BLACK DIAMOND 5500W ELECTRIC START GENERATOR
Model #: BD100619
Serial Number Range: ALL
For ordering replacement parts, please visit: black-diamond.com or call 1-888-373-8272.
Revision: 20210401
Generator Components
Generator Parts Diagram
Diagram illustrating the main generator assembly with numbered components. References Figures A, B, E, F, G, and H.
Generator Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 45.090006.20 | Bracket, Air Cleaner Support | 1 |
| 2 | 1.6177.1.06 | Lock Nut M6, Flange | 2 |
| 3 | 1.6177.1.08 | Lock Nut M8, Flange | 2 |
| 4 | 46.100001.07 | Gasket, Exhaust | 1 |
| 5 | 46.101000.12.2 | Muffler Assembly | 1 |
| 6 | 46.101300.00 | Spark Arrester Assembly | 1 |
| 7 | 1.9074.4.0510 | Screw/Washer Assembly M5 x 10 | 3 |
| 8 | 1.16674.0820 | Flange Bolt M8 x 20 | 2 |
| 9 | 151.190000.15.2 | Alternator Assembly, See Figure E | 1 |
| 10 | 1.5789.0608 | Flange Bolt M6 x 8 | 2 |
| 11 | 152.192300.01 | Vent, Alternator Fan | 1 |
| 12 | 152.190005.00 | Rubber, Fore-Cover, A | 1 |
| 13 | 152.190005.01 | Rubber, Fore-Cover, B | 1 |
| 14 | 46.603.2 | Engine, 389cc, See Figure B | 1 |
| 15 | 2.06.016 | Clamp 8.7 x b8 | 3 |
| 16 | 2.08.143.1 | Flange Bolt/Washer Assembly M6 x 20, Black | 2 |
| 17 | 152.070000.58 | Fuel Tank Assembly, See Figure F | 1 |
| 18 | 24.070014.05 | Tube, Reversal Valve, 630mm | 1 |
| 19 | 24.070030.00 | Vent, Breather Tube | 1 |
| 20 | 2.06.006 | Clamp 7 x 1 | 1 |
| 21 | 65297.100619 | Frame Assembly, See Figure H | 1 |
| 22 | 1.6177.1.10 | Lock Nut M10, Flange | 2 |
| 23 | 46.061200.00.2 | Guide Plate, Rope, Black | 1 |
| 24 | 1.819.0510 | Screw M5 x 10 | 2 |
| 25 | 152.070011.22 | Hose, Fuel 400 + 25mm | 1 |
| 26 | 2.05.009 | Clamp 12.5 x 7 | 1 |
| 27 | 122.070001.00 | Knob, Fuel Valve | 1 |
| 28 | 1.9074.4.0414.1 | Screw/Washer Assembly M4 x 14, Black | 1 |
| 29 | 83.070400.01.0 | Fuel Valve | 1 |
| 30 | 1.9074.1.0525 | Screw Assembly M5 x 25 | 2 |
| 31 | 1.5789.0835 | Flange Bolt M8 x 35 | 2 |
| 32 | 1.93.08 | Lock Washer 8 | 2 |
| 33 | 2.03.040 | Washer 8 x 24 x 3 | 2 |
| 34 | 1.62.06 | Butterfly Type Nut M6 | 1 |
| 35 | 1.97.1.06.2 | Washer 6 | 2 |
| 36 | 1.93.06.2 | Lock Waher 6 | 1 |
| 37 | 5.1900.029 | Grounding Line 150 mm | 1 |
| 38 | 1.862.06 | Lock Washer 6, Toothed | 1 |
| 39 | 1.9074.3.0510 | Screw/Washer Assembly M5 x 10 | 2 |
| 40 | 1.6177.1.05 | Lock Nut M5, Flange | 2 |
| 41 | 9.1000.150 | Battery 12V15AH | 1 |
| 42 | 152.200904.00 | Pinch, Rubber | 1 |
| 43 | 5.1900.125 | Wire, To SAE Motor | 1 |
| 44 | 152.200013.02.3 | Jacket, Wire, Red | 2 |
| 45 | 5.1900.126 | Wire, To SAE Battery | 1 |
| 46 | 152.200013.02 | Jacket, Wire, Black | 1 |
| 47 | 152.200013.03 | Sleeve, Connector | 1 |
| 48 | 1.5789.0615.1 | Flange Bolt M6 x 15, Black | 4 |
| 49 | 100619.21 | Control Panel Assembly, See Figure H | 1 |
Engine Components
Engine Parts Diagram
Diagram illustrating the engine assembly with numbered components. References Figures B and C.
