Vintage Honda EM500 - High Voltage Problem

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A subscriber sent me his Vintage Honda EM500. It served him well for over 4 decades. Recently it started producing close to 200 volts on the 120 volt outlet. Most of the parts are long discontinued. Can it be saved?
AVR Teardown Video: • Honda EM500 Generator ...
Generator Model: EM500
AVR Part: 32350-892-632
Rod joint: 16956-892-000
Service Manual Resistance Values:
Excitation winding (Y-Y): 1.04 ohms
Stator excitation (W-B): 24.7 ohms
Main winding (R-L): 2.82 ohms
Sense winding (LG-BI): 0.5 ohms
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AVR, Alternator, Bench Test, Broken Spacer, Brushless, EM500, Fixed, Generator, Hertz, High Voltage, Honda, How To, How-To, Insulation Test, Insulator, JB Weld, Kill A Watt, Load Test, Obsolete, Ohms Test, Oscilloscope, Repair, Resistance Test, Sine wave, Small Engine, THD, Too Much Power, Troubleshooting, Vintage, Volts

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Опубликовано:

1 фев 2023

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Комментарии : 640

@aboveaveragejoe6291 Год назад

He did a great job packing it in the box.

@jcondon1 Год назад

Best packing job I have seen.

@sergioaguayogarciara Год назад

@@jcondon1 Same thought here

@bcad4066 Год назад

The repurposed Omaha Steaks box was brilliant.👍

@louisbigelow1866 Год назад

Thank you.

@louisbigelow1866 Год назад

If you were going to use a universal AVR and the output voltage from that AVR was too high, then it is possible to calculate a value of a resistor to drop say 4 v, you can use ohm's law to calculate the value and since you're power supply was showing both voltage and current the calculation could be fairly easy. I you would just need to calculate the lower limit of the voltage... Might be a good experiment when another one of these comes up.

@Skynet-1 Год назад

Pretty impressive how that little generator came back to life and runs so well! On a side note, I'd hate to be in your shoes when your wife finds out you cleaned those parts in the kitchen sink... 😉👍👍👍

@donwatson8257 Год назад

I'm gonna say no it looked like some bad hammertone copper from the 70,s

@sunbeam8866 Год назад

Maybe it used to be a kitchen sink, but it's been relocated!

@michaelripley4528 4 месяца назад

I find it very very cute🥰

@hydrochloricity 6 месяцев назад

That carb insulator looks like the perfect sort of part that could be replicated by a simple 3d print. With a few measurements and the right material that could be produced as needed for anyone. I love these old suitcase gens, really cool video!

@danmenes3143 5 месяцев назад

You would have to be careful in your choice of filament/resin. Most 3D printer materials will have neither the chemical resistance nor the heat resistance to work in that location reliably. The original part appears to be phenolic, which can't be 3D printed. Maybe you could get away with nylon, but I think you need a high-temperature printer for that.

@hydrochloricity 5 месяцев назад

@@danmenes3143 That's true, though I think ABA or ABS would also be capable. ABS & Nylon can be printed ~240C which most printers can do, but they need good ventilation. I've also used PETG parts in vehicle engine bays before and they work fine, but they also aren't in contact with fuel. Ironically, I did have to create some parts that were immersed in gasoline later, and I did it in both PLA & PETG. Despite PETG supposedly being resistant to gas and PLA not, the PLA parts survived and the PETG ones failed!

@myrandabrown Год назад

Maybe a parts washer or a shop sink should be next on the list of upgrades so you’re not using the kitchen sink and harming the beautiful patina of that beautiful sink. 😆

@isettech Год назад

Just an FYI, Many of those small Honda generators of that series has a magnet embedded in one of the pole pieces to ensure startup voltage. When applying field power, it is possible to have the polarity reversed and will buck the magnet, resulting in a range where the voltage decreases with increasing field voltage. As a result of this bias magnet, polarity of the field is not symmetrical. One polarity will produce a higher voltage and a lower voltage when reversed. This is most noticable with low excitation voltage. Due to the magnet, these are designed to never lose residual magnetism and fail to excite. Nice touch by Honda. The magnet is not in the rotor, but in a pole piece of the excitation stator.

@artpatronforever Год назад

That unconnected mystery connector is possibly the AVR 50Hz plug that is swapped on a generator being run to produce 50Hz. There are 2 connectors, one for 60Hz and another for 50Hz, so one is connected to select 60Hz or 50Hz and the other is unconnected.

