625010

Honda EM5000SX Handleiding

46
Verklein
Vergroot
Pagina terug
1/79
Pagina verder
EM3800SX•EM5000SX•EM6500SX
K2:EM5000SX
See page 60 for instructions
on assembling your generator.
31Z21604
00X31-Z21-6040
Exhaust contains poisonous carbon monoxide gas that can build up
to dangerous levels in closed areas.
Breathing carbon monoxide can cause unconsciousness or death.
Never run the generator in a closed, or even partly closed area where
people may be present.
The generator is a potential source of electrical shock if misused. Do
not expose the generator to moisture, rain or snow. Do not let the
generator get wet, and do not operate it with wet hands.
Keep this owner’s manual handy so that you can refer to it at any time.
This owner’s manual is considered a permanent part of the generator
and should remain with the generator if resold.
The information and specifications included in this publication were in
effect at the time of approval for printing. Honda Motor Co., Ltd.
reserves the right, however, to discontinue or change specifications or
design at any time without notice and without incurring any obligation
whatever. No part of this publication may be reproduced without
written permission.
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
09/02/10 12:43:38 31Z21600_001
1
Congratulations on your selection of a Honda generator. We are
certain you will be pleased with your purchase of one of the finest
generators on the market.
We want to help you get the best results from your new generator and
to operate it safely. This manual contains the information on how to
do that; please read it carefully.
As you read this manual, you will find information preceded by a
symbol. That information is intended to help you avoid
damage to your generator, other property, or the environment.
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty policy
is a separate document that should have been given to you by your
dealer.
When your generator needs scheduled maintenance, keep in mind
that your Honda servicing dealer is specially trained in servicing
Honda generators. Your authorized Honda servicing dealer is
dedicated to your satisfaction and will be pleased to answer your
questions and concerns.
Best Wishes,
Honda Motor Co., Ltd.
09/02/10 12:43:44 31Z21600_002
2
A FEW WORDS ABOUT SAFETY
Safety Labels
Safety Messages
Safety Headings
Safety Section
Instructions
To help you make informed decisions about safety, we have provided
operating procedures and other information on labels and in this
manual. This information alerts you to potential hazards that could
hurt you or others.
Of course, it is not practical or possible to warn you about all the
hazards associated with operating or maintaining a generator. You
must use your own good judgement.
You will find important safety information in a variety of forms,
including:
on the generator.
These signal words mean:
be or if
you don’t follow instructions.
be or if
you don’t follow instructions.
be if you don’t follow
instructions.
Your safety and the safety of others are very important. And using
this generator safely is an important responsibility.
preceded by a safety alert symbol and one
of three signal words, DANGER, WARNING, or CAUTION.
such as
IMPORTANT SAFETY INFORMATION
.
such as
how to use this generator correctly and safely.
This entire book is filled with important safety information please
read it carefully.
You WILL KILLED SERIOUSLY HURT
You CAN KILLED SERIOUSLY HURT
You CAN HURT
GENERAT OR SAFET Y .
09/02/10 12:43:57 31Z21600_003
3
CONTENTS
..............................................................................GENERATOR SAFETY . 5
.......................................................................Safety Label Locations . 5
............................................................Important Safety Information . 6
..............................................................COMPONENT IDENTIFICATION . 8
..............................................................................................CONTROLS . 10
....................................................................................Engine Switch . 10
........................................................................................Starter Grip . 10
................................................................................Fuel Valve Lever . 11
..........................................................................................Choke Rod . 11
............................Voltage Selector Switch (Dual Voltage System) . 12
...............................................................................Ground Terminal . 12
.....................................................................................DC Terminals . 13
..........................................................................DC Circuit Protector . 13
..............................................................................Oil Alert
System . 14
......................................................................Auto Throttle
System . 14
.............................................................................AC Circuit Breaker . 15
..........................................................................AC Circuit Protector . 16
...................................................................................GENERATOR USE . 17
...............................Connections to a Building’s Electrical System . 17
..................................................................................Ground System .17
.......................................................................Special Requirements . 17
.................................................................................AC Applications . 18
.....................................................................................AC Operation . 19
...................................................................AC Receptacle Selection . 20
.....................................................................................DC Operation . 26
......................................................................Auto Throttle
System . 28
....................................................................High Altitude Operation . 29
.......................................................................PRE-OPERATION CHECK . 30
..........................................................................................Engine Oil . 30
............................................................................................Refueling . 31
....................................................................Fuel Recommendations . 32
..............................STARTING THE ENGINE/STOPPING THE ENGINE . 33
09/02/10 12:44:02 31Z21600_004
4
......................................................................................MAINTENANCE . 35
......................................................The Importance of Maintenance . 35
..........................................................................Maintenance Safety . 36
.....................................................................Maintenance Schedule . 37
............................................................................Engine Oil Change . 38
...........................................................................Air Cleaner Service . 39
...........................................................Fuel Sediment Cup Cleaning . 40
............................................................................Spark Plug Service . 41
............................................................Spark Arrester Maintenance . 42
.............................................................................Fuse Replacement . 43
................................................................................................STORAGE . 44
..........................................................................Storage Preparation . 44
...........................................................................................Cleaning . 44
...................................................................................................Fuel . 44
.........................................................................................Engine Oil . 46
.........................................................................Storage Precautions . 48
....................................................................Removal From Storage . 48
.....................................................................................TRANSPORTING . 49
.............................................................................TROUBLESHOOTING . 50
..................................................................TECHNICAL INFORMATION . 52
............................................Emission Control System Information . 52
.............................................................................................Air Index . 54
.................................................................................WIRING DIAGRAM . 55
....................................................................................SPECIFICATIONS . 57
..............................................................................................ASSEMBLY . 60
.................................................WARRANTY SERVICE INFORMATION . 72
.................................................DEALER LOCATOR INFORMATION . 72
............................................CUSTOMER SERVICE INFORMATION . 72
.....................................................................Honda PUBLICATIONS . 73
......................................................................................................INDEX . 74
09/02/10 12:44:05 31Z21600_005
5
GENERATOR SAFETY
SAFETY LABEL LOCATIONS
Non-California type
California type
These labels warn you of potential hazards that can cause serious
injury. Read them carefully.
If a label comes off or becomes hard to read, contact your Honda
generator dealer for a replacement.
09/02/25 16:50:48 31Z21600_006
6
Operator Responsibility
Carbon Monoxide Hazards
IMPORTANT SAFETY INFORMATION
Honda generators are designed to give safe and dependable service if
operated according to instructions. Read and understand this owner’s
manual before operating your generator. You can help prevent
accidents by being familiar with your generator’s controls and by
observing safe operating procedures.
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles,
and connections.
Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without
parental supervision.
Exhaust contains poisonous carbon monoxide, a colorless and
odorless gas. Breathing carbon monoxide can cause loss of
consciousness and may lead to death.
If you run the generator in a confined or even partly enclosed area,
the air you breathe could contain dangerous amount of exhaust gas.
Never run your generator inside a garage, house, or near open
windows or doors.
09/02/10 12:44:32 31Z21600_007
7
Electric Shock Hazards
Fire and Burn Hazards
The generator produces enough electric power to cause a serious
shock or electrocution if misused.
Using a generator or electrical appliance in wet conditions, such as
rain or snow, or near a pool or sprinkler system, or when your hands
are wet, could result in electrocution. Keep the generator dry.
If the generator is stored outdoors, unprotected from the weather,
check all of the electrical components on the control panel before
each use. Moisture or ice can cause a malfunction or short circuit in
electrical components that could result in electrocution.
Do not connect to a building’s electrical system unless an isolation
switch has been installed by a qualified electrician.
The exhaust system gets hot enough to ignite some materials.
Keep the generator at least 3 feet (1 meter) away from buildings
and other equipment during operation.
Do not enclose the generator in any structure.
Keep flammable materials away from the generator.
The muffler becomes very hot during operation and remains hot for
a while after stopping the engine. Be careful not to touch the muffler
while it is hot. Let the engine cool before storing the generator
indoors.
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks where the
generator is refueled or where gasoline is stored. Refuel in a well-
ventilated area with the engine stopped.
Fuel vapors are extremely flammable and may ignite after the
engine has started. Make sure that any spilled fuel has been wiped
up before starting the generator.
