How to Repair a 6500 Watt Generator


Large load capacity generators produced by different manufacturers, including 6500 watt generators, require the same, or at least similar, types of repairs. These generators are gas-powered, and because of their capacity, they require high horsepower engines to produce the wattage required by their owners. Keeping up with the recommended maintenance schedule is a very good idea. If you don’t keep up with it, you will likely have a long list of repairs on your hands. Some repairs can be quite costly and must be performed by a qualified service dealer as recommended by your 6500 watt generator manufacturer.

Things You'll Need

  • Paper towels
  • Engine oil
  • Oil container
  • Screwdriver
  • Non-flammable solvent
  • Spark plug socket
  • Ratcheting wrench
  • New spark plug
  • Gapping tool
  • Check the oil level in the generator regularly, before each use. Change the oil regularly, too. To check the oil level, locate the dipstick, unscrew it, and check the fill level on the stick. The oil level should be at, or very close to, the "full" mark on the stick. If it is near the "low" or "add" mark, add the recommended engine oil to the engine crank case via the dipstick opening. Oil recommendations vary depending on the climate the generator will be used in. Check the oil level with the dipstick as you fill the crank case so you do not add too much oil and have to pour some of it out. If the oil level does not show on the dipstick, add oil immediately. This could be an indication that the engine is experiencing more serious problems and should be inspected by a qualified service dealer. The generator engine may be burning excessive amounts of oil, which is an indication of combustion chamber issues.

  • Change the engine oil in the generator according to the engine maintenance schedule. This is usually sometime during the first month or 20 hours of use and every six months or 100 hours of use after that. It is just as important to change the oil in your 6500 watt generator as it is in your car. Use the recommended type of oil to replace the used oil. To change the oil, start the engine and let it run just long enough to warm the engine. Warm oil flows easier than cold oil. Turn the engine off and remove the dipstick. Tip the generator over and pour the used oil out into an approved oil collection container. Wipe up any oil that spills onto the generator or the ground with a paper towel. Add new oil to the crank case via the dipstick opening to the correct fill level as indicated by the dipstick.

  • Turn the inline fuel valve on your generator off. Remove the screw securing the sediment cup to the carburetor with a screwdriver and pull the sediment cup off of the carburetor. Remove the o-ring as well, if there is one. Wash the sediment cup and o-ring with a non-flammable solvent and dry them thoroughly with a paper towel. Reinstall the o-ring onto the generator engine, followed by the sediment cup. Replace the screw to secure the sediment cup in place and open the fuel valve again. Removing the sediment from the sediment cup will keep sediment (solid particles that separate from the fuel) from building up and entering the combustion chamber, and it will allow the proper amount of fuel to flow from the fuel tank to the carburetor.

  • Disconnect the spark plug wire and remove the spark plug from the generator with a spark plug socket and ratcheting wrench. Inspect the spark plug for damage. If the 6500 watt generator has been in service for six months or 100 hours, wipe the spark plug off with a paper towel and check the size of the gap with a spark plug gapping tool. The gap should measure between 0.020 and 0.030 inches depending on manufacturer specifications. If the 6500 watt generator has been in service for a year or 300 hours, replace the spark plug with a new one. Replace the spark plug with the socket and ratcheting wrench and reattach the spark plug wire.

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