Honda 6500 Watt Generator EG6500CL AT Rotor Replacement

ID: 136172

Description: This guide shows how to remove and replace the...

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.

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

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

54. Remove the stator cover.

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

56. 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.

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

58. Remove the recoil starter.

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

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

61. Insert the rotor puller tool into the rotor axle.
62. Hand-tighten the puller tool onto the rotor threads.

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

65. Remove the rotor.

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

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

72. 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.
73. You don't have to align the rotor precisely—it just needs to be in the general direction as shown.

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