09/02/10 12:44:42 31Z21600_008
8
COMPONENT IDENTIFICATION
CONTROL PANEL
CHOKE ROD
ENGINE SWITCH
CONTROL PANEL
AIR CLEANER
FUEL VALVE LEVER
ENGINE SERIAL NUMBER
AC CIRCUIT PROTECTORS
AUTO THROTTLE
SWITCH
120 ONLY 120/240
VOLTAGE SELECTOR SWITCH
DC CIRCUIT
PROTECTOR
DC OUTPUT
TERMINAL
AC CIRCUIT BREAKER
1
FUSE
1:Except EM3800SX
OIL DRAIN PLUG
OIL FILLER CAP/DIPSTICK
STARTER GRIP
GROUND TERMINAL
120/240V AC
RECEPTACLE
120V AC RECEPTACLES
09/02/25 16:50:54 31Z21600_009
9
FUEL TANK CAP
FUEL GAUGE
MUFFLER
SPARK PLUG CAP
FRAME SERIAL NUMBER
TRANSPORT HANDLE
WHEEL
STAND
Record the engine and frame serial numbers and date of purchase
for your future reference. Refer to these serial numbers when
ordering parts and when making technical or warranty inquiries (see
page ).
Date of purchase:
Engine serial number:
Frame serial number:
*
72
09/02/25 16:51:00 31Z21600_010
10
CONTROLS
Engine Switch
Starter Grip
Key position:
OFF:
ON:
START:
STARTER GRIP
ENGINE SWITCH
ON
OOFFFF
SSTTAARRTT
RECOIL STARTER
To start and stop the engine.
To start the engine, pull the starter grip lightly until resistance is felt,
and then pull briskly.
Do not allow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter.
To stop the engine. Key can be removed/inserted.
To run the engine after starting.
To start the engine by operating the starter motor.
The recoil starter is used to start the engine if the generator is not
equipped with a 12-volt battery to operate the starter motor, or if the
battery does not contain adequate charge to operate the starter motor.
09/02/10 12:45:08 31Z21600_011
11
Fuel Valve Lever
Choke Rod
OPEN
ON
FUEL VALVE LEVER
CCLLOOSSEEDD
CHOKE ROD
OOFFFF
The choke is used to provide an enriched fuel mixture when starting a
cold engine. It can be opened and closed by operating the choke rod
manually. Pull the rod out toward CLOSED to enrich the mixture for
cold starting.
The fuel valve is located between the fuel tank and carburetor. When
the valve lever is in the ON position, fuel is allowed to flow from the
fuel tank to the carburetor. Be sure to return the fuel valve lever to the
OFF position after stopping the engine.
09/02/10 12:45:14 31Z21600_012
12
Voltage Selector Switch (Dual Voltage System)
Ground Terminal
Switch Position
120/240V:
120V ONLY:
GROUND TERMINAL
VOLTAGE SELECTOR SWITCH
120V ONLY
120/240V
112200//224400VV
112200VV OONNLLYY
The voltage selector switch switches the main power carrying
windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a
240V appliance is connected to the 4-prong receptacle, the switch
must be in the ‘‘120/240V’’ position. If only a 120V appliance is being
connected to any of the 120V 3-prong receptacles, select the ‘‘120V
ONLY’’ position.
ONLY the 120V receptacles can be used. Do not use the
120/240V receptacle in this position. The most power
will be available at the 30A 120V locking plug
receptacle.
The 120V and 120/240V receptacles can be used
simultaneously.
Before using the ground terminal, consult a qualified electrician,
electrical inspector, or local agency having jurisdiction for local codes
or ordinances that apply to the intended use of the generator.
The generator ground terminal is connected to the frame of the
generator, the metal non-current-carrying parts of the generator, and
the ground terminals of each receptacle.
09/02/10 12:45:24 31Z21600_013
13
DC Terminals
DC Circuit Protector
DC CIRCUIT
PROTECTOR
NEGATIVE TERMINAL
(BLACK)
POSITIVE TERMINAL
(RED)
The DC terminals may ONLY be used for charging 12-volt automotive
type batteries.
The terminals are colored red to identify the positive ( ) terminal and
black to identify the negative ( ) terminal. The battery must be
connected to the generator DC terminals with the proper polarity
(battery positive to generator red terminal and battery negative to the
generator black terminal).
The DC circuit protector automatically shuts off the DC battery
charging circuit when the DC charging circuit is overloaded, when
there is a problem with the battery, or when the connections between
the battery and the generator are improper.
09/02/10 12:45:31 31Z21600_014
14
Oil Alert System
Auto Throttle
System
Switch Position
AUTO:
OFF:
OFF
ON
OFF
ON
AUTO THROTTLE SWITCH
If the engine stops and will not restart, check the engine oil level (see
page ) before troubleshooting in other areas.
Recommended to minimize fuel consumption and further
reduce noise levels when no load is applied to the generator.
The Auto Throttle system does not operate.
Recommended to minimize warm-up time when the
generator is started and when starting a load with large start-
up power equipments.
The Oil Alert
system is designed to prevent engine damage caused
by an insufficient amount of oil in the crankcase. Before the oil level in
the crankcase can fall below a safe limit, the Oil Alert system will
automatically stop the engine (the engine switch will remain in the ON
position). The Oil Alert system should not take the place of checking
the oil level before each use.
The Auto Throttle
system automatically reduces engine speed when
all loads are turned off or disconnected. When appliances are turned
on or reconnected, the engine returns to the rated speed.
30
09/02/10 12:45:40 31Z21600_015
15
AC Circuit Breaker
OFF
ON
AC CIRCUIT BREAKER
The AC circuit breaker will automatically switch OFF if there is a short
circuit or a significant overload of the generator at the receptacle. If the
AC circuit breaker is switched OFF automatically, check that the
appliance is working properly and does not exceed the rated load
capacity of the circuit before switching the AC circuit breaker ON again.
The AC circuit breaker may be used to switch the generator power ON
or OFF.
09/02/10 12:45:45 31Z21600_016
16
AC Circuit Protector
ON
OFF
AC CIRCUIT PROTECTORS
1
1:Except EM3800SX
The AC circuit protectors will automatically switch OFF if there is a
short circuit or a significant overload of the generator at the 20A 120V,
30A 120V locking plug, or 120/240V locking plug receptacle. If an AC
circuit protector switches OFF automatically, check that the appliance
is working properly and does not exceed the rated load capacity of the
circuit before resetting the AC circuit protector ON.
09/02/10 12:45:50 31Z21600_017
17
GENERATOR USE
Ground System
Special Requirements
Connections to a Building’s Electrical System
Improper connections to a building’s electrical system can allow
electrical current from the generator to backfeed into the utility lines.
Such backfeed may electrocute utility company workers or others
who contact the lines during a power outage, and the generator may
explode, burn, or cause fires when utility power is restored. Consult
the utility company or a qualified electrician.
There may be Federal or State Occupational Safety and Health
Administration (OSHA) regulations, local codes, or ordinances that
apply to the intended use of the generator. Please consult a qualified
electrician, electrical inspector, or the local agency having jurisdiction.
In some areas, generators are required to be registered with local
utility companies.
Honda portable generators have a system ground that connects
generator frame components to the ground terminals in the AC output
receptacles. The system ground is not connected to the AC neutral
wire. If the generator is tested by a receptacle tester, it will show the
same ground circuit condition as for a home receptacle.
Connections for standby power to a building’s electrical system must
be made by a qualified electrician. The connection must isolate the
generator power from utility power, and must comply with all
applicable laws and electrical codes. A transfer switch, which isolates
generator power from utility power, is available through authorized
Honda generator dealers.
09/02/10 12:45:58 31Z21600_018
18
AC Applications
Before connecting an appliance or power cord to the generator:
Make sure that it is in good working order. Faulty appliances or
power cords can create a potential for electrical shock.
If an appliance begins to operate abnormally, becomes sluggish, or
stops suddenly, turn it off immediately. Disconnect the appliance,
and determine whether the problem is the appliance or the rated
load capacity of the generator has been exceeded.
Make sure that the electrical rating of the tool or appliance does not
exceed that of the generator. Never exceed the maximum power
rating of the generator. Power levels between rated and maximum
may be used for no more than 30 minutes.
Limit operation requiring maximum power to 30 minutes.
Maximum power is:
Substantial overloading will open the circuit breaker. Exceeding the
time limit for maximum power operation or slightly overloading the
generator may not switch the circuit breaker or circuit protector OFF,
but will shorten the service life of the generator.
For continuous operation (longer than 30 minutes), do not exceed the
rated power.
Rated power is:
The total power requirements (VA) of all appliances connected must
be considered. Appliance and power tool manufacturers usually list
rating information near the model number or serial number.
3.3 kVA
3.8 kVA
5.0 kVA
6.5 kVA
4.5 kVA
5.5 kVA
EM3800SX:
EM5000SX:
EM6500SX:
EM3800SX:
EM5000SX:
EM6500SX:
09/02/10 12:46:09 31Z21600_019
19
AC Operation
VOLTAGE SELECTOR SWITCH
1
AC CIRCUIT PROTECTORS
AC CIRCUIT BREAKER
1:Except EM3800SX
Start the engine (see page ).
