Found in Pieces - Old Honda EM650 Generator

A subscriber was cleaning out his Dad's garage and found an old Honda EM650 in pieces hidden in the corner of the garage. He does not know if all the pieces are there or why it was taken apart in the first place. Will it run and make power?
Generator Model: Honda EM650
Fuel Filter: 16952-ZA8-800
Fuel Tank Line: 17512-ZA8-800
Fuel Tank Cap Gasket: 17631-096-701, 17631-096-702
Air Cleaner Base: 17220-ZA8-801
Air Filter: 17211-ZA8-800
NGK BMR4A: 98073-54744
I no longer use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner. Harbor Freight changed the recipe. The bottle previously stated "NON-CORROSIVE". Now it says "CORROSIVE", "do not user on Aluminum". It now damages most carburetors. Recently I have been using Simple Green PRO HD with good results.
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Evapo-Rust (ER012): amzn.to/4aadkZS
Kill A Watt: amzn.to/3Ui8WTU
Oscilloscope: amzn.to/3UkttqL
Red Kote Fuel Tank Liner: damonq.com/red-kote.html
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#hondapower #GeneratorRepair #Generator #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
Adjust Engine Speed, Alternator, Back Pressure, Barn Find, EM650, Fixed, Fuel Tank Liner, Fuel Tank Restoration, Garage Find, Generator, Governor Reset, Hertz, Honda, How To, How-To, Ignition, Load Test, No Fuel Flow, Plugged Exhaust, Plugged Fuel Valve, Power Quality, RPM Adjustment, Red Kote, Repair, Small Engine, Spark Test, Surging, Troubleshooting

[@ingagiorchestra]

Just wanted to express my much overdue gratitude for keeping the ads off for us early viewers. Can't tell you how great it is to have my Thursday lunch with your videos on the big screen and not be bombarded. A class move. Love the channel.

[@iskydivetoooo]

Absolutely.

[@paulholdredge7672]

Totally agree. Really engrossing and relaxing to watch.

[@glennschlorf1285]

Nothing like a new James Condon video..

[@Rorschach1024]

Replacing discontinued plastic parts is an excellent application for a 3d printer.

[@FunctionalPrintFriday]

Was just going to comment the same. James, if you read this comment and ever want to collab, let me know. Would love to make some parts for you.

[@Snatchwrangler1]

@@FunctionalPrintFriday I would definitely like to see that!

[@Landrew0]

@@FunctionalPrintFriday But it's not the easiest thing to make the printer files.

[@abergbe1]

I am full of admiration over Mr Condon's patience with the fuel tank.

[@DeadKoby]

I did work for a gent who "started" all the projects and left me with a bucket of parts. It's NOT a fun situation, so I commend your bravery for taking it on.

[@Ed_Stuckey]

I certainly breathed a sigh of relief when the exhaust bolts broke free instead of just breaking.

[@moconnor6275]

Love your voice! The sir David Attenborough of small engines! 😊

[@rbassettjr]

I had a Honda EM500 and a Yamaha EF1000 I used for RVing when I didn't want to run the onboard Onan. Those two were some of the best machines I've ever owned, quiet, dependable and fuel misers. Great video!

[@michaelkennedy2528]

A careful application of heat from a heat gun on that air box cover will cure what ales it.

[@robfinch1522]

And the same process on the old air box will de-stress the fatigued clip mounts.

[@cunnings309]

I had a few of these generators to repair back in the 70's when I was a mechanic for Honda. The most common problem was oil consumption. A customer even told me that in their case it was: “Check the fuel and add oil”. They were, as you mentioned, the quietest on the market.

[@philliphall5198]

20w50 castrol oil 😊

[@erik_dk842]

@@philliphall5198 10W60 exists

[@Ragnar8504]

These small Honda units used to be quite popular with market vendors who just wanted to power a few light bulbs to illuminate their stalls. They were reasonably quiet, compact and had plenty of power for, say, the five 60 W bulbs needed to light up a market stall.

[@erik_dk842]

10W-60 exists

[@cunnings309]

@@Ragnar8504 I agree with you and they were (as I mentionned) so quiet that a friend of mine told me he had his in a shed at the back of his camp and he forgot it running all night because the noise didn't bother him.

[@iskydivetoooo]

Glad to see more people are willing to send you their broken generators. It makes the channel's content more diversified. The Kipor still works flawlessly now.🤗🤗🤗

[@w.ottopeck9619]

James I’m impressed as I always am with what you can do with these small engines. What I like about you there is no, “thats good enough”. A clean tank was not good enough, a coat if red coat was still not good enough, after 2 coats it was the best it could be. That was a good catch to find the clogged fuel valve!

