Honda EG5500CXS Manual Download Page 1

How to use this manual

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How to use this manual

A Few Words About Safety

SERVICE INFORMATION

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage

this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures

require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not

recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight

while servicing this product can result in faulty operation, damage to the product, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:
 • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

required to perform the tasks safely and completely.

 • Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around

pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.

 • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

 • Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure

that the hoist hook is securely attached to the product.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will

help eliminate several potential hazards:
 • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

 • Burns from hot parts. Let the engine and exhaust system cool before working in those areas.

 • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries.
 • Use only a nonflammable solvent, not gasoline, to clean parts.

 • Never store gasoline in an open container.

 • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to

be seriously hurt or killed.

Follow the procedures and precautions in this man-

ual and other service materials carefully.

Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.

Follow the procedures and precautions in this man-

ual carefully.

Summary of Contents for EG5500CXS

Page 1: ...riate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the rep...

Page 2: ...otherwise without prior written permission of the publisher This includes text figures and tables As you read this manual you will find information that is preceded by a symbol The purpose of this me...

Page 3: ...e recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of engine oil and molybdenum grease in a ratio of 1 1 Use multi purpose grease lithium based multi purpose greas...

Page 4: ...How to use this manual 0 4 Item After Before Starter Motor Harness Clip Base OUTLINE OF CHANGES...

Page 5: ...MEMO...

Page 6: ...2 1 2 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 CABLE HARNESS ROUTING 2 2...

Page 7: ...Item Standard Service limit Starter motor Brush length 10 5 0 41 4 0 0 16 Mica depth 1 5 0 06 0 5 0 02 Terminal number Wire color Bl W Do not secure the starter cable at harness band BATTERY CABLE TE...

Page 8: ...9 1 9 9 STARTING SYSTEM STARTER MOTOR REMOVAL INSTALLATION 9 2 STARTER MOTOR DISASSEMBLY ASSEMBLY 9 3 STARTER MOTOR INSPECTION 9 4...

Page 9: ...ALLATION Disconnect the starter motor wires and battery cable from the starter motor Remove the fan cover Base shop manual page 7 9 SPRING WASHER 2 5 N m 0 3 kgf m 2 lbf ft BATTERY POSITIVE CABLE STAR...

Page 10: ...N GEAR NUT 6 mm SCREW 5 x 13 mm 2 LEFT HAND THREADS SCREW 5 x 20 mm SNAP RING ASSEMBLY Install the brush holder brush springs positive brushes negative brushes and two screws to the center bracket as...

Page 11: ...ative brushes 2 There should be continuity between both the positive brushes There should be continuity between both the negative brushes There should be no continuity from either positive brush to ei...

Page 12: ...G CLUTCH Do not apply oil or grease to the pinion gear 1 and dumper clutch 2 Do not use non flammable solvent for cleaning the pinion gear and dumper clutch Check the pinion gear operation by holding...

Page 13: ...STARTING SYSTEM 9 6 STARTER SOLENOID WIRE Check the starter solenoid wire for continuity...

Page 14: ...INDEX 10 1 2 C CABLE HARNESS ROUTING 2 2 M MAINTENANCE STANDARDS 2 2 S STARTER MOTOR DISASSEMBLY ASSEMBLY 9 3 STARTER MOTOR INSPECTION 9 4 STARTER MOTOR REMOVAL INSTALLATION 9 2 INDEX...

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