Turn the voltage selector switch to either position.
With the voltage selector switch in the ‘‘120/240V’’ position, you can
use the 120V and 120/240V receptacles simultaneously. If you are
NOT using the 120/240V receptacle, then select the ‘‘120V ONLY’’
position.
Switch the AC circuit breaker ON.
Plug in the appliance.
Be sure that all appliances are in good working order before
connecting them to the generator. If an appliance begins to operate
abnormally, becomes sluggish, or stops suddenly, turn off the ignition
switch lever immediately. Then disconnect the appliance and examine
it for signs of malfunction.
Most motorized appliances require more than their rated power for
startup.
Do not exceed the current limit specified for any one receptacle. If an
overloaded circuit causes the AC circuit breaker or AC circuit protector
to switch OFF, reduce the electrical load on the circuit, wait a few
minutes and then reset the AC circuit breaker or AC circuit protector.
1.
2.
4.
3.
33
09/02/10 12:46:20 31Z21600_020
20
AC Receptacle Selection
Power Producing Circuits
EM3800SX:
POWER
CIRCUIT 1
POWER
CIRCUIT 2
POWER CIRCUIT 1
POWER CIRCUIT 2
120V 30A
120V 20A (in total)
120V 20A (in total)
120V/240V 120V ONLY
& 120/240V 20A
4A 4B
4A
4B
The control panel, shown below, has a voltage selector switch and
four receptacles. Receptacle 4, the 240-volt receptacle, has two
powered terminals, 4A and 4B.
This generator is equipped with two power generating circuits. When
the voltage selector switch is in the 120V/240V position, each of the
two power producing circuits supplies power to specific receptacles.
When the voltage selector switch is in the 120V ONLY position, the
power producing circuits operate in parallel, sharing the total load
connected to terminal 4A and receptacles 1, 2, and 3.
09/02/10 12:46:29 31Z21600_021
21
Voltage Selector Switch
120V ONLY Position
120V/240V Position
ReceptacleSwitch Position
Set of
Receptacles
Power Producing
Circuit
Total Current
Available
Available Power
The power available to each receptacle depends on the position of the
voltage selector switch.
When the voltage selector switch is in the 120V ONLY position, you
do not need to spread the load over the receptacles. You must,
however, make sure the load on any receptacle does not exceed its
available power shown in the preceding table and the total load does
not exceed 27.5 amps.
When the voltage selector switch is in the 120V/240V position, you
must balance the load. Divide the load between the two sets of
receptacles shown below. Balancing is necessary because each set of
receptacles is powered by only one power producing circuit that can
produce a maximum of 13.8 amps.
1
2
3
4A
4B
1
2
3
4A-4B
120V ONLY
120V/240V
134B
24A
1
2
13.8A
13.8A
27.5A at 120V
20A at 120V
20A at 120V
20A at 120V
None
13.8A at 120V
13.8A at 120V
13.8A at 120V
13.8A at 240V
09/02/10 12:46:36 31Z21600_022
22
Power Producing Circuits
EM5000SX:
POWER
CIRCUIT 1
POWER
CIRCUIT 2
POWER CIRCUIT 1
POWER CIRCUIT 2
120V 30A
120V 20A (in total)
120V 20A (in total)
120V/240V 120V ONLY
& 120/240V 30A
4A 4B
4A
4B
The control panel, shown below, has a voltage selector switch and
four receptacles. Receptacle 4, the 240-volt receptacle, has two
powered terminals, 4A and 4B.
This generator is equipped with two power generating circuits. When
the voltage selector switch is in the 120V/240V position, each of the
two power producing circuits supplies power to specific receptacles.
When the voltage selector switch is in the 120V ONLY position, the
power producing circuits operate in parallel, sharing the total load
connected to terminal 4A and receptacles 1, 2, and 3.
09/02/10 12:46:45 31Z21600_023
23
Voltage Selector Switch
120V ONLY Position
120V/240V Position
ReceptacleSwitch Position
Set of
Receptacles
Power Producing
Circuit
Available Power
Total Current
Available
The power available to each receptacle depends on the position of the
voltage selector switch.
When the voltage selector switch is in the 120V ONLY position, you
do not need to spread the load over the receptacles. You must,
however, make sure the load on any receptacle does not exceed its
available power shown in the preceding table and the total load does
not exceed 37.5 amps.
When the voltage selector switch is in the 120V/240V position, you
must balance the load. Divide the load between the two sets of
receptacles shown below. Balancing is necessary because each set of
receptacles is powered by only one power producing circuit that can
produce a maximum of 18.8 amps.
1
2
3
4A
4B
1
2
3
4A-4B
120V ONLY
120V/240V
134B
24A
1
2
30A at 120V
20A at 120V
20A at 120V
30A at 120V
None
18.8A at 120V
18.8A at 120V
18.8A at 120V
18.8A at 240V
18.8A
18.8A
09/02/10 12:46:52 31Z21600_024
24
Power Producing Circuits
EM6500SX:
POWER
CIRCUIT 1
POWER
CIRCUIT 2
POWER CIRCUIT 1
POWER CIRCUIT 2
120V 30A
120V 20A (in total)
120V 20A (in total)
120V/240V 120V ONLY
& 120/240V 30A
4A 4B
4B
4A
The control panel, shown below, has a voltage selector switch and
four receptacles. Receptacle 4, the 240-volt receptacle, has two
powered terminals, 4A and 4B.
This generator is equipped with two power generating circuits. When
the voltage selector switch is in the 120V/240V position, each of the
two power producing circuits supplies power to specific receptacles.
When the voltage selector switch is in the 120V ONLY position, the
power producing circuits operate in parallel, sharing the total load
connected to terminal 4A and receptacles 1, 2, and 3.
09/02/10 12:46:59 31Z21600_025
25
Voltage Selector Switch
120V ONLY Position
120V/240V Position
ReceptacleSwitch Position
Set of
Receptacles
Power Producing
Circuit
Available Power
Total Current
Available
The power available to each receptacle depends on the position of the
voltage selector switch.
When the voltage selector switch is in the 120V ONLY position, you
do not need to spread the load over the receptacles. You must,
however, make sure the load on any receptacle does not exceed its
available power shown in the preceding table and the total load does
not exceed 45.8 amps.
When the voltage selector switch is in the 120V/240V position, you
must balance the load. Divide the load between the two sets of
receptacles shown below. Balancing is necessary because each set of
receptacles is powered by only one power producing circuit that can
produce a maximum of 22.9 amps.
1
2
3
4A
4B
1
2
3
4A-4B
120V ONLY
120V/240V
134B
24A
1
2
30A at 120V
20A at 120V
20A at 120V
30A at 120V
None
22.9A at 120V
20A at 120V
20A at 120V
22.9A at 240V
22.9A
22.9A
09/02/10 12:47:07 31Z21600_026
26
The battery gives off explosive gases; keep sparks, flames, and
cigarettes away. Provide adequate ventilation when charging or
using batteries.
DC Operation
Connecting the battery charging cables:
WARNING:
Wash hands after handling.
POSITIVE TERMINAL
(RED)
NEGATIVE TERMINAL
(BLACK)
DC CIRCUIT
PROTECTOR
The DC terminals may ONLY be used for charging 12-volt automotive
type batteries.
Start the generator.
Do not start the vehicle while the battery charging cable is connected
and the generator is running. The vehicle or the generator may be
damaged.
Connect the positive ( ) battery cable to the battery positive ( )
terminal.
Connect the other end of the positive ( ) battery cable to the
generator positive ( ) terminal.
Connect the negative ( ) battery cable to the battery negative ( )
terminal.
Connect the other end of the negative ( ) battery cable to the
generator negative ( ) terminal.
Before connecting the battery charging cables to a battery that is
installed in a vehicle, disconnect the vehicle ground battery cable
from the battery negative ( ) terminal.
Battery posts, terminals, and related accessories contain
lead and lead components.
1.
2.
3.
4.
5.
6.
09/02/10 12:47:17 31Z21600_027
27
Disconnecting the battery cables:
NEGATIVE TERMINAL
(BLACK)
POSITIVE TERMINAL
(RED)
DC CIRCUIT
PROTECTOR
Stop the engine.
An overloaded DC circuit, excessive current draw by the battery, or a
wiring problem will trip the DC circuit protector (PUSH button extends
out). If this happens, wait a few minutes before pushing in the circuit
protector to resume operation. If the DC circuit protector continues to
go OFF, discontinue charging and see your authorized Honda
generator dealer.
