Honda EZ6500CXS Shop Manual
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Honda EZ6500CXS Shop Manual

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  • Page 2: A Few Words About Safety

    If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 3 Important Safety precautions Make sure you have a clear understanding of all basic shop safety practices and are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or ...

  • Page 4: Introduction

    This includes text, figures, and tables. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment. SAFETY MESSAGES Your safety and the safety of others are very important.

  • Page 5: Service Rules

    SERVICE RULES Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do  not meet Honda’s design specifications may damage the unit. Use the special tools designed for the product.  Install new gaskets, O-rings, etc. when reassembling.

  • Page 6: Table Of Contents

    Table of Contents A Few Words About Safety ......................2 INTRODUCTION ........................4 SERVICE RULES ........................5 SYMBOLS ..........................5 1. SPECIFICATIONS ........................8 1-1. SPECIFICATIONS ......................8 1-2. PERFORMANCE CURVES ....................9 1-3. GENERAL DESCRIPTION .................... 12 1-4. SERIAL NUMBER ......................13 2.
  • Page 7 4. TROUBLE SHOOTING ......................40 ENGINE DOESN’T START. 4-1..................... 41 4-2. ELECTRIC STARTER DOES NOT OPERATE............... 42 4-3. NO ELECTRICITY AT THE A.C. RECEPTACLE............43 4-4. ALTERNATING CURRENT VOLTAGE IS 0V..............44 4-5. ALTERNATING CURRENT VOLTAGE IS LOW (50～80V)..........45 4-6.

  • Page 8: Specifications

    1-1. SPECIFICATIONS MODEL EZ6500CXS ★ENGINE Model Honda GX390H1 Displacement ℓ Oil Capacity Regarding detailed specification, please refer and confirm HONDA ENGINE shop manual. ★GENERATOR Type Self-exciting, 2pole, field rotating type Voltage regulation system Phase Single Rated power factor R, REH,...

  • Page 9: Performance Curves

    1-2. PERFORMANCE CURVES -The curve shows performance of the generator under the average conditions. -Performance may vary to some degree depending on ambient temperature and humidity. -The output voltage will be higher the usual when the generator is still cold, immediately the engine starts.
  • Page 10 L, LB Type AC EXTERNAL CHARACTERISTIC CURVES S, SB Type AC EXTERNAL CHARACTERISTIC CURVES...
  • Page 11 LS Type AC EXTERNAL CHARACTERISTIC CURVES...

  • Page 12: General Description

    1-3. GENERAL DESCRIPTION A IR C L E A N E R M A IN T E N A N C E C L E AN E L E ME N T E VE RY 5 0 H OU RS ( E VE RY 1 0 H OU RS U N D E R D U S T Y C ON D IT ION S ) .

  • Page 13: Serial Number

    1-4. SERIAL NUMBER Serial number is stamped on the label stuck on the fuel tank. NOTE: Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service. ENGINE SERIAL NUMBER GENERATOR SERIAL NUMBER...

  • Page 14: Maintenance

    100Hrs. page 20Hrs. 50Hrs. 300Hrs. ITEM Engine oil Check level Change Air cleaner Check Refer Clean O (1) HONDA ENGINE Spark plug Check-Clean shop manual. Replace Valve Check-Adjust O (2) clearance Combustion Clean After every 500 Hrs.(2) Chamber...

  • Page 15: Fuel Tank And Strainer Cleaning

    2-2. FUEL TANK AND STRAINER CLEANING Gasoline is highly flammable explosive.You can be burned or seriously injured when handing fuel. Keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. OFF Position 1) Drain the fuel into a suitable container. 2) Turn the fuel valve to the “OFF”...

  • Page 16: Fuel Tube Check

    6) Clean the sediment cup, O-ring, and filter in nonflammable or high flash point solvent. Filter 7) Reinstall the filter, O-ring, and sediment cup. O-ring can not be reused. Replace with new. O-ring Tightening torque: 4.5 N•m Sediment cup 8) Install a new O-ring to the fuel valve and install them to the fuel tank. 9) Tighten the fuel valve to the special torque.

