Difficulty

Difficult

Steps

39

Time Required

                          40 minutes - 2 hours

Sections

8

  • Honda 6500 Watt Generator EG6500CL AT Safety Precautions
  • 3 steps
  • Generator Cover
  • 2 steps
  • Brush Assembly
  • 4 steps
  • Rear Generator Housing
  • 14 steps
  • Stator Cover
  • 3 steps
  • Stator
  • 2 steps
  • Recoil Starter
  • 2 steps
  • Rotor
  • 9 steps

Flags

0

  • BackHonda 6500 Watt Generator EG6500CL AT

  • Full Screen

  • Options

  • History

  • Save to Favorites

  • Download PDF

  • Edit

  • Translate

  • Get Shareable Link

  • Embed This Guide

  • Notify Me of Changes

  • Stop Notifications

Introduction

Warning: You need a Honda rotor puller tool (07HPC-ZC2010A or 07HPC-ZC2010B) in order to complete this procedure. You will not be able to remove the rotor without this tool.

This procedure shows how to complete the procedure without removing the generator from the frame.

You will need some wooden blocks between 2-4 inches thick to support the generator and rotor. You will also need a metal rod or extra large screwdriver in order to brace and lock up the generator axle.

What you need

Step 1

              Honda 6500 Watt Generator EG6500CL AT Safety Precautions
  • Before you work on the device, make sure to switch the engine off.
  • Switch the circuit breaker off.

Before you work on the device, make sure to switch the engine off.

Switch the circuit breaker off.

1024

Step 2

              Disconnect the spark plug
  • Grab the plastic housing at the end of the spark plug wire.
  • Pull firmly to disconnect the wire from the spark plug.

Grab the plastic housing at the end of the spark plug wire.

Pull firmly to disconnect the wire from the spark plug.

Step 3

  • Twist the fuel valve clockwise into the cutoff position.

Twist the fuel valve clockwise into the cutoff position.

Step 4

              Remove the generator cover
  • Use a Phillips screwdriver to remove the two screws securing the generator cover.

Use a Phillips screwdriver to remove the two screws securing the generator cover.

Step 5

  • Remove the generator cover.

Remove the generator cover.

Step 6

              Remove the brush assembly
  • Squeeze and disconnect the stator connector from the wiring harness.

Squeeze and disconnect the stator connector from the wiring harness.

Step 7

  • Use a 10 mm socket to remove the bolt securing the brush assembly.
  • Pull the brush assembly out slightly from its recess.

Use a 10 mm socket to remove the bolt securing the brush assembly.

Pull the brush assembly out slightly from its recess.

Step 8

  • Disconnect the two spade connectors from the brush assembly.

Disconnect the two spade connectors from the brush assembly.

Step 9

  • Remove the brush assembly.
  • During reassembly, use the second photo as reference for how to wire the brush assembly.

Remove the brush assembly.

During reassembly, use the second photo as reference for how to wire the brush assembly.

Step 10

              Loosen the rear generator housing
  • Use a 10 mm socket to remove the four long bolts securing the generator cover to the generator assembly.
  • During reassembly, tighten these bolts to 7 ft-lb (10 N-m).

Use a 10 mm socket to remove the four long bolts securing the generator cover to the generator assembly.

During reassembly, tighten these bolts to 7 ft-lb (10 N-m).

Step 11

  • Use a 14 mm socket to remove the rotor bolt from the generator assembly.
  • This bolt may be difficult to loosen. If you have trouble removing the bolt, use an impact wrench or breaker bar.
  • During reassembly, tighten this bolt to 33 ft-lb (44 N-m).

Use a 14 mm socket to remove the rotor bolt from the generator assembly.

This bolt may be difficult to loosen. If you have trouble removing the bolt, use an impact wrench or breaker bar.

During reassembly, tighten this bolt to 33 ft-lb (44 N-m).

Step 12

  • Remove the rotor bolt and washer.

Remove the rotor bolt and washer.

Step 13

  • Use an 8 mm socket to remove the four nuts securing the wiring harness to the terminal.
  • Remove only the top nut from each terminal post.
  • Be careful not to lose the crush washers behind them.
  • Remove the wiring harness wires from the terminal.