Disconnect the negative ( ) battery cable from the generator
negative ( ) terminal.
Disconnect the other end of the negative ( ) battery cable from the
battery negative ( ) terminal.
Disconnect the positive ( ) battery cable from the generator
positive ( ) terminal.
Disconnect the other end of the positive ( ) battery cable from the
battery positive ( ) terminal.
Reconnect the vehicle ground battery cable to the battery negative
()terminal.
1.
2.
3.
4.
5.
6.
09/02/10 12:47:24 31Z21600_028
28
Auto Throttle System
OFF
ON
OFF
ON
AUTO THROTTLE SWITCH
With the switch in the AUTO position, engine speed is automatically
reduced when ALL loads are turned OFF or disconnected. When
appliances are turned ON or reconnected, the engine returns to rated
speed. In the OFF position, the Auto Throttle system does not operate.
Appliances with large start-up power demands may not allow the
engine to reach normal operating rpm when they are connected to the
generator. Push the Auto Throttle switch to the OFF position and
connect the appliance to the generator. If the engine still will not reach
normal operating speed, check that the appliance does not exceed the
rated load capacity of the generator.
To avoid extended warm-up periods, keep the switch OFF until the
engine reaches operating temperature.
The Auto Throttle system is not effective for use with appliances that
require only momentary power. If the tool or appliance will be turned
ON and OFF quickly, the Auto Throttle switch should be in the OFF
position.
The Auto Throttle system will not respond to electrical loads of less
than 1 ampere or intermittent loads such as a staple gun. Turn the
Auto Throttle switch to the OFF position to operate loads of less than 1
amp.
09/02/10 12:47:32 31Z21600_029
29
High Altitude Operation
At high altitude, the standard carburetor air/fuel mixture will be too
rich. Performance will decrease, and fuel consumption will increase. A
very rich mixture will also foul the spark plug and cause hard starting.
Operation at an altitude that differs from that at which this engine was
certified, for extended periods of time, may increase emissions.
Even with carburetor modification, engine horsepower will decrease
about 3.5% for each 1,000-foot (300-meter) increase in altitude. The ef-
fect of altitude on horsepower will be greater than this if no carburetor
modification is made.
High altitude performance can be improved by specific modifications
to the carburetor. If you always operate your generator at altitudes
above 5,000 feet (1,500 meters), have your dealer perform this
carburetor modification. This engine, when operated at high altitude
with the carburetor modifications for high altitude use, will meet each
emission standard throughout its useful life.
When the carburetor has been modified for high altitude operation,
the air/fuel mixture will be too lean for low altitude use. Operation at
altitudes below 5,000 feet (1,500 meters) with a modified carburetor
may cause the engine to overheat and result in serious engine damage.
For use at low altitudes, have your servicing dealer return the
carburetor to original factory specifications.
09/02/10 12:47:38 31Z21600_030
30
PRE-OPERATION CHECK
Engine Oil
UPPER LEVEL
OIL FILLER HOLE
AMBIENT TEMPERATURE
OIL FILLER CAP/DIPSTICK
ChecktheoillevelBEFORE
EACH USE with the generator on
a level surface and the engine
stopped.
Use 4-stroke motor oil that
meets or exceeds the
requirements for API service
category SJ or later (or
equivalent). Always check the
API SERVICE label on the oil
container to be sure it includes
the letters SJ or later (or
equivalent).
SAE 10W-30 is recommended for general, all-temperature use. Other
viscosities shown in the chart may be used when the average
temperature in your area is within the indicated range.
Remove the oil filler cap/dipstick and wipe the dipstick clean.
Check the oil level by inserting the dipstick into the filler neck
without screwing it in.
If the level is low, fill to the upper limit of the oil filler neck with the
recommended oil.
1.
2.
3.
09/02/10 12:47:48 31Z21600_031
31
Refueling
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
Stop engine and keep heat, sparks, and flame away.
Refuel only outdoors.
Wipe up spills immediately.
FUEL GAUGE
FUEL TANK CAP
NON-CALIFORNIA TYPE
CALIFORNIA TYPE
UPPER LIMIT MARK
UPPER LIMIT MARK
TETHER
Never refuel the engine inside a building where gasoline fumes may
reach flames or sparks. Keep gasoline away from appliance pilot lights,
barbecues, electric appliances, power tools, etc.
Spilled fuel is not only a fire hazard, it causes environmental damage.
Wipe up spills immediately.
With the engine stopped, check the fuel level gauge. Refill the fuel tank
if the fuel level is low.
Refuel in a well-ventilated area with the engine stopped. If the engine
has been running, allow it to cool first. Refuel carefully to avoid
spilling fuel. Do not fill above the upper limit mark.
09/02/10 12:47:59 31Z21600_032
32
Fuel Recommendations
Engine damage or performance problems that result from using a fuel
with percentages of ethanol or methanol greater than shown above
are not covered under warranty.
Use of fuels with content of ethanol or methanol greater than shown
above may cause starting and/or performance problems. It may also
damage metal, rubber, and plastic parts of the fuel system.
You may use regular unleaded gasoline containing no more than 10%
ethanol (E10) or 5% methanol by volume. In addition, methanol must
contain cosolvents and corrosion inhibitors.
Never use stale or contaminated gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
This engine is certified to operate on regular unleaded gasoline with a
pump octane rating of 86 or higher.
After refueling, reinstall the fuel tank cap securely.
Fuel can damage paint and plastic. Be careful not to spill fuel when
filling your fuel tank. Damage caused by spilled fuel is not covered
under warranty.
09/02/10 12:48:07 31Z21600_033
33
STARTING THE ENGINE/STOPPING THE ENGINE
Starting the Engine
Exhaust contains poisonous carbon monoxide gas that can build up
to dangerous levels in closed areas.
Breathing carbon monoxide can cause unconsciousness or death.
Never run the generator in a closed, or even partly closed area where
people may be present.
For your safety, do not operate the generator in an enclosed area such
as a garage. Your generator’s exhaust contains poisonous carbon
monoxide gas that can collect rapidly in an enclosed area and cause
illness or death.
To prevent a possible fire, keep the generator at least 3 feet (1 meter)
away from building walls and other equipment during operation. Do
not place flammable objects close to the engine.
Operating this generator less than 3 feet (1 meter) from a building or
other obstruction can cause overheating and damage the generator.
For proper cooling, allow at least 3 feet (1 meter) of empty space
above and around the generator.
Refer to the
AC OPERATION
(see page ) or
DC OPERATION
(see
page ) for connecting loads to the generator.
Perform the
PRE-OPERATION CHECK
(see page ).
Make sure that the AC circuit breaker is in the OFF position. The
generator may be hard to start if a load is connected.
Turn the fuel valve lever to the ON position.
The automatic choke will be closed if the engine is cold. If you want
to operate the choke manually, pull the choke rod out to the CLOSED
position.
Make sure the Auto Throttle switch is in the OFF position, or more
time will be required for warm up.
Turn the engine switch to the ON position.
Pull the starter grip lightly until resistance is felt, then pull briskly.
Do not allow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter.
1.
2.
3.
4.
5.
6.
7.
19
26
30
09/02/10 12:48:20 31Z21600_034
34
Stopping the Engine
In normal use:
In an emergency:
Turn the fuel valve lever to the OFF position.
Turn the engine switch to the OFF position.
Disconnect DC battery charging cables.
Turn the AC circuit breaker to the OFF position.
To stop the engine in an emergency, move the engine switch to the
OFF position.
If you wish to use the Auto Throttle system, turn the Auto Throttle
switch to the AUTO position after the engine has warmed up for 2 or
3 minutes.
If you have manually closed the choke, push it to the OPEN position
as the engine warms up.
When the engine starts, allow the engine switch to return to the ON
position.
With electric starter:
Connect the battery cables to the generator. (page )
Turn the engine switch to the START position and hold it there for
5 seconds or until the engine starts.
Operating the starter motor for more than 5 seconds can damage
the motor. If the engine fails to start, release the switch and wait
10 seconds before operating the starter again.
If the speed of the starter motor drops after a period of time, it is an
indication that the battery should be recharged.
1.
2.
3.
8.
9.
1.
2.
68
09/02/10 12:48:34 31Z21600_035
35
MAINTENANCE
Maintenance, replacement, or repair of the emission control devices
and systems may be performed by any engine repair establishment or
individual, using parts that are ‘‘certified’’ to EPA standards.
The Importance of Maintenance
Improper maintenance, or failure to correct a problem before
operation, can cause a malfunction in which you can be seriously hurt
or killed.
Always follow the inspection and maintenance recommendations and
schedules in this owner’s manual.