  • Page 17: Removal And Installation

    M8 , P1.25 22.0 brush holder mount bolt AVR unit mount bolt STANDARD TORQUE VALUES Torque Values Thread Dia. Item Remark (N・m) (mm) Screw Bolt and nut 15.0 27.0 Regarding Engine torque values, please refer and confirm HONDA ENGINE shop manual.
  • Page 18 HOW TO CONNECTION A WIRING To Fuel cut solenoid To Charge coil To Engine switch To Starter motor To Ignition coil...

  • Page 19: Removal

    3-2. REMOVAL 3.2.1 CONTROL PANEL AND CONTROL BOX 1) Remove the end cover. Bolt Bolt (M5-12L) (2). End cover 2) Remove the wiring from the control panel to the alternator. Green/Yellow wire Bolt Terminal Black wire block 3) Remove the Black wire and White wire from terminal block.
  • Page 20 7) Remove the engine wiring. Remove Remove Remove 8) Remove the control panel. Bolt (M6-25L) (4) Bolt 9) Remove the control box. CONTROL BOX...
  • Page 21 Type: R, S, K VOLT METER CIRCUIT BREAKER PILOT LAMP SWITCH FUSE Screw (M4-16) (2) AC OUTPUT GROUND TERMINAL Blade fuse midium(5A) Capacitor Assy Diode Assy Diode COMP. Engine connecting wire Black wire White wire To Engine wiring Connect for the Engine terminal Fuse (5A) Green / Yellow wire Green / Yellow wire...
  • Page 22 REH, CL Type VOLT METER CIRCUIT BREAKER PILOT LAMP SWITCH FUSE Screw (M4-16) (2) GROUND TERMINAL AC OUTPUT Black wire White wire To Alternator wiring Connect for the block terminal To Alternator wiring Green / Yellow wire Connect for the connector To Alternator wiring Connect for the bracket Capacitor Assy...
  • Page 23 RK, MK, LS Type CIRCUIT BREAKER VOLT METER PILOT LAMP SWITCH FUSE Screw (M4-16) (2) AC OUTPUT GROUND TERMINAL Black wire White wire Engine connection wiring is same to all models. Refer to Type R, S, K or wiring diagram for engine connection wiring.
  • Page 24 M Type CIRCUIT BREAKER VOLT METER PILOT LAMP FUSE SWITCH Screw (M4-16) (2) AC OUTPUT GROUND TERMINAL Black wire White wire Engine connection wiring is same to all models. Refer to Type R, S, K or wiring diagram for engine connection wiring. Black wire Green / Yellow wire Black wire...
  • Page 25 SB, LB Type CIRCUIT BREAKER VOLT METER PILOT LAMP FUSE SWITCH Screw (M4-16) (2) AC OUTPUT GROUND TERMINAL White wire Black wire Engine connection wiring is same to all models. Refer to Type R, S, K or wiring diagram for engine connection wiring. Black wire Green / Yellow wire Black wire...
  • Page 26 RA Type CIRCUIT BREAKER VOLT METER PILOT LAMP FUSE SWITCH Screw (M4-16) (2) AC OUTPUT GROUND TERMINAL Black wire White wire Engine connection wiring is same to all models. Refer to Type R, S, K or wiring diagram for engine connection wiring. Green / Yellow wire Black wire Black wire...
  • Page 27 L Type CIRCUIT BREAKER PILOT LAMP VOLT METER FUSE SWITCH Screw (M4-16) (2) GROUND TERMINAL AC OUTPUT White wire Black wire Engine connection wiring is same to all models. Refer to Type R, S, K or wiring diagram for engine connection wiring. Black wire Green / Yellow wire Black wire...

  • Page 28: 3-2.2. Fuel Tank

    3.2.2 FUEL TANK Gasoline is highly flammable explosive.You can OFF Position be burned or seriously injured when handing fuel. Keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 1) Shut the fuel valve and discharge fuel from carburetor.