Use an 8 mm socket to remove the four nuts securing the wiring harness to the terminal.

Remove only the top nut from each terminal post.

Be careful not to lose the crush washers behind them.

Remove the wiring harness wires from the terminal.

Step 14

              Reassembly tip
  • During reassembly, use these photos as a reference for how to re-stack the terminal posts. From the terminal base to tip:
  • Base washer
  • Crush washer
  • Stator wire connector
  • Nut
  • Wiring harness connector
  • Crush washer
  • Nut

During reassembly, use these photos as a reference for how to re-stack the terminal posts. From the terminal base to tip:

Base washer

Crush washer

Stator wire connector

Nut

Wiring harness connector

Step 15

  • Use an 8 mm socket to remove the three bolts securing the wiring terminal and harness.
  • Remove the Phillips screw securing the harness ground.
  • Loosen the wiring terminal and harness from their resting positions.

Use an 8 mm socket to remove the three bolts securing the wiring terminal and harness.

Remove the Phillips screw securing the harness ground.

Loosen the wiring terminal and harness from their resting positions.

Step 16

  • Use pliers to release the cable tie securing the wiring harness to the generator assembly.

Use pliers to release the cable tie securing the wiring harness to the generator assembly.

Step 17

              Loosen the mounting bolts
  • Carefully tilt the rear of the generator upwards to access the under-frame bolts.
  • Use a 12 mm socket to remove the two bolts underneath the frame, which secures the rear generator housing.

Carefully tilt the rear of the generator upwards to access the under-frame bolts.

Use a 12 mm socket to remove the two bolts underneath the frame, which secures the rear generator housing.

Step 18

  • Removing these nuts give the generator assembly enough slack to remove the rear bushings.
  • Use a 14 mm socket to remove the mounting nut next to the emissions canister.
  • Use a 14 mm socket to remove the mounting nut near the oil filler hole.

Removing these nuts give the generator assembly enough slack to remove the rear bushings.

Use a 14 mm socket to remove the mounting nut next to the emissions canister.

Use a 14 mm socket to remove the mounting nut near the oil filler hole.

Step 19

  • Use a 14 mm socket to remove the two nuts securing the rear housing to the bushings.
  • During reassembly, be sure to re-attach the ground terminal to the left bushing.

Use a 14 mm socket to remove the two nuts securing the rear housing to the bushings.

During reassembly, be sure to re-attach the ground terminal to the left bushing.

Step 20

              Remove the rear bushings
  • In these photos, the generator frame is propped on some blocks for ease of access. You do not need to do this for the procedure.
  • Tilt the generator assembly by lifting the rear housing slightly.
  • Place support blocks underneath the silver generator housing to support the generator assembly.
  • The generator weight should rest on the support blocks and no longer on the rear bushings.
  • Do not support the generator by the black stator cover.

In these photos, the generator frame is propped on some blocks for ease of access. You do not need to do this for the procedure.

Tilt the generator assembly by lifting the rear housing slightly.

Place support blocks underneath the silver generator housing to support the generator assembly.

The generator weight should rest on the support blocks and no longer on the rear bushings.

Do not support the generator by the black stator cover.

Step 21

  • Lift the rear generator housing up as far as you can and maneuver the left bushing out of its socket.
  • Remove the left bushing.

Lift the rear generator housing up as far as you can and maneuver the left bushing out of its socket.

Remove the left bushing.

Step 22

  • Repeat the previous step to remove the right bushing from its socket.

Repeat the previous step to remove the right bushing from its socket.

Step 23

              Remove the rear generator housing
  • Remove the rear generator housing from the generator assembly.

Remove the rear generator housing from the generator assembly.

Step 24

              Remove the stator cover
  • Rotate the stator cover so that the seam is at an accessible angle.

Rotate the stator cover so that the seam is at an accessible angle.

Step 25

  • Use a flathead screwdriver to pry up the tabs holding the stator cover together.

Use a flathead screwdriver to pry up the tabs holding the stator cover together.

Step 26

  • Remove the stator cover.

