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Honda 6500 Watt Generator EG6500CL AT Rotor Replacement

Introduction

This guide shows how to remove and replace the rotor for the Honda 6500 Watt Generator EG6500CL AT.

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

  1. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Honda 6500 Watt Generator EG6500CL AT Safety Precautions: step 1, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Honda 6500 Watt Generator EG6500CL AT Safety Precautions: step 1, image 2 of 2

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

    • Switch the circuit breaker off.

    Edit

  2. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Disconnect the spark plug: step 2, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Disconnect the spark plug: step 2, image 2 of 2

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

    • Pull firmly to disconnect the wire from the spark plug.

    Edit

  3. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 3, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 3, image 2 of 2

    • Twist the fuel valve clockwise into the cutoff position.

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  4. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the generator cover: step 4, image 1 of 1

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

    Edit

  5. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 5, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 5, image 2 of 2

    • Remove the generator cover.

    Edit

  6. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the brush assembly: step 6, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the brush assembly: step 6, image 2 of 2

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

    Edit

  7. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 7, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 7, image 2 of 2

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

    • Pull the brush assembly out slightly from its recess.

    Edit

  8. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 8, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 8, image 2 of 2

    • Disconnect the two spade connectors from the brush assembly.

    Edit

  9. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 9, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 9, image 2 of 2

    • Remove the brush assembly.

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

    Edit

  10. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Loosen the rear generator housing: step 10, image 1 of 1

    • 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).

    Edit

  11. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 11, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 11, image 2 of 2

    • 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).

    Edit

  12. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 12, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 12, image 2 of 2

    • Remove the rotor bolt and washer.

    Edit

  13. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 13, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 13, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 13, image 3 of 3

    • 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.

    Edit

  15. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Reassembly tip: step 14, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Reassembly tip: step 14, image 2 of 2

    • 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

    Edit

  16. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 15, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 15, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 15, image 3 of 3

    • 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.

    Edit

  17. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 16, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 16, image 2 of 2

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

    Edit

  18. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Loosen the mounting bolts: step 17, image 1 of 1

    • 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.

    Edit

  19. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 18, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 18, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 18, image 3 of 3

    • 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.

    Edit

  20. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 19, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 19, image 2 of 2

    • 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.

    Edit

  21. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the rear bushings: step 20, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the rear bushings: step 20, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the rear bushings: step 20, image 3 of 3

    • 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.

    Edit

  22. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 21, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 21, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 21, image 3 of 3

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

    • Remove the left bushing.

    Edit

  23. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 22, image 1 of 1

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

    Edit

  24. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the rear generator housing: step 23, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the rear generator housing: step 23, image 2 of 2

    • Remove the rear generator housing from the generator assembly.

    Edit

  25. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the stator cover: step 24, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the stator cover: step 24, image 2 of 2

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

    Edit

  26. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 25, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 25, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 25, image 3 of 3

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

    Edit

  27. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 26, image 1 of 1

    • Remove the stator cover.

    Edit

  28. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the stator: step 27, image 1 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the stator: step 27, image 2 of 3 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the stator: step 27, image 3 of 3

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

    Edit

  29. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Reassembly tip: step 28, image 1 of 1

    • 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.

    Edit

  30. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Remove the recoil starter: step 29, image 1 of 1

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

    Edit

  31. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 30, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 30, image 2 of 2

    • Remove the recoil starter.

    Edit

  32. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Brace the rotor: step 31, image 1 of 1

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

    Edit

  33. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 32, image 1 of 1

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

    Edit

  34. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Loosen the rotor: step 33, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Loosen the rotor: step 33, image 2 of 2

    • Insert the rotor puller tool into the rotor axle.

    • Hand-tighten the puller tool onto the rotor threads.

    Edit

  35. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 34, image 1 of 1

    • 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.

    Edit

  36. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 35, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 35, image 2 of 2

    • Remove the rotor.

    Edit

  37. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Transfer the rotor fan: step 36, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Transfer the rotor fan: step 36, image 2 of 2

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

    • Transfer the fan to your replacement rotor.

    Edit

  38. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Align and re-attach the rotor: step 37, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement, Align and re-attach the rotor: step 37, image 2 of 2

    • 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.

    Edit

  39. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 38, image 1 of 2 Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 38, image 2 of 2

    • 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.

    Edit

  40. Honda 6500 Watt Generator EG6500CL AT Rotor Replacement: step 39, image 1 of 1

    • 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.

    Edit
Conclusion

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

One other person completed this guide.

Author

Arthur Shi

Member since: 01/03/18

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