Don't really play theme teams until lately, because of a friend who going to be playing in a tournment and wants to get it down and understand it.

During his turn he moves his character and places a action token. can he use that character for the theme team PC during my turn?

When using theme team PC during a an opponent's turn does that take an action away from him for his next turn?

So if the person was using a generic keyword he has to have 6 characters in a 500 pt team to have 3 PC? Is that same with a Theme team of non-generics needing to have 6 characters to gain 3 PC?

That's fine. It is a different turn than the one from the action.

No. It never counts as an action.

Generic is 1/100, so in 500 he needs only 5 to hit theme.
(Non=4)

Once theme is determined, it is 1 PC per 2 figs, regardless of "type" of theme, so to get 3 you need six in either case.

Thanks for the information