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: https://youtu.be/UR2rh8f3WzM
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
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner https://www.harborfreight.com/1-gallon-heavy-duty-degreaser-42998.html
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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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Can you convert a foreign country generator to American. 180 HZ 60 ?
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!
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.
One thing is for sure those covers really did their job in protecting the motor.
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.
I would send the old avr off to see if it can be repaired.
A while ago you used the services of a contact to fix a generator circuit board – I would have though he could have helped here as the main problem would have been de-potting the failed component. seems like a fairly simple circuit given the date of manufacture. Might still be worth investgating ready for the next EM500…
UK. Great stuff as always. The problem with old electronics is finding someone capable of doing the impossibel. Totally off topic but my 'Lord Of the Wires' just died. After 50 odd years I have just taken up electronics again. In your language James – Oh My God. Those little black things with wiv legs are great but give me an old EL34 blasting blue electrons into the dark any day.
Hope this helps, I use a spray can with the grease remover in it. Very handy.
Your subscriber must really love this machine. The shipping costs alone were likely greater than the value of the machine by several multiples.
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.
Looking at it from a business point of view from Honda . The longer people are able to keep these old machines running the less likely they are to buy a new Honda generator. Very unlikely they will want to share that info with anyone . Always a chance you might run into a disgruntled employe LOL
Mr. Carlson from Canada could probably designed one from scratch
Time to invest in a 3D printer to make those unobtainium parts
I have the same one. Still running well after all these years.
I know with Honda, sometimes parts from newer machines will fit the older ones, definitely something to check out.
Basically it’s cheaper for a manufacturer to reuse a patent and design they already have, them to make a new one.
A 5 gallon bucket, a pump from Harbor freight, and a plastic colander make a great parts washer.