Vintage Honda EM500 - High Voltage Problem
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- čas přidán 1. 02. 2023
- 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 - Jak na to + styl
He did a great job packing it in the box.
Best packing job I have seen.
@@jcondon1 Same thought here
The repurposed Omaha Steaks box was brilliant.👍
Thank you.
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.
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... 😉👍👍👍
I'm gonna say no it looked like some bad hammertone copper from the 70,s
Maybe it used to be a kitchen sink, but it's been relocated!
I find it very very cute🥰
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!
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.
@@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!
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.
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. 😆
For future reference, a spring inside the replacement fuel line will allow you to make bends you couldn't with a non-formed line.
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.
Actually, the spring inside keeps the hose from kinking a spring on the outside would not do the same thing
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.
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.
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.
Fantastic work James as always
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
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
What love you show these generators. It's always rewarding to watch your videos. Greetings!
That's a pretty cool little generator, all it needed was a new avr and tins, nice work repairing this generator James!
As usual, I have faith in you, great job! And the little guy works like new!
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!
perfect restore on a great old Honda.. ENJOYED James ! 👍👍
Top notch repair!
Pretty impressive repairs!! First time watching you hope for more!! Thanks
Another great JC video. Thanks for posting!
Gary’s AVR video came out minutes before yours and he spoiled it for me!!!
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.
Be very careful with the brittle old plastics and you should be OK.
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.
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!!
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
What a fantastic little generator, glad it got saved.
✌♥️🇬🇧
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.
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.
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.
Would you say the same for modern Honda generators?
@@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.
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"
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.
Excellent work as usual, love watching all your videos.
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.
Continually impressed by your knowledge and skill. Great work!
Excellent video. So happy you saved that tiny and vintage generator. I really like the old and odd stuff.
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.
Beautifully packed!
I just inherited one of these generators and and been having carb issues. Thanks for the video. 👍🏼
Super great troubleshooting !!! I was on track with you're ever move!!
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 🙂
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!
My wife hasn’t tweaked that I often to turn the dishwasher on while she’s out. Shhhhhhhh🤫
@@scroungasworkshop4663 😯😳
Arrr, another (dual) fix, one for me and one for the genny, I feel better now. Cheers Jim.
Thanks for your videos you have helped me with my generator and problems I had
Wow. Gotta be your best video EVER!
Great job JIm, Thanks for the video.
Honda products are just so friggen good. Great video!
HA! Clever video work at the end. I thought I was losing my mind. Thanks for the video!
As always,you are a real trouble shooter. Love your patience
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.
Rance here…Another very good instructional video. You are an excellent caring teacher!
Thanks Rance
Great video and loved the extra meter testing!
Professor Condon once again schools us all.😁😁😁 what a great machine and thanks to you it will last another 40 years.
You make me motivated to start working on them
Amazing it runs so well, more amazing you fixed it... 🙂
Excellent video as always. Also, that is the nicest utility/garage sink I have ever seen. 🤣
Another great video and fix. Thanks James!!
oh boy there goes my morning. They are such cute generators. nice job Jim thanks for the shout out.
That Dave for the tins and letting me borrow the manual. Which reminds me I need to return it.
Thank You for the fuel line bending trick. I did not know that one!
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.
James, those hammered copper sinks are gorgeous! Not on topic, I know, but I was impressed!
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
Great job as always!!
Wow you are very good at placing the camera without blocking the view. Good verbal descriptions. Thanks
Thanks
Just learned a new trick... The hot water and the hose. Thanks!
I have one just like it, runs every time, good little camp power
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!
Very good job as usual sir!
Great video James loved it thanks 👍
This little engine must have so much sentimental value to the person who trusted you with it. Great job great human.
I'm always impressed how you tackle troubleshooting. I repair Big Pharma laboratory equipment watching you troubleshooting is very satifying.
Nice sentimental rebuild
I have the same one. Still running well after all these years.
I have 3. Whenever I see one going for cheap i buy um. My first one 10 years ago was $50. My second one last year was in pristine condition in original box $200. My most recent one was $120 and it had a few carb issues but i fixed it.
Excellent! I also really like the looks and style of those, like a micro 70's Cadillac 🙂
Amazing troubleshooting and robust engine 😊
I'm still amazed at how nicely built the old Honda power products were. My 27yo EM2500 still runs and works flawlessly..
Very well packaged wow
That's an impressive packing job... wow
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.
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!
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.
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.
My wife would kill me
My eyes rolled back in my head when I saw that.
ESPECIALLY when she discovers that it wasn't HIS toothbrush he used to do the fine detail cleaning...
😄😁😆😅😂🤣
I love your videos!!!! Very informative and educational!!!!!
Nice going James
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
The lift is a great addition to your shop, really saves back and knees!
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
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!
Nice little generator
Great job. I learn a lot from you.
Pretty impressive troubleshooting.
You’re welcome 🙏
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.
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 CZcams. Saludos from Mexico. 🇲🇽
It is vintage, classy looking well made machine....worth every penny to repair it
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
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 👍
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.
fine job you did there!!! now that gen set should last another 40 yrs. OH and thanks for sharing how to form Rubber hose, that will diff. go into my hand written note pad!!!!
Wow at how clean the gas tank is impressive for the age
Your subscriber must really love this machine. The shipping costs alone were likely greater than the value of the machine by several multiples.
Hope this helps, I use a spray can with the grease remover in it. Very handy.
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.
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.
Hot water works on some fuel lines but not all.