Good maintenance is essential for safe, economical, and trouble free
operation. It will also help reduce air pollution.
To help you properly care for your generator, the following pages
include a maintenance schedule, routine inspection procedures, and
simple maintenance procedures using basic hand tools. Other service
tasks that are more difficult or require special tools are best handled
by professionals and are normally performed by a Honda technician or
other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If
you operate your generator under severe conditions, such as
sustained high-load or high-temperature operation, or use it in
unusually wet or dusty conditions, consult your servicing dealer for
recommendations applicable to your individual needs and use.
09/02/10 12:48:40 31Z21600_036
36
Safety Precautions
Maintenance Safety
Failure to properly follow maintenance instructions and precautions
can cause you to be seriously hurt or killed.
Always follow the procedures and precautions in the owner’s manual.
Carbon monoxide poisoning from engine exhaust.
Burns from hot parts.
Injury from moving parts.
Some of the most important safety precautions follow. However, we
cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.
Make sure the engine is off before you begin any maintenance or
repairs. This will eliminate several potential hazards:
Operate outside away from open windows or doors.
Let the engine and exhaust system cool before touching.
Do not run the engine unless instructed to do so.
Read the instructions before you begin, and make sure you have the
tools and skills required.
To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a non-flammable solvent, not
gasoline, to clean parts. Keep cigarettes, sparks, and flames away
from all fuel-related parts.
Remember that your servicing dealer knows your generator best and
is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new, Honda
Genuine parts or their equivalents for repair or replacement.
09/02/10 12:48:52 31Z21600_037
37
Maintenance Schedule
Performed at every indicated
month or operating hour interval,
whichever comes first.
ITEM
First
month
or
20 Hrs.
Every
3 months
or
50 Hrs.
(1)
Each
use
Engine oil
Air cleaner
Canister
(California type)
Purge tube
(California type)
Charge tube
(California type)
Sediment cup
Spark plug
Spark arrester
Idle speed
Valve clearance
Combustion
chamber
Fuel tank and filter
Fuel tube
Failure to follow this maintenance schedule could result in non-warrantable failures.
For commercial use, log hours of operation to determine proper maintenance intervals.
These items should be serviced by an authorized Honda generator dealer, unless the owner
has the proper tools and is mechanically proficient. See the Honda Shop Manual.
Service more frequently when used in dusty areas.
Every
6 months
or
100 Hrs.
(2)
Every 2 years (Replace if necessary)(2)
After every 500 Hrs.(2)
Check level
Change
Check
Clean
Check
Check
Check
Clean
Check-adujst
Replace
Clean
Check-adujst
Check-adujst
Clean
Clean
Check
Every
year
or
300 Hrs.
(2)
(2)
(1)
(2)
(3)
Every 2 years (2)
Every 2 years (2)
Every 2 years (2)
REGULAR SERVICE PERIOD (3)
09/02/10 12:49:06 31Z21600_038
38
Engine Oil Change
UPPER LEVEL
SEALING WASHER
OIL FILLER CAP/DIPSTICK
OIL DRAIN PLUG
Drain the oil while the engine is warm to assure rapid and complete
draining.
Wash your hands with soap and water after handling used oil.
Improper disposal of engine oil can be harmful to the environment. If
you change your own oil, please dispose of it properly. Put it in a
sealed container, and take it to a recycling center. Do not discard it in a
trash bin, dump it on the ground, or pour it down a drain.
Place a suitable container below the engine to catch the oil, then
remove the oil drain plug and sealing washer, remove the oil filler
cap/dipstick, and drain the oil.
Refill with the recommended oil (see page ) and check the oil level.
Reinstall the oil drain plug and a new sealing washer. Tighten the
plug securely.
1.
2.
3. 30
09/02/10 12:49:15 31Z21600_039
39
Air Cleaner Service
AIR CLEANER COVER
ELEMENT
ELEMENT
• properly
hooked
• improperly
hooked
CLIP (2)
CLIP (2)
AIR CLEANER COVER
ELEMENT
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service more
frequently when operating the generator in extremely dusty areas.
Wash the air cleaner element in a solution of household detergent
and warm water, then rinse thoroughly, or wash in nonflammable or
high flashpoint solvent. Allow the air cleaner element to dry
thoroughly.
Soak the air cleaner element in clean engine oil and squeeze out the
excess oil. The engine will smoke during initial startup if too much
oil is left in the air cleaner element.
Reinstall the air cleaner element and the cover.
Operating the engine without an air filter or with a damaged air filter
will allow dirt to enter the engine, causing rapid engine wear. This type
of damage is not covered by the
Distributor’s Limited Warranty.
Unsnap the two air cleaner cover clips, remove the air cleaner cover,
and remove the element.
1.
2.
3.
4.
09/02/10 12:49:28 31Z21600_040
40
Fuel Sediment Cup Cleaning
SEDIMENT CUP
FUEL FILTER
FUEL VALVE LEVER
O-RING
(Replace)
OOFFFF
The sediment cup prevents dirt or water that may be in the fuel tank
from entering the carburetor. If the engine has not been run for a long
time, the sediment cup should be cleaned.
Turn the fuel valve lever to the OFF position. Remove the sediment
cup, O-ring, and filter.
Turn the fuel valve lever ON and check for leaks.
Clean the sediment cup and filter in nonflammable or high flash
point solvent.
Reinstall the filter, new O-ring, and sediment cup.
1.
2.
3.
4.
09/02/10 12:49:36 31Z21600_041
41
Recommended spark plugs:
Spark Plug Service
SPARK PLUG WRENCH
SPARK PLUG CAP
SEALING WASHER
0.028 0.031 in
(0.7 0.8 mm)
In order to service the spark plug, you will need a spark plug wrench
(commercially available).
BPR5ES (NGK) W16EPR-U (DENSO)
Visually inspect the spark plug.
Discard it if the insulator is
cracked, chipped, or fouled.
Measure the spark plug electrode
gap with a wire-type feeler gauge.
Correct the gap, if necessary, by
carefullybendingtheside
electrode.
The gap should be:
0.028 0.031 in (0.7 0.8 mm)
To ensure proper engine operation, the spark plug must be properly
gapped and free of deposits.
An incorrect spark plug can cause engine damage.
If the engine has been running, let it to cool before servicing the spark
plug.
Remove the spark plug cap.
Clean any dirt from around the spark plug base.
Use a spark plug wrench to remove the spark plug.
1.
2.
3.
4.
5.
,
09/02/10 12:49:49 31Z21600_042
42
Spark Arrester Maintenance
SPARK ARRESTER
SPARK ARRESTER SCREEN
SCREW
Afterthesparkplugisseated,tightenwithasparkplugwrenchto
compress the washer.
If installing a new spark plug, tighten 1/2 turn after the spark plug
seats to compress the washer. If reinstalling a used spark plug,
tighten 1/8 1/4 turn after the spark plug seats to compress the
washer.
A loose spark plug can overheat and damage the engine.
Overtightening the spark plug can damage the threads in the
cylinder head.
If the generator has been running, the muffler will be very hot. Allow it
to cool before proceeding.
The spark arrester must be serviced every 100 hours to keep it
functioning as designed.
Clean the spark arrester as follows:
Loosen the screw by the exhaust port of the muffler and remove the
spark arrester.
Use a brush to remove carbon deposits from the spark arrester
screen.
Inspect the screen for breaks or tears and replace it if necessary.
Install the spark arrester in the reverse order of removal.
Check that the spark plug sealing washer is in good condition, and
thread the spark plug in by hand to prevent cross-threading.
6.
7.
1.
2.
3.
09/02/10 12:50:02 31Z21600_043
43
Fuse Replacement
FUSE HOLDER
If the fuse is blown, the starter motor won’t operate.
Turn the engine switch to the OFF position.
Remove the fuse holder cover and replace the fuse.
The specified fuse is 10A.
If frequent fuse failure occurs, determine the cause and correct the
problem before attempting to operate the generator further.
Never use a fuse with a different rating from that specified. Serious
damage to the electrical system or fire may result.
1.
2.
09/02/10 12:50:11 31Z21600_044
44
STORAGE
Cleaning
Fuel
Storage Preparation
Proper storage preparation is essential for keeping your generator
trouble-free and looking good. The following steps will help to keep
rust and corrosion from impairing your generator’s function and
appearance, and will make the engine easier to start when you use the
generator again.
Wipe the generator with a moist cloth. After the generator has dried,
touch up any damaged paint, and coat other areas that may rust with a
light film of oil.
Depending on the region where you operate your equipment, fuel
formulations may deteriorate and oxidize rapidly. Fuel deterioration
and oxidation can occur in as little as 30 days and may cause damage
to the carburetor and/or fuel system. Please check with your servicing
dealer for local storage recommendations.
