A Few Words About Safety

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 cause injury to your and/others. It could also damage this Honda product or create
unsafe conditions.

This manual describes the proper methods and procedures for performing service,
maintenance, and repairs. Some procedures require the use 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 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 reliability of this
product. Any error or oversight while servicing this this product can result in faulty operation,
damage to the product, or injury to others.

WARNING
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 precauitions in this
manual and other service materials carefully.

For Your Safety

Because this manual is intended for 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 warm 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.

WARNING
Failure to properly follow instructions and
precautions can cause you to be seriosly hurt or
killed.
Follow the procedures and precauitions in this
manual carefully.

2
Important Safety precautions
Make sure you have a clear understanding of all basic shop safety practices and 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.

3
INTRODUCTION
This manual covers the service and repair procedures for the Honda FA6500X.
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 any time 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 preceded by a symbol.
The purpose of this message is to help prevent damage to this Honda product, other property,
or the environment.

SAFETY MESSAGES
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:
! DANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
! WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
! CAUTION You CAN be HURT if you don’t follow instructions.
 Instructions – how to service these products correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN

THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE
AT THE TIME OF APPROVAL FOR PRINTING.
RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND
WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN
PERMISSION.
THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE
OF MAINTENANCE ON Honda PRODUCTS.

Date of Issue: Aug. 2019

4
SERVICE RULES
 Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do
not meet Honda’s design specifications may damage the unit.
 Use the special tools designed for the product.
 Install new gaskets, O-rings, etc. when reassembling.
 When torqueing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the
specified torque diagonally, unless a particular sequence is specified.
 Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
 After reassembly, check all parts for proper installation and operation.
 Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening
these screws will strip the threads and ruin the hole.

Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with
non-metric fasteners.
The use of incorrect tools and fasteners will damage the unit.

SYMBOLS
The symbols used throughout this manual show special service procedure.
If supplementary information is required pertaining to these symbols, it will be explained specifically in
the text without the use of the symbols.

5
 Table of Contents

A Few Words About Safety .......................................................................................................... 2

INTRODUCTION ........................................................................................................................ 4
SERVICE RULES ...................................................................................................................... 5
SYMBOLS .................................................................................................................................. 5

1. SPECIFICATIONS ................................................................................................................... 8
1-1. SPECIFICATIONS ........................................................................................................... 8
1-2. PERFORMANCE CURVE ................................................................................................. 9
1-3. GENERAL DESCRIPTION ............................................................................................ 12
1-4. SERIAL NUMBER .......................................................................................................... 13

2. MAINTENANCE ................................................................................................................... 14
2-1. MAINTENANCE SCHEDULE .......................................................................................... 14
2-2. FUEL TANK AND FILTER CLEANING .......................................................................... 15
2-3. FUEL TUBE CHECK ...................................................................................................... 16

3. REMOVAL AND INSTALLATION .......................................................................................... 17

3-1. PREPARATION AND PRECAUTIONS .......................................................................... 17
3-2. REMOVAL ..................................................................................................................... 19
3-2.1. CONTROL PANEL AND CONTROL BOX .................................................................. 19
3-2.2. FUEL TANK ................................................................................................................ 29
3-2.3. MUFFLER ................................................................................................................... 30
3-2.4. ALTERNATOR ............................................................................................................ 31
3-3. INSTALLATION ............................................................................................................. 33
3-3.1. ENGINE AND FRAME ................................................................................................ 33
3-3.2. ROTOR ....................................................................................................................... 33
3-3.3. STATOR ..................................................................................................................... 34
3-3.4. BRACKET (2) ............................................................................................................... 34
3-3.5. MUFFLER ................................................................................................................... 36
3-3.6. FUEL TANK ................................................................................................................ 37
3-3.7. CONTROL PANEL AND CONTROL BOX .................................................................. 37

6
4. TROUBLE SHOOTING ........................................................................................................ 39
4-1. ENGINE DOESN’T START. ............................................................................................ 40
4-2.NO ELECTRICITY AT THE A.C. RECEPTACLE. ............................................................ 41
4-3. ALTERNATING CURRENT VOLTAGE IS 0V. ................................................................ 42
4-4. ALTERNATING CURRENT VOLTAGE IS LOW (50～80V). ........................................... 43
4-5. CHECKING STATOR .................................................................................................... 44
4-6. CHECKING ROTOR ...................................................................................................... 45
4-7. CHECKING BRUSH ...................................................................................................... 46
4-8. CHECKING A.V.R. ......................................................................................................... 47
4-9. CHECKING.OTHER ELECTRICAL ............................................................................... 48
4-10. .WIRING DIAGRAM ..................................................................................................... 49

7
1. SPECIFICATIONS
1-1. SPECIFICATIONS
MODEL EZ3000CX

★ENGINE
Model Honda GP200

Displacement cm3 196

Oil Capacity ℓ 0.6

Regarding detailed specification, please refer and confirm HONDA ENGINE shop manual.

