Janome 6500 Repair Manual

The Janome 6500 is a high-performance sewing machine featuring advanced stitching capabilities, automatic needle threading, built-in stitches, drop feed for free-motion sewing, speed control, and memory function. This repair manual covers disassembly, troubleshooting, maintenance procedures, and technical specifications for qualified technicians. Below are key sections for safety precautions, technical specifications, disassembly procedures, troubleshooting, maintenance, and parts replacement.

Technical Specifications

Key components: Motor assembly, needle bar mechanism, feed dog system, tension assembly, electronic control board.

Component	Specification
Motor Type	DC Servo Motor 85W
Stitch Length	0-5mm adjustable
Stitch Width	0-7mm adjustable
Maximum Speed	1000 stitches per minute
Built-in Stitches	50 utility, 10 decorative, 5 buttonholes
Needle System	HAx1 SP
Presser Foot	High lift (up to 13mm)
Bobbin Type	Jam Proof, Class 15 transparent
Power Requirements	110-120V, 60Hz
Machine Weight	22.5 lbs (10.2 kg)

Safety Precautions

Always disconnect power before servicing. Use proper tools and follow electrostatic discharge precautions.

1. Power disconnection: Unplug machine before any repair work.
2. Component handling: Handle circuit boards by edges to prevent ESD damage.
3. Sharp components: Wear protective gloves when handling needles and cutting tools.
4. Test procedures: Verify all safety features after repair completion.

WARNING! High voltage present in power supply section. Only qualified technicians should perform repairs.

Disassembly Procedures

Follow step-by-step disassembly for proper access to internal components.

1. Remove outer covers: Remove 6 screws from top cover, 4 from side panels.
2. Access motor assembly: Remove belt cover and disconnect motor wiring harness.
3. Needle bar removal: Remove timing belt, loosen set screw, extract needle bar.
4. Feed mechanism: Remove feed dog cover plate and feed dog assembly.
5. Control board access: Remove front panel and disconnect ribbon cables.

CAUTION! Document screw locations and cable connections for proper reassembly.

Troubleshooting Guide

• Motor not running: Check power supply, foot controller, motor brushes.
• Uneven stitches: Inspect feed dogs, check tension assembly, verify timing.
• Thread breaking: Examine needle condition, thread path, tension settings.
• Skip stitches: Check needle installation, hook timing, thread quality.
• Error codes: Refer to electronic control board diagnostic chart.
• Noise during operation: Inspect gears, bearings, and mechanical linkages.
• Buttonhole malfunction: Verify sensor operation and buttonhole mechanism.

Maintenance Schedule

Regular maintenance prevents premature wear and ensures optimal performance.

Daily: Clean lint from bobbin area, needle plate, and feed dogs.

Weekly: Oil hook race and moving parts with Janome sewing machine oil.

Monthly: Check belt tension, inspect electrical connections, test all functions.

Annual: Complete disassembly, cleaning, and lubrication by authorized technician.

Parts Replacement

Use only genuine Janome replacement parts. Common replacement components:

1. Needle bar assembly: Part #X59282601
2. Feed dog set: Part #X59294701
3. Motor brushes: Part #X59312801
4. Timing belt: Part #X59274501
5. Control board: Part #X59402901
6. Foot controller: Part #X59348201

Tip: Verify part numbers in Janome parts catalog before ordering.

Electrical System

DC servo motor system with electronic speed control and safety circuits.

1. Power supply: 120V AC input, converts to DC for motor control.
2. Motor control: PWM circuit regulates motor speed based on foot pedal input.
3. Control board: Microprocessor manages stitch patterns, memory functions.
4. Sensors: Optical sensors detect needle position, bobbin thread.
5. Display: LCD shows stitch selection, error codes, settings.

WARNING! Capacitors may retain charge even when unplugged. Discharge before servicing.

Mechanical Adjustments

Precise adjustments required for proper stitch formation and machine timing.

Adjustment	Procedure	Tolerance
Hook Timing	Align hook point with needle eye at 2.5mm above eye	±0.1mm
Needle Bar Height	Set so needle eye is 1.5mm above hook point at lowest position	±0.2mm
Feed Dog Height	Adjust to 0.8mm above needle plate at highest position	±0.1mm
Presser Foot Pressure	Adjust spring tension for even fabric feed	Factory set
Bobbin Case Tension	Set so bobbin thread pulls smoothly with slight resistance	15-25g

Calibration Procedures

Electronic calibration required after control board replacement or major repairs.

1. Enter service mode: Press and hold reverse button while turning power on.
2. Needle position calibration: Follow on-screen prompts to set top and bottom positions.
3. Stitch length calibration: Test and adjust stitch length accuracy.
4. Tension calibration: Verify and adjust upper and lower thread tension.
5. Sensor calibration: Calibrate optical sensors for proper detection.

CAUTION! Incorrect calibration may cause machine damage or poor stitch quality.

Warranty Information

Janome 6500 carries a 25-year limited warranty on mechanical parts and 5 years on electronic components. Warranty applies only to original purchaser and requires proof of purchase. Service must be performed by authorized Janome service centers to maintain warranty coverage.

Contact Information

Service Type	Contact Method	Information
Technical Support	Phone	1-800-631-0183
Parts Ordering	Online	www.janome.com/parts
Service Centers	Website Locator	www.janome.com/service-centers
Manual Downloads	Support Site	www.janome.com/support/manuals
Training Resources	Technical Portal	For authorized technicians only

Service Hours: Monday-Friday 8:00 AM - 6:00 PM EST

Emergency: For electrical hazards, contact qualified electrician immediately.