Engine Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 21.061300.01 | Handle, Recoil, Soft, Black | 1 |
| 2 | 1.5789.0608 | Flange Bolt M6 x 8 | 1 |
| 3 | 46.061100.03.2 | Cover, Recoil Starter, Black | 1 |
| 4 | 45.060005.00 | Spring, Recoil Starter | 1 |
| 5 | 45.061102.00 | Reel, Recoil Starter | 1 |
| 6 | 2.10.003.1 | Rope 4 x 1550, Black | 1 |
| 7 | 45.060003.00 | Spring, Ratchet | 2 |
| 8 | 45.060002.00 | Starter Ratchet, Steel | 2 |
| 9 | 45.060009.00 | Spring, Ratchet Guide | 1 |
| 10 | 45.060007.00 | Ratchet Guide | 1 |
| 11 | 45.060008.00 | Screw, Ratchet Guide | 1 |
| 12 | 1.5789.0612 | Flange Bolt M6 x 12 | 12 |
| 13 | 2.05.005 | Clamp 6 | 1 |
| 14 | 46.080100.01.2 | Fan Cover, Black | 1 |
| 15 | 2.02.007 | Nut M16 x 1.5 | 1 |
| 16 | 1.5789.0629 | Flange Bolt M6 x 29 | 4 |
| 17 | 45.060001.00 | Pulley, Starter | 1 |
| 18 | 46.123000.01 | Ignition Coil | 1 |
| 19 | 45.080001.00 | Cooling Fan | 1 |
| 20 | 46.120100.04 | Flywheel | 1 |
| 21 | 2.11.007 | Oil Seal 35 x 52 x 8 | 2 |
| 22 | 2.05.050 | Wire Clip, 100 mm | 1 |
| 23 | 152.070031.01 | Sheath, Wire | 1 |
| 24 | 2.03.023 | Washer 12.5 x 20 x 2, Drain Bolt | 1 |
| 25 | 46.030100.04.1 | Crankcase | 1 |
| 26 | 45.127000.02 | Oil Level Sensor | 1 |
| 27 | 1.5789.0615 | Flange Bolt M6 x 15 | 2 |
| 28 | 1.276.6202 | Bearing 6202 | 2 |
| 29 | 47.050006.00 | Weight Balancer | 1 |
| 30 | 45.050100.14 | Crankshaft | 1 |
| 31 | 46.030008.00 | Gasket, Crankcase Cover | 1 |
| 32 | 2.04.001 | Dowel Pin 9 x 14 | 2 |
| 33 | 46.080600.00 | Air Guide, Right Side | 1 |
| 34 | 1.276.6207 | Bearing 6207 | 1 |
| 35 | 46.031000.01.1 | Oil Dipstick Assembly, Black | 1 |
| 36 | 45.030007.00 | Cover, Crankcase | 1 |
| 37 | 1.5789.0840 | Flange Bolt M8 x 40 | 7 |
| 38 | 2.03.021.1 | Washer 6.4 x 13 x 1, Black | 1 |
| 39 | 45.110013.00 | Shaft, Governor Gear | 1 |
| 40 | 45.110100.00 | Gear, Governor | 1 |
| 41 | 21.110011.00 | Clip, Governor Gear | 1 |
| 42 | 45.110012.00 | Bushing, Governor Gear | 1 |
| 43 | 47.050200.00 | Connecting Rod | 1 |
| 44 | 46.050005.00 | Piston | 1 |
| 45 | 2.09.004 | Circlip 21 x 1 | 2 |
| 46 | 45.050003.00 | Pin, Piston | 1 |
| 47 | 46.050303.00 | Ring, Oil | 1 |
| 48 | 46.050302.00 | Ring, Second Piston | 1 |
| 49 | 46.050301.00 | Ring, First Piston | 1 |
| 50 | 2.04.004 | Dowel Pin 12 x 20 | 2 |
| 51 | 1.6177.1.05 | Flange Nut M5 | 6 |
| 52 | 46.080400.00 | Air Guide, Lower | 1 |
| 53 | 46.010000.00 | Cylinder Head Assembly - See Figure C | 1 |
| 54 | 1.16674.0608 | Flange Bolt M6 x 8 | 3 |
| 55 | 2.15.002 | Spark Plug F6RTC | 1 |
| 56 | 2.08.014 | Flange Bolt M10 x 80 | 4 |