★GENERATOR
Type Self-exciting, 2pole, field rotating type

Voltage regulation system AVR

Phase Single

Rated power factor 1.0

R, REH,
Type K, M, MK L, LB S, SB LS
RK, RA, CL

Rated Voltage V 220 230 120 220 230

Frequency Hz 50 60

Rated kVA 2.3 2.6

AC output
Maximum kVA 2.5 3.0

★OTHERS
Fuel Tank Capacity ℓ 11.5

Length mm 595 (660)

Size Width mm 435 (560)

Height mm 485 (530)

Continuous operating Hr 7.3(50Hz) / 6.9(60Hz)

Dry Weight Kg 44.0

() With wheel kit

Specifications are subject to change without notice.

8
1-2. PERFORMANCE CURVES
-The curve shows performance of the generator under the average conditions.
-Performance may vary to some degree depending on ambient temperature and humidity.
-The output voltage will be higher the usual when the generator is still cold, immediately the
engine starts.

R, REH, RK, RA, CL Type

AC EXTERNAL CHARACTERISTIC CURVES

K, M, MK Type
AC EXTERNAL CHARACTERISTIC CURVES

9
L, LB Type
AC EXTERNAL CHARACTERISTIC CURVES

S, SB Type
AC EXTERNAL CHARACTERISTIC CURVES

10
LS Type
AC EXTERNAL CHARACTERISTIC CURVES

11
1-3. GENERAL DESCRIPTION

A IR C L E A N E R M A IN T E N A N C E
C L E AN E L E ME N T E VE RY 5 0 H OU RS ( E VE RY
1 0 H OU RS U N D E R D U S T Y C ON D IT ION S ) .
WAS H IN H IGH F L AS H - P OIN T S OL VE N T ,
S QU E E Z E D RY,T H E N D IP IN C L E AN E N GIN E
OIL AN D S QU E E Z E OU T E XC E S S OIL .

12
1-4. SERIAL NUMBER
Serial number is stamped on the label stuck on the fuel tank.

Always specify serial number when inquiring about the generator or ordering spare parts in
order to get correct parts and accurate service.

ENGINE SERIAL NUMBER GENERATOR SERIAL NUMBER

13
2. MAINTENANCE
2-1. MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
REGULAR SERVISE PERIOD
Performed at every indicated First Every Every
Every
month or operating hour interval, month 3month Year
Each 6month Refer to
whichever comes first. or or or
use or 100Hrs. page
20Hrs. 50Hrs. 300Hrs.
(3)
ITEM (3) (3) (3)

Engine oil Check level

O
Change
O O
Air cleaner Check
O
Refer
Clean
O (1) HONDA
ENGINE
Spark plug Check-Clean
O shop
manual.
Replace
O
Valve Check-Adjust
O (2)
clearance
Combustion Clean
After every 500 Hrs.(2)
Chamber
Fuel tank and Clean
O (2) 2-2
filter
Fuel valve Clean
O (2) 2-2
sediment cup
Fuel tube Check Every 2 years (2)
2-3
(Replace if necessary)

(1) Service more frequently when used in dusty areas.

(2) These items should be serviced by your dealer, unless the owner has the proper tools and is
mechanically proficient. See the service manual.
(3) For professional commercial use, log hours of operation to determine proper maintenance
intervals.
Failure to follow this maintenance schedule could result in non-warrantable failures.

14
2-2. FUEL TANK AND FILTER CLEANING
WARNING
Gasoline is highly flammable explosive.You can
be burned or seriously injured when handing fuel.
Keep heat, sparks, and flame away.
OFF Position
Handle fuel only outdoors.
Wipe up spills immediately.

1) Drain the fuel into a suitable container.

2) Turn the fuel valve to the “OFF”

3) Remove the fuel tank.

