as it doesn't have the issue of dying while coasting, it should be fine. It is a 1986 model so the boost pump vanes should be fine.

It must be VERY FREE. Taking it apart by cutting the safety wires, then carefully pulling it out might be needed. Careful, fuel is behind the lever assembly AND there is a small pawl which likes to get lost. If this lever isn't free to move on its own after removing the stop plunger cover...

Intake flame heater. That switch on the dash controls it. The poly lines are prone to damage and leaking. Easy to fix with fittings from Home Depot. You need the tube insert fittings, little brass thimbles which go inside the poly line to prevent the ferrule collars from cutting through.

You can get a 2 kW inverter powered off 24 volts for $300. Which would power a 9000 BTU/hour window unit. Only thing is this would put a 60 amp load or more, assuming the window unit draws 12 amperes. You don't need a pure sine inverter for window units, they will make more noise with...

Twins would also be closer to the manifolds which makes them a bit more efficient. Far better to run cold/pressurized air tube since you can use silicone rubber boots and aluminum tube. Of course you have to DIY all of it, this is the fun. Now if you can find a pair of VNT-17s for cheap...