Honda 6500 Watt Generator EG6500CL AT Rear Generator Housing Replacement

ID: 135762

Description: This guide shows how to remove the rear...

Steps:

1. Before you work on the device, make sure to switch the engine off.
2. Switch the circuit breaker off.

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

5. Twist the fuel valve clockwise into the cutoff position.

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

7. Remove the generator cover.

8. Squeeze and disconnect the stator connector from the wiring harness.

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

11. Disconnect the two spade connectors from the brush assembly.

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

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

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

19. Remove the rotor bolt and washer.

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

24. During reassembly, use these photos as a reference for how to re-stack the terminal posts. From the terminal base to tip:
25. Base washer
26. Crush washer
27. Stator wire connector
28. Nut
29. Wiring harness connector
30. Crush washer
31. Nut

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

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

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

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

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

43. 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.
44. Tilt the generator assembly by lifting the rear housing slightly.
45. Place support blocks underneath the silver generator housing to support the generator assembly.
46. The generator weight should rest on the support blocks and no longer on the rear bushings.
47. Do not support the generator by the black stator cover.

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

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

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