Fuel tank cap Fuel tank

INSTALLATION：
Fuel tank filter Wash to remove the sediment, before
installing.
INSTALLATION：
Always wash with gasoline.
Before installation, clean the screen
and check for damage.

O-ring
Fuel valve filter
INSTALLATION：
Fuel valve nut
Before installation, clean the screen
20N・m and check for damage.
Replace if necessary.
Fuel valve
Filter
INSTALLATION：
Check for any leakages INSTALLATION：
after assembly. Before installation, clean the screen
and check for damage.
Sediment cup
4.5N・m
O-ring

4) Remove the fuel valve.

5) Check the screen of the fuel valve filter for clogs or damage, replace if necessary.
Clean the fuel valve filter with non-flammable solvent, and allow them to dry thoroughly.
O-ring can not be reused. Replace with new.

15
6) Clean the sediment cup, O-ring, and filter in
nonflammable or high flash point solvent.
Filter
7) Reinstall the filter, O-ring, and sediment cup.
O-ring can not be reused. Replace with new.
O-ring
Tightening torque: 4.5 N•m
Sediment cup

8) Install a new O-ring to the fuel valve and install them to the fuel tank.

9) Tighten the fuel valve to the special torque.

Tightening torque: 20.0 N•m

10) After installation, check for any signs of fuel leakage.

2-3. FUEL TUBE CHECK

WARNING
Gasoline is highly flammable explosive.You can
be burned or seriously injured when handing fuel.
Keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.

1) Check the fuel tube foe deterioration, cracks or signs or leakage.

Replace if necessary.
Fuel tube

16
3. REMOVAL AND INSTALLATION

3-1. PREPARATION AND PRECAUTIONS

1) For safety, drain engine oil and gasoline to before work.

2) Be sure to memorize the location of individual parts when disassembling the generator so
that the generator can be reassembled correctly.
Tag the disassembled part with the necessary information to facilitate easier and smoother
reassemble.

3) For more convenience, divide the parts into several groups and store them in boxes.

4) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them
temporarily to their original position.

5) Handle disassembled parts with care; clean them before reassemble using a neutral
cleaning fluid.

6) Use all disassembly / assembly tools properly, and use the proper tool for each specific job.

TORQUE VALUES
Thread Dia. Torque Values
Item Remark
(mm) (N・m)

Fuel valve nut - 20.0

Sediment cup - 4.5
Generator rotor bolt 5/16-24UNF 23.0
Exhaust pipe mount nut M8 , P1.25 20.0
Muffler bracket mount bolt M6 9.0
brush holder mount bolt M5 3.0
AVR unit mount bolt M5 3.0

STANDARD TORQUE VALUES

Thread Dia. Torque Values
Item Remark
(mm) (N・m)
Screw M4 1.4
Bolt and nut M5 4.0
M6 7.0
M8 15.0

Regarding Engine torque values, please refer and confirm HONDA ENGINE shop manual.

17
HOW TO CONNECTION A WIRING

18
3-2. REMOVAL
3.2.1 CONTROL PANEL AND CONTROL BOX
1) Remove the end cover.
Bolt (M5-12L) (2)
Bolt

End cover

2) Remove the wiring from the control Green/Yellow wire

White wire
panel to the alternator.

3) Remove the Black wire and White wire

Bolt
from terminal block.
Black
wire

Terminal
4) Remove the Green/Yellow wire from
block
bracket (2).
Bolt (M5-12L) (1)

Bracket (2)

5) Disconnect the engine wiring.

Wire band Cutting.
Wire band can not be reused.
Replace with new.

Engine wire Wire band

Bolt

6) Remove the control panel.

Bolt (M6-20L) (4)

7) Remove the control box.