  • Page 29: 3-2.3. Muffler

    3.2.3 MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. 1) Remove the Muffler from the muffler bracket. Bolt (M8-16L) (2) Bolt Bush Pipe...
  • Page 30 4) Remove the Muffler Bracket. Bolt (M8-16L) (1) Bolt (M8-16L) Bolt (M8-25L) (1) Bush pipe Bush Pipe Muffler Bracket Bolt (M8-25L)

  • Page 31: 3-2.4. Alternator

    3.2.4 ALTERNATOR 1) Remove the wiring from the alternator. Brush holder Disconnect Disconnect the AVR unit connector. 2) Remove the AVR unit from bracket (2). Bolt AVR unit mount bolt (M5-16L) (2) Remove the brush holder from bracket (2) Bolt Brush holder mount bolt (M5-16L) (1) Bracket (2) 3) Set the generator set with the bracket (2) upwards.
  • Page 32 8) Remove the Generator rotor bolt of the rotor. Generator rotor bolt (M10 × 275L) (1) Hold the rotor using a commercially available strap wrench. Loosen the Generator rotor bolt. 9) Use a bolt and oil as a tool for pulling out rotor in the following procedures: Pour engine oil into the center hole of rotor shaft.

  • Page 33: Removal And Installation

    3-3. INSTALLATION 3.3.1. ENGINE AND FRAME Anti-vibration rubber 1) Install the anti-vibration rubbers to the frame. Insert the setting tongue of anti-vibration rubbers into the hole on the frame and tighten the nut from the bottom of the frame. Nut (M8) (4) Tightening torque: 15.0 N•m Nut (M8) 2) Install the engine into the frame from the side of it.

  • Page 34: 3-3.3. Stator

    3.3.3. STATOR 1) Put the stator in the engine. 3.3.4. BRACKET (2) 1) Put the bracket (2) over the rotor. Plastic hammer Pull out the stator wirings through the opening of the bracket (2). Be careful not to give cuts to wires when pulling them out from the bracket (2).
  • Page 35 5) Install the connectors to the brush holder and AVR unit onto the bracket (2). Brush holder Connect Connect the AVR unit connector. AVR unit mount bolt (M5-16L) (2) Brush holder mount bolt (M5-16L) (1) Bolt Tightening torque: 3.0 N•m Bolt Bracket (2) Brush holder...

  • Page 36: 3-3.5. Muffler

    3.3.5. MUFFLER 1) Install the Muffler Bracket. Bolt (M8-16L) Bolt (M8-16L) (1) Bolt (M8-25L) (1) Bush pipe (1) Tightening torque: 15.0 N•m Bush Pipe Muffler Bracket Bolt (M8-25L) 2) Install the exhaust pipe from the engine. Mount the Exhaust pipe and the gasket on the cylinder head. Nut (M8) (2) Lock Washer (M8) (2) Bush pipe (2)
  • Page 37 3) Install the muffler from the exhaust pipe. Mount the Exhaust pipe and the gasket on the muffler. Bolt (M8-32L) (2) Lock Washer (M8) (2) Gasket can not be reused. Replace with new. Tightening torque: 22.0 N•m 4) Install the Muffler from the muffler bracket. Bolt (M8-16L) (2) Tightening torque: 15.0 N•m Bolt...

  • Page 38: 3-3.6. Fuel Tank

    3.3.6 FUEL TANK Bolt 1) Install the fuel tank. Washer 2) Install the rubber pipe from the fuel valve. Bolt (M6-25L) (4) Washer (M6) (4) Tightening torque: 7.0 N•m 3.3.7 CONTROL PANEL AND CONTROL BOX Bolt 1) Install the control panel. Bolt (M6-25L) (4) Tightening torque: 7.0 N•m 2) Install the wiring from the control panel to the...
  • Page 39 6) Install the cover bracket to the bracket (1). Bolt (M5-12L) (2) Tightening torque: 4.0 N•m Cover Bracket 7) Connect the cell motor wiring. Connect 8) Connect the engine wiring. Connect Connect Connect 9) Cover the tube. Fix with wire band. Wire band can not be reused.

