Honda 6500 Watt Generator EG6500CL AT Stator Replacement

Introduction

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

This procedure shows how to complete the procedure without removing the generator from the frame.

You will need some wooden blocks that are about 2.5 inches tall to support the generator.

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Étape 1 Honda 6500 Watt Generator EG6500CL AT Safety Precautions

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Honda 6500 Watt Generator EG6500CL AT Safety Precautions: étape 1, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Honda 6500 Watt Generator EG6500CL AT Safety Precautions: étape 1, image 2 de 2

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

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Étape 2 Disconnect the spark plug

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Disconnect the spark plug: étape 2, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Disconnect the spark plug: étape 2, image 2 de 2

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

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Étape 3

Twist the fuel valve clockwise into the cutoff position.

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Étape 4 Remove the generator cover

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the generator cover: étape 4, image 1 de 1

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

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Étape 5

Remove the generator cover.

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Étape 6 Remove the brush assembly

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the brush assembly: étape 6, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the brush assembly: étape 6, image 2 de 2

Squeeze and disconnect the stator connector from the wiring harness.

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Étape 7

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

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Étape 8

Disconnect the two spade connectors from the brush assembly.

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Étape 9

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

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Étape 10 Loosen the rear generator housing

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Loosen the rear generator housing: étape 10, image 1 de 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).

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Étape 11

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).

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Étape 12

Remove the rotor bolt and washer.

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Étape 13

Honda 6500 Watt Generator EG6500CL AT Stator Replacement: étape 13, image 3 de 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.

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Étape 14 Reassembly tip

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Reassembly tip: étape 14, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Reassembly tip: étape 14, image 2 de 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

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Étape 15

Honda 6500 Watt Generator EG6500CL AT Stator Replacement: étape 15, image 3 de 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.

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Étape 16

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

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Étape 17 Loosen the mounting bolts

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Loosen the mounting bolts: étape 17, image 1 de 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.

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Étape 18

Honda 6500 Watt Generator EG6500CL AT Stator Replacement: étape 18, image 3 de 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.

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Étape 19

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.

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Étape 20 Remove the rear bushings

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the rear bushings: étape 20, image 1 de 3

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the rear bushings: étape 20, image 2 de 3

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the rear bushings: étape 20, image 3 de 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.

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Étape 21

Honda 6500 Watt Generator EG6500CL AT Stator Replacement: étape 21, image 3 de 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.

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Étape 22

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

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Étape 23 Remove the rear generator housing

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the rear generator housing: étape 23, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the rear generator housing: étape 23, image 2 de 2

Remove the rear generator housing from the generator assembly.

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Étape 24 Remove the stator cover

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the stator cover: étape 24, image 1 de 2

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the stator cover: étape 24, image 2 de 2

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

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Étape 25

Honda 6500 Watt Generator EG6500CL AT Stator Replacement: étape 25, image 3 de 3

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

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Étape 26

Remove the stator cover.

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Étape 27 Remove the stator

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the stator: étape 27, image 1 de 3

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the stator: étape 27, image 2 de 3

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Remove the stator: étape 27, image 3 de 3

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

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Étape 28 Reassembly tip

Honda 6500 Watt Generator EG6500CL AT Stator Replacement, Reassembly tip: étape 28, image 1 de 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.

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