Gasoline will oxidize and deteriorate in storage. Old gasoline will
cause hard starting, and it leaves gum deposits that clog the fuel
system. If the gasoline in your generator deteriorates during storage,
you may need to have the carburetor and other fuel system
components serviced or replaced.
The length of time that gasoline can be left in your fuel tank and
carburetor without causing functional problems will vary with such
factors as gasoline blend, your storage temperatures, and whether the
fuel tank is partially or completely filled. The air in a partially filled fuel
tank promotes fuel deterioration. Very warm storage temperatures
accelerate fuel deterioration. Fuel deterioration problems may occur
within a few months, or even less if the gasoline was not fresh when
you filled the fuel tank.
The does not cover fuel system damage or
engine performance problems resulting from neglected storage
preparation.
You can extend fuel storage life by adding a gasoline stabilizer that is
formulated for that purpose, or you can avoid fuel deterioration
problems by draining the carburetor, sediment cup (if applicable) and/
or fuel tank.
Distributor’s Limited Warranty
09/02/10 12:50:21 31Z21600_045
45
STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO
PREVENT HARD STARTING
Service according to the table below:
Less than 1 month
1 to 2 months
2 months to 1 year
1 year or more
No preparation required
Fill with fresh gasoline and add gasoline
stabilizer *.
Fill with fresh gasoline and add gasoline
stabilizer *.
Drain the carburetor float bowl (page 46 ).
Drain the fuel sediment cup (page 40 ).
Fill with fresh gasoline and add gasoline
stabilizer *.
Drain the carburetor float bowl (page 46 ).
Drain the fuel sediment cup (page 40 ).
Remove the spark plug. Put a teaspoon of
engine oil into the cylinder. Turn the engine
slowly with the recoil starter to distribute the
oil. Reinstall the spark plug.
Change the engine oil (page 38 ).
After removal from storage, drain the stored
gasoline into a suitable container, and fill
with fresh gasoline before starting.
Use gasoline stabilizers that are formulated to extend storage
life.
Follow the manufacturer’s instructions for use.
Contact your authorized Honda generator dealer for stabilizer
recommendations.
*
09/02/10 12:50:26 31Z21600_046
46
Draining the Fuel Tank and Carburetor
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
Stop the engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
DRAIN SCREW
Drain the carburetor by loosening the drain screw. Drain the
gasoline into a suitable container.
Place a suitable gasoline container below the sediment cup, and use
a funnel to avoid spilling gasoline.
Remove the sediment cup (see page ), and then turn the fuel
valve lever to the ON position.
Allow the gasoline to drain completely, and then install the sediment
cup (see page ).
1.
2.
3.
4.
40
40
09/02/10 12:50:34 31Z21600_047
47
Engine Oil
STARTER GRIP
Align the notch on the starter pulley
with the hole at the top of recoil starter.
Slowly pull the starter grip until resistance is felt. At this point, the
piston is coming up on its compression stroke and both the intake
and exhaust valves are closed. Storing the engine in this position
will help to protect it from internal corrosion. Return the starter grip
gently.
Reinstall the spark plug.
Pull the starter grip several times to distribute the oil in the cylinder.
Pour a teaspoon (5 10 cc) of clean engine oil into the cylinder.
Remove the spark plug (see page ).
Change the engine oil (see page ).1.
2.
3.
4.
5.
6.
38
41
09/02/10 12:50:42 31Z21600_048
48
Storage Precautions
Removal From Storage
If your generator will be stored with gasoline in the fuel tank and
carburetor, it is important to reduce the hazard of gasoline vapor
ignition.
Do not use sheet plastic as a dust cover. A nonporous cover will trap
moisture around the generator, promoting rust and corrosion.
With the engine and exhaust system cool, cover the generator to keep
out dust. A hot engine and exhaust system can ignite or melt some
materials.
Place the generator on a level surface. Tilting can cause fuel or oil
leakage.
Unless all fuel has been drained from the fuel tank, leave the fuel valve
in the OFF position to reduce the possibility of leakage.
If possible, avoid storage areas with high humidity, because that
promotes rust and corrosion.
Also avoid any area with a spark-producing electric motor, or where
power tools are operated.
Select a well ventilated storage area away from any appliance that
operates with a flame, such as a furnace, water heater, or clothes dryer.
If the fuel was drained during storage preparation, fill the tank with
fresh gasoline. If you keep a container of gasoline for refueling, be
sure that it contains only fresh gasoline. Gasoline oxidizes and
deteriorates over time, causing hard starting.
If the cylinder was coated with oil during storage preparation, the
engine may smoke briefly at startup. This is normal.
Check your generator as described in the
PRE-OPERATION CHECK
chapter of this manual (see page ).30
09/02/10 12:50:54 31Z21600_049
49
TRANSPORTING
Contact with a hot engine or exhaust system can cause serious burns
or fires. Let the engine cool before transporting or storing the
generator.
When transporting the generator, turn the engine switch and the fuel
valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor
or spilled fuel may ignite.
Take care not to drop or strike the generator when transporting. Do not
place heavy objects on the generator.
When transporting the generator by loading it on to a vehicle, secure
to the generator frame as shown.
09/02/25 16:51:05 31Z21600_050
50
TROUBLESHOOTING
When the engine will not start:
Is there fuel in the
tank?
Is there enough oil
in the engine?
Is the spark plug in
good condition?
Is the fuel reaching
the carburetor?
If the engine still
does not start, take
the generator to an
authorized Honda
generator dealer.
Clean the fuel
sediment cup
(page 40).
Turn off the engine switch and loosen
the drain screw (page 46).
Turn the fuel valve to ON. Fuel should
flow from the drain when the fuel valve
is turned ON.
Refill the fuel tank
(page 31).
Add the recom-
mended oil (page
30).
Readjust gap and
dry the spark plug.
Replace it if
necessary (page
41).
To check:
YES
YES
YES
NO
NO
NO
YES
NO
1)
2)
09/02/10 12:51:08 31Z21600_051
51
Is the AC circuit breaker
ON.
Check the electrical ap-
pliance or equipment for
any defects.
No electricity at the AC receptacles:
Turn the AC circuit breaker
ON (page 15).
Take the generator to an
authorized Honda generator
dealer.
Replace the electrical ap-
pliance or equipment.
Take the electrical ap-
pliance or equipment to an
electrical shop for repair.
YES
DEFECTS
NO DEFECTS
NO
09/02/10 12:51:13 31Z21600_052
52
TECHNICAL INFORMATION
Emission Control System Information
Source of Emissions
The U.S. and California Clean Air Acts
Tampering and Altering
Honda utilizes appropriate air/fuel ratios and other emissions control
systems to reduce the emissions of carbon monoxide, oxides of
nitrogen, and hydrocarbons.
The combustion process produces carbon monoxide, oxides of
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of
nitrogen are very important because, under certain conditions, they
react to form photochemical smog when subjected to sunlight. Carbon
monoxide does not react in the same way, but it is toxic.
Additionally, Honda fuel systems utilize components and control
technologies to reduce evaporative emissions.
EPA and California regulations require all manufacturers to furnish
written instructions describing the operation and maintenance of
emission control systems.
The following instructions and procedures must be followed in order
to keep the emissions from your Honda engine within the emission
standards.
Tampering with or altering the emission control system may increase
emissions beyond the legal limit. Among those acts that constitute
tampering are:
Removal or alteration of any part of the intake, fuel, or exhaust
systems.
Altering or defeating the governor linkage or speed-adjusting
mechanism to cause the engine to operate outside its design
parameters.
09/02/10 12:51:23 31Z21600_053
53
Problems That May Affect Emissions
Replacement Parts
Maintenance
If you are aware of any of the following symptoms, have your engine
inspected and repaired by your servicing dealer.
Hard starting or stalling after starting.
Rough idle.
Misfiring or backfiring under load.
Afterburning (backfiring).
Black exhaust smoke or high fuel consumption.
Follow the
Maintenance Schedule
on page . Remember that this
schedule is based on the assumption that your machine will be used
for its designed purpose. Sustained high-load or high-temperature
operation, or use in unusually wet or dusty conditions, will require
more frequent service.
The emission control systems on your Honda engine were designed,
built, and certified to conform with applicable emission regulations.
We recommend the use of Honda Genuine parts whenever you have
maintenance done. These original-design replacement parts are
manufactured to the same standards as the original parts, so you can
be confident of their performance. The use of replacement parts that
are not of the original design and quality may impair the effectiveness
of your emission control system.
