Vintage Honda EM500 - High Voltage Problem

[@aboveaveragejoe6291]

He did a great job packing it in the box.

[@jcondon1]

Best packing job I have seen.

[@sergioaguayogarciara]

@@jcondon1 Same thought here

[@bcad4066]

The repurposed Omaha Steaks box was brilliant.👍

[@louisbigelow1866]

Thank you.

[@louisbigelow1866]

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.

[@emehlhar]

When the engineers asked Soichiro Honda how long they should design these old generators to last, he just replied "Yes". Great repair job.

[@hydrochloricity]

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]

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]

@@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!

[@Skynet-1]

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]

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

[@sunbeam8866]

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

[@michaelripley4528]

I find it very very cute🥰

[@elviraraff6809]

Hi James, solid state components only started showing up in the very late 60s, and the number of those available were few. The component in the middle nearest your thumb appears to be a 7805 5v voltage regulator, especially since you mentioned it took 5v to get 120v out. It would be helpful if you could find an old parts catalog from Radio Shack. I used to be a radio tech for the NYS Police Troop L, and it was easier to get parts at RS than GE who supplied their radios

[@larrytalley117]

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.

[@henkdouma8448]

At first I thought it was inside the garage and that it couldn't be true that James, a very clean working man with the engines, would have a steel sink (I imagined) that heavily rusted. Now I read your comment it is all clear to me now. First time I see a copper sink. Am always a bit carefull with copper and food/drinks. As we are not from the planet Vulcan copper is not very healthy to get inside of our body.

[@davidblake6889]

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]

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

[@geoffreymichalisko8994]

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.

[@wildefox1478]

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

[@GH-wt7ww]

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]

Would you say the same for modern Honda generators?

[@GH-wt7ww]

@@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]

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"

[@michaelripley4528]

What a beauty !! 🥰!!! I would have one of Them on a shelf💯 Just because it have the look!!!! So pretty!!!!!❤️🤗 Industrial piece of art!!💋 I find it very very cute!!!

[@tubemember21]

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.

[@workaholic5318]

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]

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]

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

[@themaritimegirl]

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_]

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

[@hanselmanryanjames]

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.

[@davedemo8229]

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

[@jcondon1]

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

[@bruceeverett5372]

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!

[@myrandabrown]

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. 😆

[@davidsmith-ih2kk]

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

[@m.pearce3273]

All considering that this tiny Honda that rolled down a hill and falling out of the truck. A miraculous super save of the little Honda that could. And lucking into the metal box screens was perfect.🎉🎉🎉

[@giggiddy]

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.

[@breikowski]

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

[@isettech]

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.

[@dirtroadsailing6418]

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]

My wife would kill me

[@RPRosen-ki2fk]

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

[@HappilyHomicidalHooligan]

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

[@derbruzzler7574]

Just a month ago i ran into the same issue with my european version of this generator. Its a EX500 and the voltage went up to over 300volts. I searched the internet, but the result was the same as in your case. Parts are too expensive for what its worth. So i tried to get the resin off the AVR. And i managed to get the soldering side free of it. The only thing wrong was a bad soldering joint. With some tape and zipties i made it fit in the rest of the plastic housing of the AVR. Generator runs again, for zero money spent! Too bad this video came out too late, it would have saved me a lot of time figuring out how to get to the AVR.

[@zrkn1]

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 🙂

[@iandennis7836]

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

[@ericvaughn1126]

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]

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

[@ericvaughn1126]

@@scroungasworkshop4663 😯😳

[@angeloogden9102]

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

[@deangentles4966]

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

[@AntonioClaudioMichael]

Very cool to see the old RadioShack Multimeter

[@MrTonyPiscatelle]

I haven't seen an old Simpson multi meter like the one in the manual in over twenty five years. When I got into the industrial heavy machinery industry it was the professional meter of choice. That was back in the early 1980's. Nice job James

[@1pcfred]

I have a couple 260s and a 270. Sometimes analog is the way to go for watching trends.

[@MrTonyPiscatelle]

@@1pcfred I've used them and owned one way back in the day.

[@1pcfred]

@@MrTonyPiscatelle I still have a few that I use from time to time.

[@P_RO_]

@@1pcfred You can sometimes find old cheapo hobbyist analog meters at yard sales and flea markets, and they're perfect for 'trends' or rough readings where a DMM will just go bonkers with the variance.

[@1pcfred]

@@P_RO_ that's where I've found all of my meters.

[@somerandomguy3868]

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

[@rjlinnovations1516]

Pretty impressive troubleshooting.

[@rjlinnovations1516]

You’re welcome 🙏

[@NY411Info]

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.

[@andrewrussack8647]

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.

[@justinvanaulen2478]

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]

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.

[@j9products]

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]

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]

Hot water works on some fuel lines but not all.

[@eurokid83]

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.

[@davida1hiwaaynet]

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

[@artpatronforever]

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.

[@GlennsSpeedShop]

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

[@bertgrau3934]

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_]

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]

@@P_RO_ Excellent point sir!

[@mikeg3893]

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

[@mikekenyon3322]

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

[@davidfogelberg8989]

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

[@MRMONKIBONES]

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!!

[@idontneedaname85]

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.

