Honda EG5500CXS Manual
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How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
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.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you 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 repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda EG5500CXS

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. 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 2 As you read this manual, you will find information that is MUFFLER preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment. ENGINE REMOVAL/INSTALLATION CYLINDER HEAD SAFETY MESSAGES CYLINDER BLOCK Your safety and the safety of others are very important.
  • Page 3 How to use this manual SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommended engine oil, unless otherwise specified.
  • Page 4 OUTLINE OF CHANGES How to use this manual Item After Before Starter Motor Harness Clip Base...
  • Page 5 MEMO...
  • Page 6: Service Information

    2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 CABLE/HARNESS ROUTING ······················ 2-2...
  • Page 7: Maintenance Standards

    SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Starter motor Brush length 10.5 (0.41) 4.0 (0.16) Mica depth 1.5 (0.06) 0.5 (0.02) CABLE/HARNESS ROUTING ( + ) BATTERY CABLE HARNESS BAND TERMINAL STARTER SOLENOID CABLE TERMINAL Do not secure the starter Terminal...
  • Page 8: Starting System

    9. STARTING SYSTEM STARTER MOTOR REMOVAL/ STARTER MOTOR DISASSEMBLY/ INSTALLATION·············································9-2 ASSEMBLY ··················································· 9-3 STARTER MOTOR INSPECTION ················ 9-4...
  • Page 9: Starter Motor Removal/Installation

    STARTING SYSTEM STARTER MOTOR REMOVAL/INSTALLATION STARTING SYSTEM Disconnect the starter motor wires and battery (+) cable from the starter motor. Remove the fan cover (Base shop manual : page 7-9). BOLT (8 x 35 mm) STARTER MOTOR WASHER STARTER SOLENOID WIRE BATTERY POSITIVE (+) CABLE SPRING WASHER NUT (6 mm)
  • Page 10 STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ASSEMBLY Remove the starter motor (page 9-2). BRUSH HOLDER BRUSH ASSEMBLY: NEGATIVE SPRING (4) I nstall the brush holder, brush BRUSH (2) springs, positive brushes, negative brushes, and two screws SCREW (2) to the center bracket as shown. BRUSH SPRING HOUSING ASSEMBLY:...
  • Page 11: Starter Motor Inspection

    STARTING SYSTEM STARTER MOTOR INSPECTION STARTER SOLENOID Connect the positive (+) lead of a 12V battery to the solenoid terminal [1] and the negative (-) lead to the solenoid wire terminal [2]. Measure the resistance between the starter motor solenoid terminals as shown. Continuity should exist when the battery is connected and not exist when the battery is disconnected.
  • Page 12: Overrunning Clutch

    STARTING SYSTEM ARMATURE CONTINUITY CHECK - COMMUTATOR TO SHAFT Check for continuity between the commutator and the armature shaft. Replace the armature if continuity exists between any of the commutator segments and the armature shaft (page 9-3). ARMATURE CONTINUITY CHECK - COMMUTATOR SEGMENTS Check for continuity between segments.
  • Page 13 STARTING SYSTEM STARTER SOLENOID WIRE Check the starter solenoid wire for continuity.
  • Page 14 INDEX INDEX CABLE/HARNESS ROUTING ········································2-2 STARTER MOTOR INSPECTION·································· 9-4 MAINTENANCE STANDARDS·······································2-2 STARTER MOTOR REMOVAL/INSTALLATION ··········· 9-2 STARTER MOTOR DISASSEMBLY/ASSEMBLY ··········9-3 10-1...

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