| 57 | 46.020002.00 | Gasket, Cylinder Head Cover | 1 |
| 58 | 46.021000.00 | Cover, Cylinder Head | 1 |
| 59 | 45.020001.02 | Breather Tube | 1 |
| 60 | 45.020100.00 | Bolt, Cylinder Head Cover | 1 |
| 61 | 2.08.039 | Drain Bolt M12 x 1.5 x 15 | 1 |
| 62 | 46.041000.00 | Camshaft | 1 |
| 63 | 45.040013.00 | Lifter, Valve | 2 |
| 64 | 45.125000.03 | Starter Motor Assembly | 1 |
| 65 | 43.130200.00 | Support, Choker Rod | 1 |
| 66 | 46.040005.00 | Push Rod | 2 |
| 67 | 45.125200.03 | Relay, Starter, Three Gear | 1 |
| 68 | 1.93.05 | Lock Washer 5 | 2 |
| 69 | 1.16674.0516 | Flange Bolt M5 x 16 | 2 |
| 70 | 45.125100.00 | Starter Motor | 1 |
| 71 | 45.121000.00 | Coil, Charging | 1 |
| 72 | 1.5789.0835 | Flange Bolt M8 x 35 | 2 |
| 73 | 45.040008.00 | Rotator, Exhaust Valve | 1 |
| 74 | 46.040004.00 | Guide Plate, Push Rod | 1 |
| 75 | 46.040016.00 | Shaft, Rocker Arm | 1 |
| 76 | 46.040201.00 | Retainer, Rocker Arm | 1 |
| 77 | 46.040009.00 | Rocker Arm, Intake Valve | 1 |
| 78 | 46.040018.00 | Rocker Arm, Exhaust Valve | 1 |
| 79 | 1.97.1.06 | Washer 6 | 2 |
| 80 | 22.040012.00 | Screw, Valve Adjustment | 2 |
| 81 | 1.6177.1.06 | Flange Nut M6 | 2 |
| 82 | 21.040021.00 | Nut M6 x 0.5, Lock | 2 |
| 83 | 45.030006.00 | Plate, Coil | 1 |
| 84 | 46.130002.20 | Gasket, Insulator | 1 |
| 85 | 45.130001.00 | Insulator, Carburetor | 1 |
| 86 | 46.130003.20 | Gasket, Carburetor | 1 |
| 87 | 46.131000.30 | Carburetor | 1 |
| 88 | 46.130004.20 | Gasket, Air Cleaner | 2 |
| 89 | 1.6177.06 | Flange Nut M6 | 3 |
| 90 | 46.091100.09 | Base, Air Cleaner | 1 |
| 91 | 45.091002.20 | Seal, Air Cleaner | 1 |
| 92 | 45.091001.20 | Separator, Air Cleaner | 1 |
| 93 | 45.091003.20 | Element, Air Cleaner | 1 |
| 94 | 46.091200.09 | Cover, Air Cleaner | 1 |
| 95 | 45.110001.00 | Shaft, Governor Arm | 1 |
| 96 | 2.03.019 | Washer 8.2 x 17 x 0.8 | 1 |
| 97 | 2.11.006 | Oil Seal 7 x 14 x 5 | 1 |
| 98 | 45.110008.00 | Pin, Shaft | 1 |
| 99 | 45.110003.00 | Arm, Governor | 1 |
| 100 | 2.08.040 | Bolt M6 x 21, Governor Arm | 1 |
| 101 | 45.110006.00 | Rod, Governor | 1 |
| 102 | 45.110005.00 | Spring, Throttle Return | 1 |
| 103 | 45.110007.00 | Spring, Governor | 1 |
| 104 | 46.080300.20 | Air Guide, Upper | 1 |
| 105 | 46.131017.20 | Standard Main Jet(#106) | 1 |
| 105 | 46.131017.20.01 | Altitude Main Jet(#104) | / |
| 106 | 46.091000.09 | Air Cleaner Assembly | 1 |
| 107 | 46.061000.03.2 | Recoil Assembly | 1 |
| 108 | 46.040200.00 | Rocker Arm Assembly | 1 |
Cylinder Head Components
Cylinder Head Diagram
Diagram illustrating the cylinder head assembly with numbered components. Reference Figure C.
