HONDA ES6500 GENERATOR DISASSEMBLY

When we visited the tower trailer to replace the tilt motor, this generator was working as expected.  It started right up, ran fine, and provided power to the motors for operation.  When we visited again in the summer of 2024, it did not start.  More air was coming OUT of the carburetor than was going in, and we theorized a valve might be stuck open.  Mike opened the valve cover during field day and saw everything was moving fine, so this was going to need way more research.  It turns out the timing belt has skipped six teeth.  According to honda engine and generator repair forums, this does happen sometimes.  Thankfully the valves are non-interference and do not hit the pistons in any position.  When disassembling the engine, I noticed a lot of mouse house supplies on the tiny gear at the drive shaft.  Maybe the engine skipped a bunch of timing teeth as the grass and mouse fluff passed under the belt.  There were no dead mice in the belt, just a failed attempt at building a nest.   Getting parts for this generator, possibly built between 1985-1995, is still possible but some items are no longer available.  I'm removing only what is necessary and it seems we will only need some gaskets and all the rubber hoses.  The fuel tank is not damaged from rust, which is fortunate as a replacement tank is several hundred dollars!    

Quinn will tell you how challenging it is to lift this monster.  Most of the weight is the copper in the generator, followed by five gallons of fuel and the engine and the frame.  It took an angle grinder and impact driver to remove it from the trailer.  Four of the eight bolts were welded shut.

This is where I'm finding replacement parts

Honda Power Sport Parts 


Chassis serial EA1-1035066

Engine serial GAOI-1201184


PAINT AND RE-ASSEMBLY

Not done yet.  I'm ultrasonic cleaning everything that will fit in my ultrasonic cleaner, then Rustoleum Restore painting everything steel.    Everything else will get a wonderful coating of Fluid Film.  We need to get Fluid Film to sponsor our club, somehow.