[@dondonaldson1684]

And vent

[@kd5byb]

One of my favorite generators in my collection is an old two-stroke Homelite military unit. When I got it, it had broken rings and a muffler COMPLETELY FILLED with thick, sludge-like oil. When it would start and get hot enough, it would fog all the mosquitos in the neighborhood. I mean ALL OF THEM. HAHAHA. After about three hours of running under load, it all burned out and now the exhaust is as clear as any other two-stroke. 😀

[@bbeauregard4181]

Well done James, you helped me rebuild a commercial Ariens self propelled walk behind mower that my neighbor was going to trash. Much appreciated!

[@wesleypulkka7447]

James, I realize that you are a perfectionist (about clean or dirty power) but the little Honda still gets the job done at age 39! I always go with what Mr. Harley said to Mr. Davidson 100+ years ago "what's good is what works"! Kudos for another great revival!

[@octaviofigueroafigueroa9794]

To clean inside of a tank, I have seen guys attaching the tank in a lawn tractor wheel (wheels of course in the air). They turn on the wheels for a while. So you do not need to shake manually several times. As usual, your video was a Master Class. Saludos from Mexico.

[@TheTkiller9999]

was that Mustie1?

[@CleaveBuscemi]

He's actually done this before in a previous video! It's a really smart way to clean up a tank

[@octaviofigueroafigueroa9794]

No, but he is a great guy. I also follow his channel and I think I missed that chapter 😢. I can not find the episode you mention.

[@Ragnar8504]

@@TheTkiller9999 He actually jacked up his Toyota pickup truck to do that 😂 Put it into 2WD drive and let it idle.

[@johnmeyer8495]

cracking find on the exhaust vent port James...Looks like some bug made a nest in there and sealed the fate of the machine until the right man was tasked with the resurrection. These tiny genny's may seem small for what we use these days, but with LED lighting, this would run your rv lighting no problems and even keep the battery for your fridge topped up on a rainy day.. With a rectifier on the output and then a DC to ac grid tied inverter in the mix, you would get a clean output for lights and laptops at a cheap running cost as they do sip the fuel...Always a pleasure to see you at work and making the decommissioned kit brought back from the scrap heap..... Bravo James😁

[@hoveycorbin5712]

Aloha James. Way to go once again on resurrecting an older generator. I love your narrative and how you describe every step of a refurbishment on old equipment. Please keep up the great work, and myself and many others will continue sitting through an hour and a half plus repair video because they are very interesting and informative. I love the channel. Aloha.

[@justinvanaulen2478]

I'll take a 40+ year old Honda in pieces over a brand new one bought in 2024 @ a Big Box store. As usual, great video James!

[@MalleusSemperVictor]

I don't know if you can really make a blanket statement like that. I'd rather have something modern that has parts availability.

[@v-g-z3689]

@@MalleusSemperVictor Yeah, because for the modern one, you´ll need them :D

[@justinvanaulen2478]

@@MalleusSemperVictor Search online, you would be very surprised how much of these stuff is still available, as new, from Honda. But...doubtful you would need anything but the normal plugs/airfilter/oil to keep it going.

[@masoncross-om3oc]

You are so right, brother...?? That's all we'll buy is honda. Our Gen sets 4 wheelers outboard for our boat and our side by side.. all made by honda... we never have any problem with them...????

[@MalleusSemperVictor]

​@@justinvanaulen2478I suppose I am surprised.

[@kenjones4139]

Hey James! Another very enjoyable video. As others have said, I have had great success using a heat gun to "reshape" old misshapen plastic parts. If you can make a jig to put and hold pressure as it cools, it will work just great. I have had great success with the Briggs airboxes with the built in primer that are kniwn to warp.

[@jaygee999]

James you must have had angels on both shoulders with this project -- Double Up on the Collection Plate this Sunday ❤

[@swallowinn4410]

Hello James: You sure do go the extra mile on your projects, This rebuild/repair another testament to your quality and attention to detail. Keep up the good work .😊

[@iconoclad]

James, i have to thank you for your calming demeanor. I have had a tough year with the death of two of my long time friends topped off with a bladder cancer diagnosis. I have had corrective surgery and may be out of the woods. I cant tell you how much your videos have helped me in my stressful periods.

[@BWGPEI]

Nothing like getting a puzzle that fits your interests. You were having good days and that makes my day. Many Thanks!