@geoffreymichalisko8994 Год назад

I recently purchased a gear from a fellow who prints them from a 3d printer if he has the original. It might be possible to print your carb-housing since you have most of the parts. Good luck, great video.

@workaholic5318 Год назад

For future reference, a spring inside the replacement fuel line will allow you to make bends you couldn't with a non-formed line.

@1Walrus23 Год назад

A spring on the outside is just as effective, and would cause less impedance on the flow. The bonus is its less likely to be corroded by any impurities in the fuel. Downside is it can be corroded by everything in the air. 😅 I've used this in low volume water cooling for insanely bright LED lamps, where in the water loop I'm running de-ionised water to reduce conductivity, so the less different metals in the system the better, hence external springs.

@ronaldmiller2031 3 месяца назад

Actually, the spring inside keeps the hose from kinking a spring on the outside would not do the same thing

@tubemember21 Год назад

Thanks for this video! I have a 40 year old EM800 which has been used to power my family's off grid cabin since the 80s. It probably has thousands of hours on it. The only maintenance has been oil changes and spark plugs and a new air filter. I think the pull rope is even original. As far as I can tell the EM-500, 600, and EX800 are very similar. So I'll come back to this video if I ever have any issues! Great job like always.

@GH-wt7ww Год назад

Japanese quality period , and I also was amazed with the THD. Vintage Hondas units were built to last and become heirlooms if taken care of. Once again James great video.

@douglofreddo7886 Год назад

Would you say the same for modern Honda generators?

@GH-wt7ww Год назад

@@douglofreddo7886 No, my brother bought a Honda EU2200 3 years ago. Upon opening and first start he had to return and exchange for another because it would not run right. The second ran good but you can feel the cheaper materials being used today. Still runs and works today but kinda walks when running in eco mode.

@gerardb.ducoudray8881 9 месяцев назад

When I was a child [10y old] I remember my dad telling the machine operator that was sleeping on the job "Wake up the japanese are coming"

@davidblake6889 Год назад

Really great video. Thanks, James. I am sure Big Clive could reverse engineer the AVR for you, and probably get the values of the components as well. I feel sure they could be made for a lot less than 200 USD

@KensSmallEngineRepair Год назад

Gary’s AVR video came out minutes before yours and he spoiled it for me!!!

@ericvaughn1126 Год назад

Glad I'm not the only one without a slop/laundry sink. Lots of air filter housings and covers cleaned in my kitchen sink too if I can't, or decide not to, do it outside with a pressure washer. Nice repair AND resto as it turned out!

@scroungasworkshop4663 Год назад

My wife hasn’t tweaked that I often to turn the dishwasher on while she’s out. Shhhhhhhh🤫

@ericvaughn1126 Год назад

@@scroungasworkshop4663 😯😳

@larrytalley117 Год назад

James! That’s a hammered copper sink!! Your wife must be an angel. Once I cleaned a quadrajet carb in our dishwasher. That was almost 30 years ago and I will never do that again.

@PeterHynes Год назад

Once again james - top job - I remain addicted to your content. I love the science lessons embedded in your fixes. Doing homework now on excitation windings, stator excitation and sensor windings to try to keep up! Please keep the content coming!

@wildefox1478 Год назад

That's a pretty cool little generator, all it needed was a new avr and tins, nice work repairing this generator James!

@davidfogelberg8989 Год назад

What love you show these generators. It's always rewarding to watch your videos. Greetings!

@zrkn1 Год назад

Such a beautiful lil genny, thank goodness you saved her and even cleaned her up a bit. I hope you get the info on the ancient AVR to save even more EM500s. Excellent video production and liked the short split screen effect, surprised me 🙂

@phillipeaston6738 Год назад

You are a terrific guy - I watch hours on end into your work and hats off to you. Keep it coming and thanks for all your input

@idontneedaname85 Год назад

Fantastic video. You just thrust me into understanding the magic pixies electron flow. Seriously that experiment was awesome. You fill in a few gaps i had.

@csit8513 Год назад

Excellent work as usual, love watching all your videos.

@mikeg3893 Год назад

Pretty impressive repairs!! First time watching you hope for more!! Thanks

@shawnmrfixitlee6478 Год назад

perfect restore on a great old Honda.. ENJOYED James ! 👍👍

@deangentles4966 Год назад

Hi James always great sitting in your class mate A 40 year old Honda a quality machine glad to see you have given it another life time of use thanks for sharing

@arthurbiringer5676 Год назад

As usual, I have faith in you, great job! And the little guy works like new!

