Honda EG5500CXS, EG6500CXS Manual 14 Pages

The Honda EG5500CXS is a powerful and reliable generator designed to provide backup power in a variety of applications. It features a robust engine, a durable construction, and a user-friendly design. This generator can power essential appliances and equipment, such as lights, refrigerators, and small tools, during power outages or when accessing electricity is limited. Its compact size and portability make it ideal for camping, tailgating, or other outdoor activities.

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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 manual 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 precautions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this manual 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.
0-1
How to use this manual
INTRODUCTION
This supplement covers the construction, function, and
servicing procedures of the Honda EG5500CXS/
EG6500CXS Generator.
OUTLINE OF CHANGES
SPECIFICATIONS
1
SERVICE INFORMATION
2
MAINTENANCE
3
TROUBLESHOOTING
4
FUEL SYSTEM
5
GOVERNOR SYSTEM
6
GENERATOR/CHARGING SYSTEM
7
IGNITION SYSTEM
8
STARTING SYSTEM
9
OTHER ELECTRICAL
10
preceded by a
symbol. The purpose of this
message is to help prevent damage to this Honda
product, other property, or the environment.
MUFFLER
11
ENGINE REMOVAL/INSTALLATION
12
SAFETY MESSAGES
CYLINDER HEAD
13
CYLINDER BLOCK
14
TECHNICAL FEATURES
15
WIRING DIAGRAMS
16
For service information that is not covered in this
supplement, please refer to the EG5500CXS/
EG6500CXS base shop manual (part number
82Z3000).
All information contained in this manual is based on the
latest product information available at the time of
printing. We reserve the right to make changes at
anytime without notice.
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any
means, electronic, mechanical, photocopying,
recording, or otherwise, without prior written permission
of the publisher. This includes text, figures, and tables.
As you read this manual, you will find information that is
Your safety and the safety of others are very important.
To help you make informed decisions, we have
provided safety messages and other safety information
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated
with servicing these products. You must use your own
good judgement.
You will find important safety information in a variety of
forms, including:
· Safety Labels – on the product.
· Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER,
WARNING, or CAUTION.
These signal words mean:
INDEX
The marked sections contain no changes.
They are not covered in this supplement.
Note this supplement is applicable only to the engine serial
numbers listed in the table shown below.
Model
Engine serial number
GX390H1 GCAFH-0372947 and subsequent
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
· Instructions – how to service these products correctly
and safely.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: September 2013
0-2
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.
Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use marine grease (water resistant urea based grease).
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use automatic transmission fluid.
(
0-3
x )( )
page 1-1
Indicates the diameter, length, and quantity of metric bolts used.
Indicates the reference page.
OUTLINE
OFthis
CHANGES
How to use
manual
Item
Starter Motor
After
Before
Harness Clip
Base
0-4
MEMO
2. SERVICE INFORMATION
2
MAINTENANCE STANDARDS ·····················2-2
CABLE/HARNESS ROUTING ······················ 2-2
2-1
SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
ENGINE
Part
Starter motor
Item
Brush length
Mica depth
Unit: mm (in)
Service limit
4.0 (0.16)
0.5 (0.02)
Standard
10.5 (0.41)
1.5 (0.06)
CABLE/HARNESS ROUTING
(+) BATTERY CABLE
TERMINAL
HARNESS BAND
STARTER SOLENOID
CABLE TERMINAL
Do not secure the starter
cable at harness band
Terminal
number
Wire color
Bl
W
STARTER SOLENOID
CONNECTOR
2-2
Terminal
number
Wire color
Bl/W
9. STARTING SYSTEM
STARTER MOTOR REMOVAL/
INSTALLATION·············································9-2
STARTER MOTOR DISASSEMBLY/
ASSEMBLY ··················································· 9-3
STARTER MOTOR INSPECTION ················ 9-4
9-1
9
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)
2.5 N·m (0.3 kgf·m, 2 lbf·ft)
9-2
STARTING SYSTEM
STARTER MOTOR DISASSEMBLY/ASSEMBLY
Remove the starter motor (page 9-2).
BRUSH HOLDER
BRUSH
ASSEMBLY:
SPRING (4)