  • Page 40: Trouble Shooting

    MAIN WIRING RED WIRE(＋) (Main COIL) WHITE BRUSH WIRE DC WIRING (DC COIL) BRACKET Fig 5-1 ALTERNATOR RESISTANCE TABLE EZ6500CXS Item Standard level Resistance (Ω) R, REH, Type M, K, MK L, LB S, SB RK, RA, CL Limits Rated Voltage【V】...

  • Page 41: Engine Doesn't Start

    Turn the fuel valve to the “ON” position. position? Is the switch at “ON” Turn the switch to the “ON” position. position? Is there enough oil in Add the recommended the engine? oil. Please refer trouble shooting of HONDA ENGINE shop manual.

  • Page 42: Electric Starter Does Not Operate

    Is the battery working? Charge the battery. Check the connect battery. Replace the battery. Check the battery of voltage. Check the fuse. Melted of the fuse? Check “4-10 OTHER ELECTRICAL” . Replace the fuse. Please refer trouble shooting of HONDA ENGINE shop manual.

  • Page 43: Electricity At The A.c. Receptacle

    4-3. NO ELECTRICITY AT THE A.C. RECEPTACLE. Check " 4-1. Engine doesn't Is the generator working? start " . Is the AC circuit breaker, Push to reset the AC circuit "ON"? breaker is "ON".

  • Page 44: Alternating Current Voltage Is 0V

    4-4. ALTERNATING CURRENT VOLTAGE IS OV.

  • Page 45: Alternating Current Voltage Is Low (50～80V)

    4-5. ALTERNATING CURRENT VOLTAGE IS LOW (50～80V). Is the Brush working? Replace the brush. Check " 4-7. CHECKING BRUSH " . Is the AVR unit working? Check " 4-8. CHECKING Replce the AVR unit. A.V.R " . Is the Stator working? Check "...

  • Page 46: Checking Stator

    4-6. CHECKING STATOR 1) Remove control panel and disconnect stator wires at the connectors. 2) Measure the resistance between terminals CIRCUIT TESTER on stator leads. (Resistance) Check here the table (Fig 5-1) If stator is faulty, replace it with a new one. 3) Check the insulation resistance between stator core and each stator lead using a megger tester.

  • Page 47: Checking Rotor

    4-7. CHECKING ROTOR CIRCUIT TESTER 1) Remove the brush holder and measure (Resistance) resistance between the slip rings. Check here the table (Fig 5-1) If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.

  • Page 48: Checking Brush

    4-8. CHECKING BRUSH Check for continuity between the each brush tip and wire terminal as shown. ④ ③ CONTINUITY： ① (+)probe ① ② ③ ④ ○ ① (-)probe ○ ② ○ ③ ② ○ ④ The brushes must be smooth where they contact the slip rings.

  • Page 49: Checking A.v.r

    4-9. CHECKING A.V.R. (AUTOMATIC VOLTAGE REGULATOR) 1) Features This A.V.R. operates to control the field current in order to maintain the output voltage for the AC current, which generated by the magnetic flux by the field coil. 2) A.V.R. trouble may be identified by simply looking at the A.V.R., or by the inter-lead resistance with a tester, or actually mounting it in the generator and operating...

  • Page 50: Checking Other Electrical

    4-10. OTHER ELECTRICAL Circuit breaker inspection There should be continuity between the terminals with the circuit breaker in the ON position and no continuity with the circuit breaker in the OFF position. Voltmeter inspection Check the position to the pointer of Voltmeter. Pointer position 120V ：...

  • Page 51: Wiring Diagram

    4-11. WIRING DIAGRAM R, S, K Type...
  • Page 52 RK, LS, MK Type...
  • Page 53 REH, CL Type...
  • Page 54 M Type...
  • Page 55 SB, LB Type...
  • Page 56 L Type...
  • Page 57 62EAB00 2019.Sep...

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