@bruceeverett5372 Год назад

First off --Lewis -- excellent packing...I spotted the Omaha Steaks cooler, and I have one waiting in my basement for just such duty! James, you are 1/2 artist, 1/2 mad Scientist ! I always enjoy your thoughtfully presented content. I am the owner of an EM500 myself, still run it twice a year just to keep it serviceable, have the original manual and 12v leads as well. Mine gets a bit wonky at 350 + watts but still hangs in there. I've used it to power a small (1/5 hp) pump to drain a flooded basement (3+" standing), it still has it's value and will probably keep working for years to come. I have three other Honda gennies including the newest Eu7000is which will run a home if necessary ! Quality lasts and inspires confidence...thank you Soichiro!

@johnnybgoode6466 Год назад

yet again another great video James. The Honda build quality speaks for itself when you clearly see them here 40 years later. Hopefully someone will have the details for a new circuit board construction. Keep em coming James.

@persistent25u Год назад

James Condon, Nice job with this genny :-) Thanks for the content. You taught me stuff in your video and pushed me to keep stopping it to look stuff up. I really liked the video and am impressed with your KSAs.

@andrewrussack8647 Год назад

Your calm manner and attention to detail is sublime! It is great to see equipment and plant returned to service rather than just chucked out.

@davidsmith-ih2kk Год назад

Don't beat yourself up about nicking the fuel line, other seasoned mechanics probably do the same, I know I do. From my perspective your pretty well clued up on exiltation fields and field coil resistance, and voltages, so rest easy about the fuel line. It's good watching you fault find to this level of expertise. A very good comprehensive video, great to ⌚️ watch well done my friend well done

@davedemo8229 Год назад

oh boy there goes my morning. They are such cute generators. nice job Jim thanks for the shout out.

@jcondon1 Год назад

That Dave for the tins and letting me borrow the manual. Which reminds me I need to return it.

@justinvanaulen2478 Год назад

Nice video Jim. I love old Honda Generators. The quality and craftsmanship of these is second to none. Even the newer EU2000, EU2200 and EU3200 have amazing build quality and fit an finish. It's amazing you were able to get that AVR! I couldn't tell by the logo on the side of the AVR, but was that made by Sawafuji? Nice troubleshooting as usual. 100k subs is near!

@rickolson9011 Год назад

Where can I get the service manuals for the EU 2000. So often that seems to be the secret to knowing resistance values etc. another great video. Thank you.

@davida1hiwaaynet Год назад

Excellent video. So happy you saved that tiny and vintage generator. I really like the old and odd stuff.

@kerrygleeson4409 Год назад

Fantastic work James as always

@bobsrepairshop Год назад

Thanks James, I learned a lot about generator AVR's. Loved the trouble shooting, and explanation with three voltmeters. That sort of thing is what sets you apart from other content creators.

@themaritimegirl Год назад

Thank you for covering every detail meticulously and with such high quality. I received an EM600 three years ago, and while it always used to run perfectly, it recently started being hard to start, hunts, and it will die with a big enough load on it. I've never worked on an engine, but this video will help me hopefully clean the carb and go through any other troubleshooting steps.

@P_RO_ Год назад

Be very careful with the brittle old plastics and you should be OK.

@tombenvenuto204 Год назад

Another great JC video. Thanks for posting!

@lpconserv6074 Год назад

Another great outcome from what I thought was going to be a sure dead end. Determined to do it right and success was in the bag. Thanks for the education!!

@iandennis7836 Год назад

Arrr, another (dual) fix, one for me and one for the genny, I feel better now. Cheers Jim.

@lesallison9047 Год назад

What a fantastic little generator, glad it got saved. ✌♥️🇬🇧

@NY411Info Год назад

Nice to see the owner wanted to save her from the boneyard. Nice diag. and fix. Thanks from all of us here in comment land.

@ericblackwood1286 Год назад

Thanks for your videos you have helped me with my generator and problems I had

@mafosa8519 Год назад

Top notch repair!

@mdiamond5482 26 дней назад

Continually impressed by your knowledge and skill. Great work!

@rodneymiddleton9624 Год назад

Another great video and fix. Thanks James!!

@TheBeardedDog Год назад

Excellent video as always. Also, that is the nicest utility/garage sink I have ever seen. 🤣

@Me11oIngenuity Год назад

HA! Clever video work at the end. I thought I was losing my mind. Thanks for the video!