CONTROL BOX

19
Type: R, S

SWITC VOLT METER CIRCUIT BREAKER

Screw (M4-16) (2)

AC OUTPUT
GROUND TERMINAL

White wire Black wire

Green wire Black wire

Black wire
Green/Yellow wire
To Alternator wiring
Green/Yellow wire Connect for the bracket

To Engine wiring
Black wire
White wire
To Alternator wiring
Connect for the block terminal

20
Type: RK, MK, LS

CIRCUIT BREAKER
VOLT METER
SWITCH

Screw (M4-16) (2)

AC OUTPUT
GROUND TERMINAL

White wire Black wire Green wire Black wire

Black wire
Green/Yellow wire
Black wire
White wire
To Alternator wiring
Connect for the block terminal

Green/Yellow wire To Engine wiring

To Alternator wiring
Connect for the bracket

21
Type: REH

VOLT METER CIRCUIT BREAKER

SWITCH

Screw (M4-16) (2)

AC OUTPUT

GROUND TERMINAL

Black wire
Black wire
White wire Green wire

Green/Yellow wire Black wire

Black wire
White wire
To Alternator wiring
Connect for the block terminal
To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

22
Type: M

SWITC VOLT METER CIRCUIT BREAKER

Screw (M4-16) (2)

AC OUTPUT
GROUND TERMINAL

White wire Black wire Green wire Black wire

Black wire
Green/Yellow wire
Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

23
Type: K

SWITC VOLT METER CIRCUIT BREAKER

Screw (M4-16) (2)

AC OUTPUT
GROUND TERMINAL

White wire
Black wire Green wire Black wire

Black wire
Green/Yellow wire
Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

24
Type: SB, LB

SWITC VOLT METER CIRCUIT BREAKER

Screw (M4-16) (2)

AC OUTPUT GROUND TERMINAL

Green wire Black wire

Black wire
White wire

Black wire
Green/Yellow wire

Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

25
Type: CL

CIRCUIT BREAKER
SWITC VOLT METER

Screw (M4-16) (2)

AC OUTPUT GROUND TERMINAL

White wire Green wire Black wire

Black wire

Black wire
Green/Yellow wire

Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

26
Type: RA

CIRCUIT BREAKER
SWITC VOLT METER

Screw (M4-16) (2)

AC OUTPUT GROUND

White wire Green wire Black wire

Black wire

Green/Yellow wire Black wire

Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

27
Type: L

CIRCUIT BREAKER
SWITC VOLT METER

Screw (M4-16) (2)

AC OUTPUT GROUND

White wire Green wire Black wire

Black wire

Black wire
Green/Yellow wire

Black wire
White wire
To Alternator wiring
Connect for the block terminal

To Engine wiring
Green/Yellow wire
To Alternator wiring
Connect for the bracket

28
3.2.2 FUEL TANK
WARNING Rubber pipe OFF Position

Gasoline is highly flammable explosive.You can

be burned or seriously injured when handing fuel.
Keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.

1) Shut the fuel valve and discharge fuel from

carburetor.
Washer FUEL TANK

Bolt

2) Remove rubber pipe from the fuel valve.

3) Remove the fuel tank.

Bolt (M6-25L) (4)
Washer (M6) (4)

Fuel tank cap Fuel tank

INSTALLATION：
Fuel tank filter Wash to remove the sediment, before
installing.
INSTALLATION：
Always wash with gasoline.
Before installation, clean the screen
and check for damage.

O-ring
Fuel valve filter
INSTALLATION：
Fuel valve nut
Before installation, clean the screen
20N・m and check for damage.
Replace if necessary.
Fuel valve
Filter
INSTALLATION：
Check for any leakages INSTALLATION：
after assembly. Before installation, clean the screen
and check for damage.
Sediment cup
4.5N・m
O-ring

29
3.2.3 MUFFLER

CAUTION
The muffler becomes very hot during operation and Bolt
remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.

1) Remove the Muffler.

Bolt (M8-16L) (2)

Muffler
2) Remove the Muffler.
Exhaust pipe mount nut M8 (2)
Lock washer (M8) ‘(2) Gasket

Gasket cannot be reused.

Replace with new.

Exhaust pipe
mount Nut

Lock washer
3) Remove the Muffler bracket.
Muffler bracket mount bolt (M6-16L) (1)
Flat washer (M6) (1)
Lock washer (M6) (1) Muffler bracket
Nut (M8) (1)

Nut M8

Flat washer Muffler bracket

Lock washer mount bolt

30
3.2.4 ALTERNATOR
1) Remove the end cover.
Bolt (M5-12L) (2).

Bolt

2) Remove the wiring from the alternator.

Brush holder
Disconnect
3) Remove the AVR unit from bracket (2).
Bolt
Disconnect the AVR unit connector.
AVR unit mount bolt (M5-16L) (2)

Remove the brush holder from bracket (2).