Install the brush holder, brush
springs, positive brushes,
negative brushes, and two screws SCREW (2)
to the center bracket as shown.
NEGATIVE
BRUSH (2)
BRUSH SPRING
HOUSING
ASSEMBLY:
Make sure there is no
obstruction on the magnets.
POSITIVE BRUSH
SCREW
(5 x 30 mm) (3)
POSITIVE
BRUSH (2)
CENTER BRACKET
BRUSH HOLDER
ARMATURE
SNAP RING
NUT (6 mm)
SCREW (5 x 13 mm) (2)
2.5 N·m (0.3 kgf·m, 2 lbf·ft)
(LEFT HAND THREADS)
STARTER
SOLENOID
WASHER (2)
SCREW
(5 x 20 mm) (2)
NEGATIVE
BRUSH (2)
SCREW (5 x 20 mm)
BRUSH
SPRING (4)
5 N·m (0.5 kgf·m, 4 lbf·ft)
POSITIVE
BRUSH (2)
SPRING WASHER
SNAP RING
SEAL
STARTER
SOLENOID WIRE
WASHER
NUT (6 mm)
3.7 N·m (0.4 kgf·m, 3 lbf·ft)
CENTER BRACKET
DRIVE
PINION GEAR
REDUCTION
GEAR
OVERRUNNING CLUTCH/PINION GEAR
DRIVE SIDE
HOUSING
9-3
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.
[2]
[1]
BRUSH LENGTH
Measure the brush length.
If the negative brush length is less than the service limit,
replace the center bracket.
If the positive brush length is less than the service limit,
replace the center bracket.
STANDARD:
10.5 mm (0.41 in)
SERVICE LIMIT: 4.0 mm (0.16 in)
BRUSH CONTINUITY CHECK
Check for continuity between the positive (+) brushes
[1] and negative (-) brushes [2].
There should be continuity between both the positive
brushes.
There should be continuity between both the negative
brushes.
There should be no continuity from either positive brush
to either negative brush.
If the correct continuity of the positive (+) brushes is not
obtained, replace the center bracket (page 9-3).
If the correct continuity of the negative (-) brushes is not
obtain, replace the negative (-) brushes.
ARMATURE MICA DEPTH
Visually inspect the commutator surface for dust, rust,
or other damage. If necessary, wipe it with a clean lintfree cloth. If rusted or damaged, dress with a fine emery
cloth.
When the mica is clogged, or its depth is smaller than
the service limit value, recut the grooves using a
hacksaw blade or a small file.
STANDARD:
1.5 mm (0.06 in)
SERVICE LIMIT: 0.5 mm (0.02 in)
9-4
[1]
[2]
[2]
[1]
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. If an open
circuit (no continuity) exists between any two segments,
replace the armature (page 9-3).
OVERRUNNING CLUTCH
• Do not apply oil or grease to the pinion gear [1] and
dumper clutch [2].
• Do not use non-flammable solvent for cleaning the
pinion gear and dumper clutch.
Check the pinion gear operation by holding the pinion
gear shaft [3] and turning the pinion gear. The pinion
gear should turn clockwise freely and should not turn
counterclockwise.
If the pinion gear operation is not smooth, apply grease
to the pinion gear shaft or replace the overrunning
clutch if necessary.
[1]
Check the pinion gear for wear or damage, and
replace the overrunning clutch if necessary.
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.
[2]
[3]
9-5
STARTING SYSTEM
STARTER SOLENOID WIRE
Check the starter solenoid wire for continuity.
9-6
INDEX
INDEX
CABLE/HARNESS ROUTING ········································2-2
MAINTENANCE STANDARDS·······································2-2
STARTER MOTOR DISASSEMBLY/ASSEMBLY ··········9-3
C
M
STARTER MOTOR INSPECTION·································· 9-4
STARTER MOTOR REMOVAL/INSTALLATION ··········· 9-2
S
2
10-1

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Key Features

  • Powerful engine
  • Reliable performance
  • Durable construction
  • User-friendly design
  • Portable and compact
  • Quiet operation
  • Fuel-efficient operation
  • Easy maintenance
  • Extended runtime
  • Automatic voltage regulation

Frequently Answers and Questions

What is the maximum power output of the Honda EG5500CXS?
The Honda EG5500CXS has a maximum power output of 5500 watts.
How long can the Honda EG5500CXS run on a full tank of fuel?
The runtime of the Honda EG5500CXS depends on the load being used. However, it can provide several hours of runtime on a full tank of fuel.
Is the Honda EG5500CXS easy to start?
Yes, the Honda EG5500CXS is designed for easy starting and includes a user-friendly electric start system.
How do I maintain the Honda EG5500CXS?
Regular maintenance is important for optimal performance and longevity. You should refer to the user manual for specific maintenance instructions, including oil changes, air filter cleaning, and spark plug replacement.
What kind of fuel does the Honda EG5500CXS use?
The Honda EG5500CXS generator uses unleaded gasoline.

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