Cylinder Head Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 46.010100.00 | Cylinder Head | 1 |
| 2 | 2.01.010 | Stud Bolt M8 x 35 | 2 |
| 3 | 45.040002.00 | Valve, Intake | 1 |
| 4 | 45.040006.00 | Valve, Exhaust | 1 |
| 5 | 45.040015.00 | Retainer, Valve Spring | 2 |
| 6 | 45.040017.00 | Oil Seal, Valve | 2 |
| 7 | 45.040003.00 | Spring, Valve | 2 |
| 8 | 45.040001.00 | Retainer, Intake Valve Spring | 1 |
| 9 | 23.040010.00 | Bolt, Rocker Arm | 2 |
| 10 | 45.040007.00 | Retainer, Exhaust Valve Spring | 1 |
| 11 | 2.01.008 | Stud Bolt M6 x M8 x 105 | 2 |
| 12 | 46.030009.01 | Gasket, Cylinder Head | 1 |
Alternator Components
Alternator Diagram
Diagram illustrating the alternator assembly with numbered components. Reference Figure E.
Alternator Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 152.190300.00 | Carbon Brush Assembly | 1 |
| 2 | 122.190004.01 | Pinch, Carbon Brush | 1 |
| 3 | 1.9074.15.0520 | Bolt/Washer Assembly M5 x 20 | 1 |
| 4 | 1.9074.17.0516 | Screw/Washer Assembly M5 x 16 | 2 |
| 5 | 122.190400.00 | Terminal Block | 1 |
| 6 | 152.190003.00.2 | End Housing Cover, Black | 1 |
| 7 | 1.16674.0512.2 | Flange Bolt M5 x 12 | 3 |
| 8 | 1.16674.0516 | Flange Bolt M5 x 16 | 2 |
| 9 | 153.190200.03 | AVR | 1 |
| 10 | 152.190002.00 | End Housing | 1 |
| 11 | 2.08.096 | Flange Bolt/Washer Assembly M6 x 149 | 4 |
| 12 | 2.08.097 | Bolt M5 x 184 | 2 |
| 13 | 1.93.05 | Lock Washer 5 | 2 |
| 14 | 1.97.1.05 | Washer 5 | 2 |
| 15 | 1.6175.05 | Nut M5 | 2 |
| 16 | 151.191002.15.2 | Stator Cover, Black | 1 |
| 17 | 2.08.095 | Flange Bolt/Washer Assembly M10 x 235 | 1 |
| 18 | 151.191200.15 | Stator Assembly, Al, 190 x 110 mm, CSA | 1 |
| 19 | 151.191100.15 | Rotor Assembly, Al, 190 x 110 mm, CSA | 1 |
Fuel Tank Components
Fuel Tank Diagram
Diagram illustrating the fuel tank assembly with numbered components. Reference Figure F.
Fuel Tank Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 152.070011.21 | Tube, Fuel 115 + 25mm | 1 |
| 2 | 2.06.016 | Clamp 8.7 x b8 | 1 |
| 3 | 21.070600.03 | Fitting, Fuel Tank with Filter | 1 |
| 4 | 122.070015.01 | Mount Vibration, Fuel Tank | 2 |
| 5 | 152.071000.58.2 | Fuel Tank, 32L, Black | 1 |
| 6 | 152.070800.00 | Reversal Valve | 1 |
| 7 | 122.070300.03 | Fuel Filter | 1 |
| 8 | 122.070100.09 | Fuel Tank Cap | 1 |
| 9 | 1.819.0510 | Screw M5 x 10 | 2 |
| 10 | 152.072000.04 | Fuel Gauge Assembly | 1 |
| 11 | 152.070024.01 | Mount Vibration, Fuel Tank | 2 |
Control Panel Components
Control Panel Diagram
Diagram illustrating the control panel assembly with numbered components. Reference Figure G.