Brush holder mount bolt (M5-16L) (1)
Bolt

AVR

Bracket (2)

4) Set the generator set with the bracket (2) upwards.

Bracket (2)
Anti-vibration rubber

5) Remove the nut fixing bracket (2). onto the

mount base with anti-vibration rubber.
Nut (M8) (1)

6) Remove the bracket (2).

Bolt (M6-155L) (4) Bolt

Nut

31
7) Take out stator cover with crows (2 pcs)
raised up by using a commercially available
screw driver.

8) Remove the stator.

The stator is heavy.

Be careful do not hit the coil of the stator to the rotor.

9) Remove the Generator rotor bolt of the rotor.

Generator rotor bolt (5/16-24UNF×205L) (1)

Hold the rotor using a commercially available

strap wrench.
Loosen the Generator rotor bolt.

10) Use a bolt and oil as a tool for pulling out rotor in the
following procedures :

Pour engine oil into the center hole of rotor shaft. Fill
with oil to the shaft end.
Size: M10 × 1.5

Apply a few turns of seal tape around the tip of the bolt.
Use commercially available 0.1mm thick and
oil resistant seal tape.

SEAL TAPE

Screw the bolt into the thread of the rotor shaft.

Torque the bolt using a socket wrench until the rotor

comes off loose.

* The hydraulic pressure inside the rotor shaft takes

apart the rotor from the engine shaft.

32
3-3. INSTALLATION

3.3.1. ENGINE AND FRAME Anti-vibration rubber

1) Install the anti-vibration rubbers to the frame.
Insert the setting tongue of anti-vibration rubbers
into the hole on the frame and tighten the nut
from the bottom of the frame.

Nut (M8) (4)

Nut
Tightening torque: 15.0 N•m

2) Install the engine into the frame from the side of

it.
Tighten the nuts over the anti-vibration rubber
bolts to fix.

Nut (M8) (2)

Tightening torque: 15.0 N•m

3.3.2. ROTOR
Nut
1) Wipe off oil, grease and dust from the tapered
portion of engine shaft and matching tapered
hole of rotor shaft.

2) Mount the rotor to the engine shaft.

Tighten the Generator rotor bolt.

Generator rotor bolt (5/16-24UNF×205L) (1)

Generator rotor bolt
Tightening torque: 23.0 N•m

33
3.3.3. STATOR
1) Put the stator in the engine.

3.3.4. BRACKET (2)

Plastic hammer
1) Put the bracket (2) over the rotor.
Pull out the stator wirings through the opening of Bracket (2)
the bracket (2).

Be careful not to give cuts to wires when pulling

them out from the bracket (2).

2) Tap on the rear cover evenly with a plastic

hammer to press the rotor bearing into the
bracket (2). Bolt
3) Fix the rear cover with bolts.

Bolt (M6-155L) (4)

Tightening torque: 7.0 N•m Anti-vibration rubber

Tighten the bolts evenly and in turns.

4) Install the bracket (2) into the anti-vibration rubber.

Nut (M8) (2)

Nut
Tightening torque: 7.0 N•m

34
 Brush holder
5) Install the brush holder and AVR unit onto
the bracket (2).
Connect the AVR unit connector.

AVR unit mount bolt (M5-16L) (2)

Brush holder mount bolt (M5-16L) (1)
Connect
Tightening torque: 3.0 N•m AVR

Bracket (2)

Brush holder
Push the brush holders so that the brushes
will be perpendicular to the slip rings, and
tighten the brush holder mount bolt.

If the brush is installed oblique to the slip ring, there is possibility that the
brush holder can break when the screw is tightened: or the brush may break
when generator of started.
Make this process carefully.

6) Set stator cover with the crow inserted into

slit and bent (2 pcs).
Insert the bend into the slit and caulking with
commercially available pliers.

35
3.3.5. MUFFLER

1) Install the Muffler bracket.

Muffler bracket mount bolt (M6-16L) (1)
Flat washer (M6) (1)
Lock washer (M6) (1)
Muffler bracket

Tightening torque: 9.0 N•m

Install the flange nut.

Nut (M8) (1)

Tightening torque: 15.0 N•m

Nut M8

Flat washer Muffler bracket

Lock washer mount bolt

2) Install the Muffler.

Mount the Exhaust pipe and the gasket on the cylinder head.
Exhaust pipe mount nut (M8) (2)
Lock washer (M8) (2)
Gasket
Gasket cannot be reused.
Replace with new.