A manufacturer of an aftermarket part assumes the responsibility that
the part will not adversely affect emission performance. The
manufacturer or rebuilder of the part must certify that use of the part
will not result in a failure of the engine to comply with emission
regulations.
37
09/02/10 12:51:30 31Z21600_054
54
Air Index
(Models certified for sale in California)
The bar graph is intended to provide you, our customer, the ability to
compare the emissions performance of available engines. The lower
the Air Index, the less pollution.
The durability description is intended to provide you with information
relating to the engine’s emission durability period. The descriptive
term indicates the useful life period for the engine’s emission control
system. See your
Emission Control System Warranty
for additional
information.
Descriptive Term
Moderate
Intermediate
Extended
Applicable to Emission Durability Period
50 hours (0 80 cc, inclusive)
125 hours (greater than 80 cc)
125 hours (0 80 cc, inclusive)
250 hours (greater than 80 cc)
300 hours (0 80 cc, inclusive)
500 hours (greater than 80 cc)
1,000 hours (225 cc and greater)
An Air Index Information label is applied to engines certified to an
emission durability time period in accordance with the requirements
of the California Air Resources Board.
09/02/10 12:51:42 31Z21600_055
55
WIRING DIAGRAM
EM3800SX
09/02/10 12:52:05 31Z21600_056
56
EM5000SX, EM6500SX
09/02/10 12:52:28 31Z21600_057
57
SPECIFICATIONS
Dimensions
Engine
Generator
ITEM MAINTENANCESPECIFICATION
Tuneup Specifications
193.1 lbs (87.6 kg)
28.4 in (721 mm)
27.2 in (691 mm)
40.9 in (1,040 mm)
EAMC
192.0 lbs (87.1 kg)
Non-California type
(AN type)
California type
(AC type)
Model
Type
Description code
Length
Width
Height
Dry mass [weight]
Model
Type
Engine type
Displacement
[Bore Stroke]
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
Model
Rated voltage
AC Rated frequency
output Rated current
Rated output
Maximum output
DC output
Spark plug gap
Valve clearance
Other specifications No other adjustments needed.
IN: 0.15 0.02 mm (cold)
EX: 0.20 0.02 mm (cold)
Refer to page 41
See your authorized
Honda dealer.
0.028 0.031 in (0.7 0.8 mm)
Only for charging 12V automotive batteries.
Maximum charging output 8.3A
3.8 kVA
3.3 kVA
27.5/13.8 A
60 Hz
120/240 V
BPR5ES (NGK) W16EPR-U (DENSO)
Transistorized magneto
Forced air cooling
3,600 rpm
8.2 : 1
2.9 2.3 in (73.0 58.0 mm)
14.8 cu-in (242 cm
)
California type
(AC type)
Non-California type
(AN type)
GX240
1.2 US qt (1.1 L)
6.21 US gal (23.5 L)
,
EM3800SX
EM3800SX
[]
Specifications may vary according to the types, and are subject to
change without notice.
4-stroke, overhead valve, single cylinder
09/02/10 12:52:44 31Z21600_058
58
Dimensions
Engine
Generator
ITEM MAINTENANCESPECIFICATION
Tuneup Specifications
Model
Type
Description code
Length
Width
Height
Dry mass [weight]
Model
Type
Engine type
Displacement
[Bore Stroke]
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
Model
Rated voltage
AC Rated frequency
output Rated current
Rated output
Maximum output
DC output
California type
(AC, ACH type)
Non-California type
(AN, ANH type)
222.9 lbs (101.1 kg)
28.4 in (721 mm)
27.2 in (691 mm)
41.3 in (1,049 mm)
EANC
221.8 lbs (100.6 kg)
Spark plug gap
Valve clearance
Other specifications No other adjustments needed.
IN: 0.15 0.02 mm (cold)
EX: 0.20 0.02 mm (cold)
Refer to page 41
See your authorized
Honda dealer.
0.028 0.031 in (0.7 0.8 mm)
Only for charging 12V automotive batteries.
Maximum charging output 8.3A
5.0 kVA
4.5 kVA
37.5/18.8 A
60 Hz
120/240 V
BPR5ES (NGK) W16EPR-U (DENSO)
Transistorized magneto
Forced air cooling
3,600 rpm
8.0 : 1
3.2 2.5 in (82.0 64.0 mm)
20.6 cu-in (337 cm
)
California type
(AC, ACH type)
Non-California type
(AN, ANH type)
GX340
1.2 US qt (1.1 L)
6.21 US gal (23.5 L)
,
EM5000SX
EM5000SX
[]
Specifications may vary according to the types, and are subject to
change without notice.
4-stroke, overhead valve, single cylinder
09/02/10 12:53:01 31Z21600_059
59
Tuneup Specifications
ITEM MAINTENANCESPECIFICATION
Dimensions
Engine
Generator
Specifications may vary according to the types, and are subject to
change without notice.
228.4 lbs (103.6 kg)
28.4 in (721 mm)
27.2 in (691 mm)
41.9 in (1,064 mm)
EAPC
California type
(AC, ACH type)
Non-California type
(AN, ANH type)
227.3 lbs (103.1 kg)
Spark plug gap
Valve clearance
Other specifications No other adjustments needed.
IN: 0.15 0.02 mm (cold)
EX: 0.20 0.02 mm (cold)
Refer to page 41
See your authorized
Honda dealer.
0.028 0.031 in (0.7 0.8 mm)
Model
Type
Description code
Length
Width
Height
Dry mass [weight]
Model
Type
Engine type
Displacement
[Bore Stroke]
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
Model
Rated voltage
AC Rated frequency
output Rated current
Rated output
Maximum output
DC output
Only for charging 12V automotive batteries.
Maximum charging output 8.3A
6.5 kVA
5.5 kVA
45.8/22.9 A
60 Hz
120/240 V
BPR5ES (NGK) W16EPR-U (DENSO)
Transistorized magneto
Forced air cooling
3,600 rpm
8.0 : 1
3.5 2.5 in (88.0 64.0 mm)
23.7 cu-in (389 cm
)
GX390
California type
(AC, ACH type)
Non-California type
(AN, ANH type)
1.2 US qt (1.1 L)
6.21 US gal (23.5 L)
,
EM6500SX
EM6500SX
[]
4-stroke, overhead valve, single cylinder
09/02/10 12:53:19 31Z21600_060
60
ASSEMBLY
The Importance of Proper Assembly
Improper assembly can cause an unsafe condition that can lead to
serious injury or death.
Follow the procedures and precautions in the assembly instructions
carefully.
Failure to properly follow instructions and precautions can cause you
to be seriously hurt or killed.
Follow the procedures and precautions in this manual carefully.
Proper assembly is essential to operator safety and the reliability of
the machine. Any error or oversight made by the person assembling
and servicing a unit can easily result in faulty operation, damage to the
machine, or injury to the operator.
Some of the most important safety precautions are given below.
However, we cannot warn you of every conceivable hazard that can
arise in performing this assembly. Only you can decide whether or not
you should perform a given task.
09/02/10 12:53:25 31Z21600_061
61
Important Safety Precautions
Carbon monoxide poisoning from engine exhaust.
Burns from hot parts.
Injury from moving parts.
Make sure you have a clear understanding of all basic shop safety
practices and that you are wearing appropriate clothing and safety
equipment. When performing this assembly, be especially careful of
the following:
Make sure the engine is off before you begin any maintenance or
repairs. This will help eliminate several potential hazards:
Read the instructions before you begin, and be sure you have
the tools and skills required to perform the tasks safely.
Operate outside away from open windows or doors.
Let the engine and exhaust system cool before touching.
Do not run the engine unless the instruction tells you to do so.
Even then, keep your hands, fingers, and clothing away. Do not
run the engine when any protective guard or shield is removed.
To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries. Use only a non-flammable
solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and
flames away from all fuel-related parts.
09/02/10 12:53:33 31Z21600_062
62
Loose Parts (Wheel kit and handle)
Unpacking
Remove the generator and loose parts box from the carton.
Compare the loose parts with the inventory list below.
Tools Required:
Check all loose parts against the following list. Contact your dealer if
any of the loose parts shown below are not included with your
generator.
1.
2.
12 mm wrench (2), pliers
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
Qty.
2
1
1
1
1
1
2
12
2
2
4
Description
Wheel
Axle
Left upper handle assy
Right upper handle assy
Left handle bracket
Right handle bracket
Stand
8 16 mm Flange bolt
20 mm Washer
4.0 28 mm Cotter pin
8 mm Flange nut
09/02/25 16:51:14 31Z21600_063
63
Handle Installation
TORQUE:
RIGHT HANDLE
BRACKET
LEFT HANDLE BRACKET
8 16 mm FLANGE BOLT (4)
LEFT UPPER HANDLE ASSY
RIGHT UPPER HANDLE ASSY
Install the right and left handles on the generator upper frame using
the handle brackets and four flange bolts.