Remove the stator cover.

Step 27

              Remove the stator
  • Remove the stator by pulling it straight out of the generator assembly.

Remove the stator by pulling it straight out of the generator assembly.

Step 28

              Reassembly tip
  • During reassembly, you don’t need to install the stator in a precise rotational position. Just make sure the stator cables wires are in the top-left corner.

During reassembly, you don’t need to install the stator in a precise rotational position. Just make sure the stator cables wires are in the top-left corner.

Step 29

              Remove the recoil starter
  • Use a 10 mm socket to remove the three bolts securing the recoil starter.

Use a 10 mm socket to remove the three bolts securing the recoil starter.

Step 30

  • Remove the recoil starter.

Remove the recoil starter.

Step 31

              Brace the rotor
  • Place wooden blocks under the flat side of the rotor to prevent it from rotating.

Place wooden blocks under the flat side of the rotor to prevent it from rotating.

Step 32

  • Insert a metal rod or a large screwdriver through the starter pulley to lock the rotor axle in place.

Insert a metal rod or a large screwdriver through the starter pulley to lock the rotor axle in place.

Step 33

              Loosen the rotor
  • Insert the rotor puller tool into the rotor axle.
  • Hand-tighten the puller tool onto the rotor threads.

Insert the rotor puller tool into the rotor axle.

Hand-tighten the puller tool onto the rotor threads.

Step 34

  • Use a 19 mm socket to tighten the puller tool until it breaks the rotor free from the generator assembly.
  • If you have trouble freeing the rotor, use a breaker bar to tighten the puller tool.

Use a 19 mm socket to tighten the puller tool until it breaks the rotor free from the generator assembly.

If you have trouble freeing the rotor, use a breaker bar to tighten the puller tool.

Step 35

  • Remove the rotor.

Remove the rotor.

Step 36

              Transfer the rotor fan
  • Use an 8 mm socket to remove the three bolts securing the rotor fan.
  • Transfer the fan to your replacement rotor.

Use an 8 mm socket to remove the three bolts securing the rotor fan.

Transfer the fan to your replacement rotor.

Step 37

              Align and re-attach the rotor
  • The next three steps show how to align and re-attach the rotor back onto the generator assembly.
  • Rotate the starter pulley until the top-dead-center marker is facing straight up.
  • The top-dead-center marker is a faint triangular indent on the starter pulley.
  • Once aligned, do not rotate the starter pulley or drive shaft until you’ve attached the rotor.

The next three steps show how to align and re-attach the rotor back onto the generator assembly.

Rotate the starter pulley until the top-dead-center marker is facing straight up.

The top-dead-center marker is a faint triangular indent on the starter pulley.

Once aligned, do not rotate the starter pulley or drive shaft until you’ve attached the rotor.

Step 38

  • Align the rotor such that the flat side of a rotor coil sits perpendicular to the alignment arrow at the top-right edge of the generator case.
  • You don’t have to align the rotor precisely—it just needs to be in the general direction as shown.

Align the rotor such that the flat side of a rotor coil sits perpendicular to the alignment arrow at the top-right edge of the generator case.

You don’t have to align the rotor precisely—it just needs to be in the general direction as shown.

Step 39

  • Insert the rotor bolt and washer into the rotor axle.
  • Use a 14 mm socket and torque wrench to tighten the rotor bolt to 33 ft-lb (44 N-m).
  • Reassemble the rest of the generator by following the instructions in reverse.

Insert the rotor bolt and washer into the rotor axle.

Use a 14 mm socket and torque wrench to tighten the rotor bolt to 33 ft-lb (44 N-m).

Reassemble the rest of the generator by following the instructions in reverse.

To reassemble your device, follow these instructions in reverse order.

Cancel: I did not complete this guide.

                                                                                      One other person completed this guide.

Author

                    Arthur Shi

Member since: 01/03/2018

211,874 Reputation

                                      442 Guides authored                  



                       Badges:
                       46







                                                        +43 more badges

Team

                       iFixit                        

                                                  Member of iFixit 



                    Community                     


                                            141 Members                     


                                            15,772 Guides authored