Tightening torque: 18.0-22.0 N•m

Exhaust pipe
mount Nut

Lock washer
Bolt M8
3) Install the muffler and the muffler bracket.
Bolt (M8-16L) (2)

Tightening torque: 15.0 N•m

Muffler

36
3.3.6 FUEL TANK
1) Shut the fuel valve and discharge fuel from carburetor.

2) Install the fuel tank.

3) Connect rubber pipe from the fuel valve. Washer FUEL TANK

Bolt (M6-25L) (4)

Bolt
Washer (M6) (4)

Tightening torque: 7.0 N•m

3.3.7 CONTROL PANEL AND CONTROL BOX

1) Install the control panel.
Bolt (M6-20L) (4) Bolt

Tightening torque: 7.0 N•m

2) Install the wiring from the control panel to

the alternator.

CONTROL BOX

Green/Yellow wire
White wire

3) Install the Black wire and White wire

from terminal block.
Black
wire

4) Install the Green/Yellow wire from

bracket (2).
Bolt (M5-12L) (1)
Terminal
Tightening torque: 4.0 N•m block

Bracket (2)

37
5) Connect the engine wiring.
Fix with Wire band.
Wire band can not be reused.
Replace with new.

Engine wire Wire band

5) Install the end cover to the bracket (2). End cover

Bolt (M5-12L) (2)

Tightening torque: 4.0 N•m

Bolt M5

38
4. TROUBLE SHOOTING
Alternator view EARTH
GREEN/YELLOW
WIRE
BRUSH

YELLOW WIRE(－)

AC TERMINAL
BLOCK
BLUE WIRE(＋)

BLACK
WIRE

MAIN WIRING
(Main COIL)

WHITE
AVR WIRE

YELLOW WIRE
YELLOW WIRE

BRACKET
BROWN WIRE
BLUE WIRE

SUB WIRING
(SUB COIL)
Fig 5-1 ALTERNATOR RESISTANCE TABLE
EZ3000CX
Item Standard level
Resistance
(Ω)
R, REH, RK, RA,
Type K, M, MK L, LB S, SB LS Limits
CL
Rated Voltage【V】 220 230 120 220 230
Frequency 【Hz】 50 60
Main coil
1.550 0.300 1.100 ±10％
(Black - White)
Sub coil
2.900 2.400 1.600 ±10％
(Yellow - Yellow)
Rotor coil 46.0 ±10％
(Ω)

39
4-1. ENGINE DOESN’T START.

Is there fuel in the NO

Refill the fuel tank.
tank?

YES NO

Is the fuel valve “ON” NO Turn the fuel valve to the

position? “ON” position.

NO
YES

Is the switch at “ON” NO Turn the switch to the

position? “ON” position.

NO
YES

Is there enough oil in NO Add the recommended

the engine? oil.

YES NO

Please refer trouble shooting of HONDA ENGINE shop manual.

40
4-2. NO ELECTRICITY AT THE A.C. RECEPTACLE.

NO Check " 4-1. Engine doesn't

Is the generator working?
start " .

YES

Is the AC circuit breaker, NO

Push to reset the AC circuit
"ON"?
breaker is "ON".

41
4-3. ALTERNATING CURRENT VOLTAGE IS OV.

Remove the Panel wireing.

Start the engine, check the main coil voltage.

Check the Panel.

YES Check the cirecuit breaker is

ON position.
Check the wire for deterioration,
cracks or signs of leakage.

NO

Check the Brush ? NO

Replace is new.
Check " 4-7. CHECKING BRUSH ".

YES NO

Check the A.V.R ? NO

Check " 4-8. CHECKING A.V.R. ". Replace is new.

YES NO

Check the Stator ? NO

Replace is new.
Check " 4-5. CHECKING STATOR ".

YES NO

Check the Rotor ? NO

Replace is new.
Check " 4-6. CHECKING ROTOR".

42
4-4. ALTERNATING CURRENT VOLTAGE IS LOW (50～80V).

Is the Brush working? NO

Check " 4-7. CHECKING Replace the brush.
BRUSH " .

YES NO

Is the AVR unit working?

Check " 4-8. CHECKING NO Replce the AVR unit.
A.V.R " .

YES NO

Is the Stator working?

Check " 4-5. CHECKING NO Replce the stator.
STATOR " .