[@dalee.mccombs8571]

Whaaat? No leftover parts? Not my usual basket case project! 😂😂 Good job, James 👏👏. I always look forward to your videos. Entertaining, interesting, and quite educational!! Thank You.

[@marvinunderwood545]

I learn so much from you every time I watch your videos. Your delivery, your knowledge and no stone left unturned. I have already applied some of your techniques on my own equipment. Keep them coming!

[@johncourtneidge]

Immaculate! As usual! Thanks to you, Subscriber Steve and his Dad! At 1:20 it seemed z long time back when you were struggling to get the spark-plug boot off! Hurrah!

[@benjamincresswell3713]

Hello Mr. Condon. I am very impressed with your video once again. The attention to detail and knowledge of how things work. E.g. Figuring out how the governor and link worked, how to use the Evapo-Rust, Red Kote, and make adj to the speed & Hz. No matter how many times I watch your videos I find something out I didn't know. AND FYI: I inherited a 6,000 watt generator from a window contractor who used it on remote jobs in his window replacement business. I needed it and when I got it running, it had the proverbial hunting issue. Thanks to you putting videos up on the net fixing hunting issues, I was able to pull the carb all apart and go thru it in just a few minutes to get it running reliably. Then I ran it for about 1 whole day and another 1/2 mostly for 2 sump pumps and the water well pump at a house I own. So, my hat's off to you for the education you gave me. ben/ michigan

[@Amy_McFarland]

What an awesome video! I so look forward to my Thursday morning coffee with your videos!

[@Rick-S-6063]

Considering how everything was half taken apart and boxed up I had been wondering how this episode would turn out. Well, there's only one word to describe the results and that word is "outstanding." Thank you for another informative video.

[@scroungasworkshop4663]

Hi James, i’ve cleaned a few fuel tanks and jerry cans before using Red Coat so I made a very simple jig for the cleaning. I got an old large bicycle wheel and forks, cut off one arm of the forks and mounted the rim to the remaining fork with just one bolt. I cut the axle stub off the other side. This allowed me to strap the can to the wheel with elastic straps and /or tape. I had the fork bolted to a piece of board using the head stock fittings and an old inner tube connecting the rim to a small electric motor. This allowed me to use only half a litre of Evapo Rust (it’s very expensive in Australia) and a handful of nuts to do the cleaning quite quickly and I could just let it run for hours. It cost me nothing to build and the large wheel and tiny pulley on the electric motor slowed the whole thing down perfectly. I didn’t even bother with a special pulley on the motor, I just used the standard “A” section pulley that was on it. It worked for years without a problem. Thanks for another great video. Will the generator be going back to the owner? Cheers, Stuart 🇦🇺

[@habana7638]

The reason Honda sounded so nice and where so reliable is that they ran at 3000 rpm at the time..

[@sparkplug5481]

I’ve had one for 25+ years , use it once and a while……love it

[@stephenhaslam680]

Good instruction on the importance of a clean fuel delivery system end to end which is all it really needed. Thanks James.

[@JustAnAverageBrad]

that era of little hondas are great little machines..

[@jimh2887]

I have to save this video until Friday night. It's gonna be an hour and thirty six minutes of fun!!😊

[@andenmcleod7355]

Perfect timing, just when i was waking up and starting to eat. like actualy was about to follow the endless wormhole of finding the perfect video when this came out, thanks again james for making my mornings just that much better.

[@JR-bj3uf]

This is the best kind of project, it comes in multiple boxes.

[@user-os1xv5oi9q]

another one rescued, great work as always James!!

[@melkiorwiseman5234]

My first guess as to why that genny was disassembled and left like that would be that the blockage in the fuel cutoff wasn't discovered by whoever was attempting to revive the generator. Anyway, it's nice to once again see a discarded piece of equipment saved from the scrapheap. That little generator would be useful to run a few lights during a blackout. Maybe even a small fridge.

[@markbarrett2225]

James I always enjoy your videos! Thank you!

[@DrDre-ir4gu]

Hi James, I own next to my other generators also a Honda EM650. A leaking gas valve is the only repair I had to make until today. The set up of that cable/ spring for the choke, you got it right.

[@rkins100]

An oldie but goodie and another success. Thanks for posting Jim.