Control Panel Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 152.210002.36.29 | Control Panel Housing, Cool Gray 11C | 1 |
| 2 | 5.1210.920 | 20Amp Circuit Breaker, Push Button, CSA | 2 |
| 3 | 5.1870.014 | Circuit Breaker Cover, Push Button | 2 |
| 4 | 1.9074.4.0306.1 | Screw/Washer Assembly M3 x 6, Black | 4 |
| 5 | 5.1430.008.99 | Intelligauge, VFT-2 | 1 |
| 6 | 5.1000.001.3 | Ignition Switch, Red | 1 |
| 7 | 152.130200.00 | Pull Choke Assembly | 1 |
| 8 | 152.259.1.2 | Control Panel | 1 |
| 9 | 5.1240.923 | 23Amp Circuit Breaker, Double Pole, CSA | 1 |
| 10 | 5.1870.020 | Receptacle Cover, L14-30R | 1 |
| 11 | 5.1120.026 | Receptacle L14-30R, CSA | 1 |
| 12 | 5.1120.050 | Receptacle 5-20R, Duplex GFCI | 2 |
| 13 | 5.1870.022 | Receptacle Cover, 5-20R, Duplex GFCI | 2 |
| 14 | 1.6177.1.04.1 | Lock Nut M4, Flange, Black | 6 |
| 15 | 5.1810.000 | Over Voltage Protector, CSA | 1 |
| 16 | 1.818.0514.2 | Screw M5 x 14 | 2 |
| 17 | 5.1800.000 | Bridge Rectifier | 1 |
| 18 | 1.6177.1.05 | Lock Nut M5, Flange | 6 |
| 19 | 152.210003.01 | Wire Jacket, Control Box, CSA | 1 |
| 20 | 5.1320.024 | Sheath, Wire, CSA | 1 |
| 21 | 152.210003.05 | Plug, End Cover | 1 |
| 22 | 100619.21.10 | Wire Assembly | 1 |
Frame Components
Frame Diagram
Diagram illustrating the generator frame assembly with numbered components. Reference Figure H.
Frame Parts List
| # | Part Number | Description | Qty. |
|---|---|---|---|
| 1 | 11.110008.00 | "R" Shape | 2 |
| 2 | 152.200703.05 | Long Pin, Handle | 2 |
| 3 | 1.894.1.08 | Circlip 8 | 2 |
| 4 | 152.200703.02 | Short Pin, Handle | 2 |
| 5 | 152.200700.20 | Handle, U Shape | 1 |
| 6 | 152.200702.02 | Cover, Handle | 1 |
| 7 | 152.201200.04 | Engine Mount 2 | 1 |
| 8 | 65297.0.8.2 | Frame, 755 x 561 x 600 | 1 |
| 9 | 122.201501.23.1 | Pin Roll, Wheel, 16 x 10 x 97, Black | 2 |
| 10 | 152.201701.09.29 | 10 in. Wheel, PU, Cool Gray 11C | 2 |
| 11 | 2.16.001.1 | Pin 2 x 33, "R" Shape , Black | 2 |
| 12 | 1.6177.1.08 | Lock Nut M8, Flange | 9 |
| 13 | 152.201200.03 | Engine Mount 1 | 1 |
| 14 | 152.201200.00 | Alternator Mount | 2 |
| 15 | 152.200002.19.2 | Support Leg 62 mm | 2 |
| 16 | 1.5789.0816 | Flange Bolt M8 x 16 | 4 |
| 17 | 122.201400.04 | Rubber, Support | 2 |
| 18 | 1.5789.0825 | Flange Bolt M8 x 25 | 2 |
Electrical System
Wiring Diagram
Diagram detailing the electrical connections for the generator, including components like the rectifier, ignition coil, battery, starter, circuit breakers, and control switches.
Black-Diamond