@dirtroadsailing6418 Год назад

Great video. I like to see people bring these old Honda's back to life, they are precision built machines, unlike most things made today. I liked the trick with the wire and hot water to make a bend in the fuel line, I never would have thought of that. I certainly hope that that sink you cleaned that baseplate in was in your shop and not in your wife's kitchen, or this may be your last video.

@oyemendigo7344 Год назад

My wife would kill me

@RPRosen-ki2fk Год назад

My eyes rolled back in my head when I saw that.

@HappilyHomicidalHooligan Год назад

ESPECIALLY when she discovers that it wasn't HIS toothbrush he used to do the fine detail cleaning... 😄😁😆😅😂🤣

@pc5569 Год назад

Hello James. Very interesting little generator. I guess you just can't put a Honda to rest. Thank you for adding the waveform and THD data on your repair.

@RobertKohut Год назад

Amazing it runs so well, more amazing you fixed it... 🙂

@johncourtneidge Год назад

Beautifully packed!

@YukonHawk1 Год назад

Professor Condon once again schools us all.😁😁😁 what a great machine and thanks to you it will last another 40 years.

@erictofsrud7932 Год назад

Super great troubleshooting !!! I was on track with you're ever move!!

@tedheierman1181 Год назад

Great video and loved the extra meter testing!

@rancelynch6514 Год назад

Rance here…Another very good instructional video. You are an excellent caring teacher!

@jcondon1 Год назад

Thanks Rance

@breikowski Год назад

The lift is a great addition to your shop, really saves back and knees!

@gregsappington9991 Год назад

Great job as always!!

@Brokynwings Год назад

I just inherited one of these generators and and been having carb issues. Thanks for the video. 👍🏼

@jimhager8583 Год назад

As always,you are a real trouble shooter. Love your patience

@myrandabrown Год назад

Wow. Gotta be your best video EVER!

@MrHugawa Год назад

Honda products are just so friggen good. Great video!

@hanselmanryanjames 10 месяцев назад

This guy has 3 multimeters, a bench power supply going, wires everywhere, all while bottle feeding gas through a tube. What we are witnessing here is a peak generator serviceman in action. Well done sir.

@GlennsSpeedShop Год назад

I have had an EM300, an EM 400 ( used many years), EM500, and currently I have an EM600 in the shed that I picked up a year or so ago for $50, it's waiting for me to do a will it run again video on my channel. I too love these little guys, you proved just how good they are! I have a vintage truck camper on a vintage truck, I think the EM600 will be perfect for that rig. Thanks again Glenn

@watermanone7567 Год назад

Great job JIm, Thanks for the video.

@duaneclarke7411 Год назад

Great video James loved it thanks 👍

@mikekenyon3322 Год назад

I'm still amazed at how nicely built the old Honda power products were. My 27yo EM2500 still runs and works flawlessly..

@phillipchen7749 Год назад

Very good job as usual sir!

@angeloogden9102 Год назад

This little engine must have so much sentimental value to the person who trusted you with it. Great job great human.

@rwsams Год назад

James, those hammered copper sinks are gorgeous! Not on topic, I know, but I was impressed!

@somerandomguy3868 Год назад

I expect the isolator was cracked or even broken during it little trip off the tail gate and down the hill, these really are well designed and built, you always get an A+ James

@andytaylor6781 9 месяцев назад

You make me motivated to start working on them

@roc31539 Год назад

Wow you are very good at placing the camera without blocking the view. Good verbal descriptions. Thanks

@jcondon1 Год назад

Thanks

@benkanobe7500 Год назад

Thank You for the fuel line bending trick. I did not know that one!

@brasilman11 Год назад

I'm always impressed how you tackle troubleshooting. I repair Big Pharma laboratory equipment watching you troubleshooting is very satifying.

@raymondhellberg3600 Год назад

Excellent! I also really like the looks and style of those, like a micro 70's Cadillac 🙂

@octaviofigueroafigueroa9794 Год назад

You are Awsome!!! I love that you always take care of the Factory/shop specifications (like torque). In this case, you had to work with what is available… but you do a big effort to get the original parts. I always wonder, how you get the shop specifications (like torque set point). Congratulations!!! I am a engineer (dedicated to Finance). That means, DIYer. I really love your channel. Probably the Best in RU-vid. Saludos from Mexico. 🇲🇽

@darrelllitherland8880 Год назад

i dont say a lot on public media but i really enjoy your videos . i would like to say i learn a lot lol but im a hands on learner but i really try to retaine the info.. just wish i could find a couple old ones even to just take apart ya know . and i can alsways find a use for the frames if it comes to it lol.. thanks agian for your time and efforts . Darrell

@AntonioClaudioMichael Год назад

Very well packaged wow

@j9products 4 месяца назад

James, I am about ready to go through my EM 500. I have not started it in years. Its in great shape, and this video was a blessing. I have never used it. Got it for $50 bucks about 10 years ago from a guy that his Dad passed away. Wish me luck!