YES NO

Is the Rotor working?

Check " 4-6. CHECKING NO Replce the Rotor.
ROTOR " .

43
4-5. CHECKING STATOR

1) Remove control panel and disconnect stator wires at the connectors.

2) Measure the resistance between terminals

on stator leads.
Check here the table (Fig 5-1) CIRCUIT TESTER
(Resistance)
If stator is faulty, replace it with a new one.

3) Check the insulation resistance between

stator core and each stator lead using a
megger tester.

If insulation is bad, replace stator with a new

one.

MEGGER TESTER

44
4-6. CHECKING ROTOR

1) Remove the brush holder and measure

resistance between the slip rings. CIRCUIT TESTER
(Resistance)
Check here the table (Fig 5-1)

If the circuit tester is not sufficiently accurate, it may not show the values given and may give
erroneous readings.
Erroneous reading will also occur when there is a wide variation of resistance among coil
windings or when measurement is performed at ambient temperatures different from 20°C
(68°F).

2) Cleaning Slip rings the slip ring surfaces

must be uniformly bright.
Slip rings showing black spots, excessive
wear, or uneven wear must be repaired.
A stained slip ring lowers generator efficiency
and output voltage. SLIP RING
Polish the slip rings with fine sandpaper while
turning the rotor until rough spots disappear.
Care should be taken not to touch the rotor
coils with the sandpaper.

SAND PAPER

45
4-7. CHECKING BRUSH

Check for continuity between the each brush tip

and wire terminal as shown.
③ ④
CONTINUITY：
①
(+)probe
① ② ③ ④
① - - - ○
② - - ○ -
(-)probe
③ - ○ - - ②
④ ○ - - -

The brushes must be smooth where they

contact the slip rings. If not, polish smooth the BRUSH
brushes with sandpaper. A brush that is not
smooth produces arcs between the brush and
slip ring leading to possible damage.
Usable brush lengths are from 7 mm to 11 mm.
A brush shorter than 7 mm must be replaced
because decreased contact pressure between
the brush and slip ring lowers generator
efficiency and output voltage. 7 mm

46
4-8. CHECKING A.V.R.
(AUTOMATIC VOLTAGE REGULATOR)

1) Features
This A.V.R. operates to control the field
current in order to maintain the output voltage
for the AC current, which generated by the
magnetic flux by the field coil.

2) A.V.R. trouble may be identified by simply

looking at the A.V.R., or by the inter-lead
resistance with a tester, or actually mounting AVR
it in the generator and operating it.

Replace the case where the resistance is

significantly deviated from the measured new
one.
A.V.R.
TYPE
Yellow
Blue
Blue
AVR Brown
Yellow
Yellow

TESTER POLARITY ‘－’ （Ω）

CIRCUIT TESTER
Brown
Yellow(a) Blue(b) Blue① Yellow③ Yellow④
②
Yellow(a) - 1.5M ∞ ∞ 3.8M 4.3M
Blue(b) 3.9M - 2.2M ∞ 2.0M 2.1M
TESTER
POLARITY Blue① ∞ ∞ - 4.1M ∞ ∞
‘＋’ Brown② ∞ ∞ 3.4M - ∞ ∞
（Ω）
Yellow③ 8.5M 1.7M ∞ ∞ - 4.3M
Yellow④ 8.5M 1.6M ∞ ∞ 4.2M -
(Ω)(R±20%)

47
4-9. CHECKING OTHER ELECTRICAL
Circuit breaker inspection
There should be continuity between the terminals
with the circuit breaker in the ON position and no
continuity with the circuit breaker in the OFF ON
position.

OFF

Switch inspection
There should be continuity between the terminals ON
with the switch in the ON position and no continuity
with the circuit switch in the OFF position.

OFF

Voltmeter inspection
Check the position to the pointer of Voltmeter.

Pointer position
120V ： 110V to 130V.
220V ： 210V to 230V.
230V ： 220V to 240V.

Terminal
Make sure that the connector does not break the
cover.
Check that the female terminal does not open too
much.
If rusting occurs on the terminals, correct with sand
paper before connecting.

48
4-10. WIRING DIAGRAM
R, S Type

49
RK, MK, LS Type

50
REH Type

51
M Type

52
K Type

53
LB, SB Type

54
L Type

55
CL Type

56
RA Type

57
62EAA00 2019.Sep