[@brasilman11]

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

[@roc31539]

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

[@jcondon1]

Thanks

[@YukonHawk1]

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

[@rwsams]

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

[@matthewcrews4034]

Nice sentimental rebuild

[@jeffgulledge132]

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]

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

[@P_RO_]

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 😱

[@erictofsrud7932]

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

[@rancelynch6514]

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

[@jcondon1]

Thanks Rance

[@persistent25u]

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.

[@fredanderson1753]

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.

[@myrandabrown]

Wow. Gotta be your best video EVER!

[@Barracuda48082]

Have to admit, this elevator platform you bought was a great investment.

[@jameslarson6555]

A small parts washer set-up would be a handy addition to your shop. I never knew how handy they are till I got one and my wife appreciates me not cleaning parts in the kitchen.

[@jcondon1]

It would be nice. Need a bigger garage.

[@P_RO_]

@@jcondon1 Make it portable on a rolling work table. A free sink from a remodeling job, a free used veggie-oil container from a restaurant on the bottom shelf, and a cheap 12V fuel pump in between. Keep the pump pick-up off the bottom and the veggie-oil container will act as a sediment trap. On wheels it's never in the way.

[@brucejones2354]

I have found in my life, it doesn't matter how big your garage is you could always use a little more room.

[@MrHugawa]

Honda products are just so friggen good. Great video!

[@kevinblevins2612]

Can’t beat the old Honda products!!

[@HappyHands.]

One thing is for sure those covers really did their job in protecting the motor.

[@johnnybgoode6466]

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.

[@jameskrivitsky9715]

YeeHaa James, you made a SILK PURSE out of a Sow's Ear ! I was wondering if you were going to break out some body shop tools to beautify those tins. Impressive total restore.

[@mdiamond5482]

Continually impressed by your knowledge and skill. Great work!

[@barthanes1]

You can carve JB Weld like soap if you wait 10 or 15 minutes after applying it. It makes it super easy to clean up any squeeze out.

[@whatdoyouthinktodd]

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.

[@alanb76]

Great packing job. I bought one of those new back in the day. Sorry I didn't keep it now. It was very cute. Noisy but handy.

[@jesterr7133]

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

[@shanemadden1907]

I like that sink. I’ve never seen a copper one before.

[@lpconserv6074]

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!!

[@lesallison9047]

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

[@phillipeaston6738]

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

[@bobsrepairshop]

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.

[@citylockapolytechnikeyllcc7936]

Asking Honda to put this data public domain would be an awesome gesture on the part of Honda and other manufacturers who no longer have an interest in making such parts. Sounds like a good crossover for Louis Rossman's channel. He has a repository for such data on any and all electronics for the community to lift from, and share into.

[@arthurbiringer5676]

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

[@AntonioClaudioMichael]

Wow at how clean the gas tank is impressive for the age

[@mafosa8519]

Top notch repair!

[@jimhager8583]

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

[@69uremum]

That clip for the fuel shut off rod looks just like the clips used on automotive door locks, they serve the same purpose to affix a steel rod into a lever .

[@PeterHynes]

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!

[@octaviofigueroafigueroa9794]

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 KZbin. Saludos from Mexico. 🇲🇽

[@memimonimo]

Thanks for this great video. Imagine from 40 years this machine have cdi , oil gard , automatic choke,....etc. I have the same AVR problem without the chance to replace it. i found that when we apply about 75 percent of load we got acceptable voltage and hertz reading. I manage also to use LPG on this generator with very good result as i get a broken carb floter and bad shut off valve. In my country we have a serious problem of electricity as we get not more than 5 hours of electricity per day, really my generator has undefined hours of running hours and still in service till now.

[@sunbeam8866]

Honda used to make some beautiful stuff. I have one of the early Honda OHV/shaft-drive self-propelled mowers. Most or all of the exterior covers and plates are painted steel like this generator.. If I had a dead one of these generators, it wouldn't be going to a landfill, but up on a display-shelf in my garage!

[@kendibben3179]

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 👍

[@larrykelly2838]

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]

It’s a great little machine

[@billiehydrick6417]

Thanks!

[@jcondon1]

Thanks Billie! Very generous.

[@billiehydrick6417]

Wish it was more for you my friend 🙏

[@NY411Info]

Nice hose bending trick, never thought of it. We used to take plywood and leave it in water a couple days so we could put it in a jig to hold it to make arches in a house. I don't think that style is too popular now though.

[@AntonioClaudioMichael]

Very well packaged wow

[@chip9177]

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

[@ericblackwood1286]

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

[@darrelllitherland8880]

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

[@RandomZ88]

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

[@Brokynwings]

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

[@vinatechcoy]

James, regarding all the parameters of the AVR that you provided in the video, it doesn't need reverse engineering to have the replacement made. Just design a new circuitry with more reliable components including a multi-turn pot. That was what I had done in the past 30 years before my retirement. I am referring to you a genius design engineer of a young generation. He would be your partner if you two plan to commercialize the project. The cost to build such AVR is probably in the $15 range. His youtube channel is "the post apocalyptic inventor"

[@pc5569]

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.

[@tombenvenuto204]

Another great JC video. Thanks for posting!