@r8118830 Год назад

Very nice work James. I see that you have recently taken to using JB Weld in places that are non critical on the machines. A carburetor heat insulator/spacer is important to stop vacuum leaks as well as keep the carb cool but the mechanical stresses on it are not great. JB Weld should last a very long time here. I have not seen you use hot water to bend fuel pipes before. It seemed to work very well.

@jcondon1 Год назад

Hot water works on some fuel lines but not all.

@giggiddy Год назад

James, did you ever think you'd have 100k people watching your work? Think about it. Thats every person in a very large football stadium watching. Great job.

@haneyoakie14 Год назад

Great job. I learn a lot from you.

@kecah04 5 месяцев назад

I love your videos!!!! Very informative and educational!!!!!

@sodapops408 Год назад

I've always wanted one of those little generators, just because they're a Honda, old, very small and reliable. However, they are too pricey for my pocket. Good job, and thanks.

@fredanderson1753 Год назад

I have the exact same unit. I got it in the original packing, previous owner used it 1 time and left the gas in it. I got it after it set for over 10 years, cleaned the carb, changed the new oil in it. And it works perfectly.

@ragazzo8134 Год назад

Out of the 18 v leads, you can rectify and put a filter, and a voltage regulator 7805 and that is all you need to maintain the 5 volts. It would be the same as you are now doing with your added power supply.

@jeffgulledge132 Год назад

James, I have a Honda EM500 that was giving to me years ago. I have rebuilt the unit and it seems to work well. Sounds like I should part it out! Always enjoy your videos.

@jcondon1 Год назад

The parts are worth a lot of money to those trying to keep theirs running.

@P_RO_ Год назад

The sum of the parts might be worth more than the value of the whole. Some popular old cars are like that, which is why those rank high on the most-stolen list 😱

@kendibben3179 Год назад

Hi, I have one I bought for £40, great little generators if you only need 500 watts, just missing the side panels, luckily found another em500 on eBay for spares so hoping I’m the winning bidder, great video , your very inspiring to tinker and fix . Electrics are a misteryfor me but I have a general understanding thanks to you 👍

@jesterr7133 Год назад

Your subscriber must really love this machine. The shipping costs alone were likely greater than the value of the machine by several multiples.

@eurokid83 Год назад

Old school Japanese quality. I’ve repaired quite a few of those old Honda generators, every one so far came back to life and worked flawlessly.

@meandmyboys259 Год назад

I have one just like it, runs every time, good little camp power

@MRMONKIBONES Год назад

How did you learn so much about generators and the electrical connections? Very impressive to me who would be challenged by these problems. Thanks so much!!

@matthewrichmond5179 Год назад

Just learned a new trick... The hot water and the hose. Thanks!

@chip9177 2 месяца назад

It is vintage, classy looking well made machine....worth every penny to repair it

@larrykelly2838 Год назад

Wonderful video Doc., tracing and measuring everything was so informative. That 500 should be worth $300 to $400 I would think, it's a great little generator.

@jcondon1 Год назад

It’s a great little machine

@andrewgrace4410 8 месяцев назад

Amazing troubleshooting and robust engine 😊

@bertgrau3934 Год назад

One thing I really like is you do a great job of cleaning the parts. I don't care what I work on, I take way too much time to clean. Most folks don't want to pay to have me clean, I don't really care, to me the job isn't finished until it's clean. I do charge more than most other shops too. I had a guy bring me a chain saw, all it needed was the carburetor cleaned, but I checked the chain, and bar. He was happy it looked as he said, like new. Some folks do appreciate the extra work.

@P_RO_ Год назад

I learned long ago that it's not only easier to work on a clean machine, it helps you better see other problem areas you wouldn't have otherwise noticed.

@bertgrau3934 Год назад

@@P_RO_ Excellent point sir!

@whatdoyouthinktodd 8 месяцев назад

You know I was always taught If it isn't broke don't fix it. My grandfather used to tell me this all the time. He was the Rolex guy for Fox jeweler in Grand Rapids Michigan in the mid 30's to early '40s 😊 He came home from the war unable to do his job. They drafted him at 32 years of age with two kids and a wife.