[@garrydonnelly6433]

Thanks James for another entertaining and educational video. I like the way you give us close up views of what you are doing complete with descriptions and your opinions on options when they are available. Some KZbinrs just show the back of their hands when filming in tight places. cheers from OZ

[@clownhands]

I love when I feel like the restoration is on the home stretch, but then I look at the KZbin video and see we’re less than halfway done. And then I speculate about the known unknowns…

[@oldodger]

Another win. Love your attention to detail !

[@1SmittysGarage]

What intriguing piece! Full of surprises and came together beautifully. Awesome workmanship indeed! Blessings and respect!

[@tonygriffiths2485]

Such a small device and so much work needed, but you got there in the end. Fantastic to watch, thankyou :)

[@siegfriedjunghans]

Hello James, I'm happy about every new video from you. I've already learned so much from you that since I've been watching your videos I have a completely different view of broken engines and it's always fun to repair something, whereas it used to be hell for me 😊 Many thanks and best wishes from Germany

[@jeepersdawgs4105]

I always enjoy watching your videos. Your personality really comes through in your clips.

[@brianwood5220]

Well, James. Yet another excellent video. You always come up with something interesting. Thanks for sharing.

[@buydirectusa4954]

Every time you work on these things i feel a bit more educated. Was able to get my 2011 weed eater working. It wasnt running so a couple shots of wd40 helped clean the carb. Had to replace the fuel lines, the primer bulb, new spark plug, clean it up and it started right up. Fixed the cracked case with jb weld plastic repair.

[@RiverratGoRVing]

Great 👍 save James 👏. Keep posting and will keep a frig up and running in an power outage.

[@gregorygomez7975]

NICE JOB JAMES. CAME OUT GOOD.

[@Kiltylake]

Well done James!

[@bazz4697]

You did amazing job on that petrol tank looks spot on injoyed this video 👍😉

[@DanKoning777]

With each new video I'm seeing how much I've learned. I try to anticipate what's needed, what the issue is, and/or what you'll suggest. I don't know about everyone else, but I'm less intimidated now re: small engines. Hopefully I won't have that "deer in the headlight" look when the time comes. 🤔 👍👍👍 God bless.

[@robfinch1522]

Had one of these when they first came on the market (240v). Gave us light and TV at the caravan. Just purred away quietly no issues ever. They don`t make the quality like Honda did then.

[@davecole2230]

G'day there, I think you do a awesome job repairing these machines.

[@jcondon1]

Thanks

[@danielcovel6236]

I am Not A very good mechanic….this channel has been very helpful

[@johnsalmon2501]

Great video! Looks perfect for old generator. Glad you red coated the fuel tank. Thanks!

[@user-tn1hk6zm2f]

I would never use water on bare metal as a cleaner. Instant rust starts. I would have used acetone to clean out the rustevapo. But you are an expert. Very good at what you do.

[@bborkzilla]

I used that Red-Kote stuff to line a Ford Jubilee tank that had several pinholes. It's been leak free for over 10 years now.

[@philliphall5198]

It works every time 😊

[@paulholdredge7672]

Great video as always, James. I’ve had very good experience with POR-15 gas tank sealer, easier and more complete in one application. I agree the redkote looked thin and also time consuming to apply.

[@silvinotavaresdelima7875]

HEY JAMES YOU ARE A GREAT PROFESIONAL IN ALL YOU DO MAY GOD BLESS YOU AND FAMILY GREETINGS FROM BRASIL

[@marcheld]

Top notch, as always!

[@jeffclark2725]

That generator is a real find, , I would send you a couple of my old ones but i am by Seattle,thumbs up,great video

[@loucinci3922]

Enjoyed the video. Thanks for sharing

[@hitoortega1616]

Excellent work

[@kendoeditionfuego1619]

Yo me quedó sorprendido como un hombre sin tener un mega taller, un mega marketing por grandes empresas que fabrican generadores eléctricos, un solo hombre es capaz de darle vida útil a todo tipo de generadores eléctricos, desde que conocí este canal he aprendido más, será muy díficil para mi que me quité de este canal porque James condon es para mí uno de los mejores técnicos de generadores eléctricos que yo haya visto en mi vida.. éxitos.. desde Cuba saludos.

[@cameroncassel994]

Great video! I found when using evaporust when your done don't use tap water. I found using distilled water prevents flash rust in the tank and after that heat the tank on a barbecue grill or an oven until dry and there will be no rusting afterwards.

[@RequiredSugar]

As always, a magician with small engines! I have a partially running Honda eu1000 sitting in my garage I picked up after watching your videos. I would like to attempt a refurbishment.

