I recently made a video on this Honda EM500 generator. A subscriber sent it to me after it started producing almost 200 volts out of the 120 volt outlet. The ultimate issue was that the automatic voltage regulator (AVR) had failed. The part was obsolete and not available new or used. Even worse Honda potted the board with a resin that could not easily be removed and did not publish any circuit diagrams. I did manage to find a new old stock AVR for $200 from a seller out of the Netherlands. I purchased what was the last one available for sale in the world.

A lot of these 40+ year old generators are new failing. Mechanically they are sound, but the electronics in the AVR are going bad. After publishing the first video a few came forward and offered to assist with designing a new replacement board. I sent the failed board to Bill. Within weeks he had produced several design options.

Today I am going to gather some more data, choose an AVR design and build a prototype board. I have zero board building experience. Should be interesting.

Generator Model: EM500
AVR Part: 32350-892-632

First Honda EM500 Video
Vintage Honda EM500 - High Voltage Problem
   • Vintage Honda EM500 - High Voltage Pr...  

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AVR, Alternator, Automatic Voltage Regulator, Depotting, EM500, Fixed, Generator, Hertz, High Voltage, Honda EM500, Honda, How To, How-To, Kill A Watt, Load Test, Obsolete, Oscilloscope, Prototype, Repair, Small Engine, Too Much Power, Troubleshooting, Vintage Honda