[@andrewgrace4410]

Great fix James 😸👍🏾

[@minouchat]

another good video as always. THANKS🍺🍺

[@ericvaughn1126]

Nice save, James. I've done a tank with Red Kote and it takes some doing to work quickly so it doesn't dry too fast and keeping the vent/fuel ports clear can be a challenge too. You CAN thin Red Kote with acetone as noted on the can or their website. So you can likely do that with what you have left in your can. I always closed the Red Kote can immediately after pouring out what I needed since the stuff dries so fast.

[@charlesharris4021]

I like your work ethic. Your videos do relax me.

[@WILD35]

Something to watch in hot summer day in UK

[@venenareligioest410]

James, the warped top - try putting it in very hot water, plastic retains a memory of its original moulded shape.

[@arthurbiringer5676]

Another great job!

[@twaggs6523]

Thanks for all the detail. You do great work! I've had pretty good luck applying heat to plastic parts, usually with a heat gun, to get them back into shape. Maybe that airbox cover could have been re-shaped with some heat? Cheers sir!

[@jgreitz]

Love your videos! Here's a thought about the Honda carb settings: 1985 there was no ethanol and much better gas. That carb wasn't engineered for ethanol. But it sounded great when all together. Speaks to honda engineering and quality.

[@d1gardner]

I don't recall the brand of tank liner I used for a gas can probably 8-10 years ago. It took a long time to cure, so I placed it in full sun which added enough safe heat to fully cure the product. It was a hot day with full sun. I still use the gas can....no leaks.

[@tomschmidt381]

Great you were able to bring it back to life.

[@bbaaspencer1]

We used that in the 80’s to installed new garage doors because during the new home construction phase, the electricity has rarely hooked up

[@alialhaidary1072]

awesome as usual

[@teddrewflack400]

Wow this is a great video , I love old motors , my grandfather used to restore old Johnson and Evinrude boat engines .

[@peterouellette3874]

Nice going, James

[@woody95124]

Another fab job on a basket case...Por -15 works really good on tank sealer...

[@redneckbryon]

34:00, in a situation like this, when dealing with a plugged exhaust, Dawn dish soap, and water is your friend. When there’s no torque spec be your own judge, that applies to a lot of different things.

[@philipjohnson1103]

Another great job, I had a similar Honda where the exhaust was obstructed with oily carbon, I had to heavy touch it to burn it out. In your case it looks like mud dobber wasps made a home in the muffler. Maybe filling the muffler with water and shaking would have also removed the nest entirely. Love your videos!

[@oldbonesbushcraftrodjackso474]

You got lightning. I love those Hondas. Any Honda machine is up there. I borrowed my neighbor's Makita generator wow what a machine. I am Japanese all the way. Even Nissan is a much better car than Mercedes. Very pleasant video. You are very calm with your speech.

[@AbeFrohman528]

I have the exact generator with the same air box lid issue.. I used a heat gun to relax the lid, and cold water to make it take a set to the new shape... I believe the clamp is what makes the lid distort over time..

[@martyb3783]

Great work as always. I have used Redcoat with poor results. I hope it works well for you. Great video!

[@jcondon1]

Fingers crossed!

[@rjp-bd4mc]

One reason you may have had rust show up after cleaning the fuel tank is that you used gasoline for the final rinse and that won't mix with any residual water. Any trances of water sink to the bottom and -- rust. The acitone others have mentioned does mix with water and will absorb it. Ethanol will do that as well. Or you just blow a lot of air through it to dry it faster. A replacement for now hard to get incandent lamp would be brooder (heat) lamp bulbs which have not been banned. You can find these at farm stores.

[@dannyhartline2648]

A very good good cleaner that is safe to use for exteriors and interiors is Goop. Available at auto parts and box stores. Probably Harbor Freight as well. Used it for hard to clean areas and stains on office equipment for many years. Use denatured alcohol to clean glass as it does not leave a residue.

[@texascottonfarmer]

Once again, nice work. 👍👍👌👌 I think I would have put that gas tank in the sun for several hours, or in a 120 degree oven for a couple hours, to help that coating cure. Thanks for the video.

[@MitchEllis-dn9lf]

Yep I have a set of crapsman(craftsman) cutters like those you have and they are great

[@phillipshannon4210]

Hey James,,, I was watching as you were unpacking the Honda 650 generator and it looks like their is still a small part in the plastic bag,,,, you might want to take a look,,, I enjoy watching your work and appreciate the fact that you are so meticulous,,,, Phillip

[@WarrenKimpel]

another nice video THANKS

[@larrykelly2838]

Great video, nice restore.