17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)
09/02/10 12:53:50 31Z21600_064
64
Wheel Kit Installation
TORQUE:
WHEEL (2)
8 16 mm FLANGE BOLT (4)
GENERATOR
SIDE
8 16 mm FLANGE BOLT (4)
4.0 30 mm COTTER PIN (2)
STAND (2)
20 mm WASHER (2)
LONGER
8 mm FLANGE NUT (4)
AXLE
Install the axle assembly on the generator using four 8 16 mm
flange bolts and 8 mm flange nuts.
Install the two stands on the under frame using four 8 16 mm
flange bolts.
17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)
Apply grease to the axle shaft as shown below, and install the two
wheels on the axle shaft using the washers and split pins.
1.
2.
3.
09/02/25 16:51:21 31Z21600_065
65
Hanger Kit Installation (optional)
TORQUE:
HANGER
HANGER
GENERATOR
SIDE
HANGER BRACKET (2)
8 16 mm FLANGE BOLT (4)
280 mm (11 in)
Position the hanger at the generator’s balance point as shown below.
Fit the end tabs of the hanger through the bracket slots, and bolt the
brackets to the hanger and tighten securely.
17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)
1.
2.
09/02/10 12:54:04 31Z21600_066
66
Remote Control Kit (optional)
REMOTE CONTROL
CABLE
REMOTE CONTROL
CABLE
CABLE TIES
REMOTE CONTROL
BOX
Remove the blind 6-P connector from the back of the control panel.
Connect the remote control cable to the back of the control panel
and remote control box.
Connect the blind connector when not using the remote control.
Engine will not start unless the blind connector is connected.
Install the two cable ties as shown.
1.
2.
3.
09/02/25 16:51:26 31Z21600_067
67
Remote Control Box
PILOT LAMP
START BUTTON STOP BUTTON
Starting the engine with remote control
Turn the fuel valve on the generator to the ON position.
Turn the Auto Throttle switch on the generator to the OFF position.
Turn the engine switch on the generator to the ON position.
Press the start button until engine starts and the pilot lamp comes
on.
Stopping the engine with remote control
Press the stop button.
Turn the engine switch on the generator to the OFF position.
Turn the fuel valve lever on the generator to the OFF position.
1.
2.
3.
4.
1.
2.
3.
09/02/10 12:54:21 31Z21600_068
68
Battery posts, terminals, and related accessories contain lead and
lead compounds. Wash hands after handling.
Battery Tray Kit (optional)
Follow the instructions that come with the battery tray kit and install
the kit on the generator frame.
Route the starter cable under the tank and connect it to the starter
solenoid.
Connect the ground cable to the generator rear housing.
Set the battery on the battery tray and secure with the battery
bracket.
Connect the starter cable to the battery positive ( ) terminal first,
then to the negative ( ) terminal. When disconnecting, disconnect
at the battery negative ( ) terminal first.
Install the battery guard plate on the battery guards.
1.
2.
3.
4.
5.
09/02/10 12:54:29 31Z21600_069
69
BATTERY
TRAY
BATTERY
GUARD PLATE
STARTER CABLE
(positive)
BATTERY
BRACKET
BATTERY
GUARD
STARTER SOLENOID
GROUND
CABLE
BATTERY
GUARD
BATTERY
Use a battery rated at
51R
STARTER
CABLE
CABLE
TIE
CABLE TIE
GROUND
CABLE
09/02/25 16:51:45 31Z21600_070
70
Engine Oil
WITHOUT OIL
Fuel
OIL FILLER HOLE
OIL FILLER CAP/DIPSTICK
UPPER LEVEL
AMBIENT TEMPERATURE
The generator is shipped
in the engine.
Place the generator on a level
surface. Add enough of the
recommended oil to bring the
oil level to the top of the oil
filler neck.
Refer to page .
Use a 4-stroke motor oil that
meets the requirements for
API service category SJ or
later (or equivalent).
SAE 10W-30 is recommended
for general, all-temperature
use. Other viscosities in the
chart may be used when the
temperature in your area is
within the indicated range.
Do not overfill the engine
with oil. If the engine is
overfilled, the excess oil may
get transferred to the air
cleaner housing and air filter.
31
09/02/10 12:54:51 31Z21600_071
71
BEFORE OPERATION
CONTROLS
GENERATOR USE
STARTING THE ENGINE
STOPPING THE ENGINE
GENERATOR SAFETY
Before using your generator, you should become familiar with
information contained in the following chapters and sections:
(page )
(page )
(page )
(page )
(page )
10
17
5
33
33
09/02/10 12:54:58 31Z21600_072
72
WARRANTY SERVICE INFORMATION
DEALER LOCATOR INFORMATION
CUSTOMER SERVICE INFORMATION
To find an authorized Honda Servicing Dealer anywhere in the United
States:
visit our web site:
www.hondapowerequipment.com
Servicing dealership personnel are trained professionals. They should
be able to answer most questions you may have. If you encounter a
problem that your dealer does not solve to your satisfaction, please
discuss it with the dealership’s management. The Service Manager or
General Manager can help. Almost all problems are solved in this way.
If you are dissatisfied with the decision made by the dealership’s
management, contact the Honda Power Equipment Customer
Relations Office. You can write to:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, Georgia 30005-8847
Or telephone: (770) 497-6400 8:30 am to 7:00 pm ET
When you write or call, please give us this information:
Model and serial number (see pages and )
Name of dealer who sold the generator to you
Name and address of dealer who services your generator
Date of purchase
Your name, address, and telephone number
A detailed description of the problem
98
09/02/10 12:55:08 31Z21600_073
73
Shop Manual
Parts Catalog
Accessories Catalog
Honda PUBLICATIONS
This manual covers complete maintenance and overhaul procedures.
It is intended to be used by a skilled technician.
Available through your Honda dealer or through Helm Inc. at 1 888-
292-5395 or visit www.hondapowerequipment.com
This manual provides complete, illustrated parts lists. Available
through your Honda dealer.
Your authorized Honda power equipment dealer offers a wide
selection of accessories (optional equipment) to make your generator
even more useful.
Visit www.hondapowerequipment.com
09/02/10 12:55:15 31Z21600_074
74
INDEX
..............................................................................................ASSEMBLY . 60
..............................................................COMPONENT IDENTIFICATION . 8
................................................................................................CONTENTS . 3
..............................................................................................CONTROLS . 10
.............................................................................AC Circuit Breaker . 15
..........................................................................AC Circuit Protector . 16
......................................................................Auto Throttle
System . 14
..........................................................................................Choke Rod . 11
..........................................................................DC Circuit Protector . 13
.....................................................................................DC Terminals . 13
....................................................................................Engine Switch . 10
................................................................................Fuel Valve Lever . 11
...............................................................................Ground Terminal . 12
..............................................................................Oil Alert
System . 14
........................................................................................Starter Grip . 10
............................Voltage Selector Switch (Dual Voltage System) . 12
..............................................................................GENERATOR SAFETY . 5
............................................................Important Safety Information . 6
.......................................................................Safety Label Locations . 5
...................................................................................GENERATOR USE . 17
.................................................................................AC Applications . 18
.....................................................................................AC Operation . 19
...................................................................AC Receptacle Selection . 20
......................................................................Auto Throttle
System . 28
...............................Connections to a Building’s Electrical System . 17
.....................................................................................DC Operation . 26
.................................................................................Ground System . 17
....................................................................High Altitude Operation . 29
.......................................................................Special Requirements . 17
......................................................................................MAINTENANCE . 35
...........................................................................Air Cleaner Service . 39
............................................................................Engine Oil Change . 38
...........................................................Fuel Sediment Cup Cleaning . 40
.............................................................................Fuse Replacement . 43
..........................................................................Maintenance Safety . 36
.....................................................................Maintenance Schedule . 37
............................................................Spark Arrester Maintenance . 42
............................................................................Spark Plug Service . 41
......................................................The Importance of Maintenance . 35
09/02/10 12:55:20 31Z21600_075
75
.......................................................................PRE-OPERATION CHECK . 30
..........................................................................................Engine Oil . 30
....................................................................Fuel Recommendations . 32
............................................................................................Refueling . 31
....................................................................................SPECIFICATIONS . 57
..............................STARTING THE ENGINE/STOPPING THE ENGINE . 33
................................................................................................STORAGE . 44
.........................................................................Storage Precautions . 48
..........................................................................Storage Preparation . 44
....................................................................Removal From Storage . 48
..................................................................TECHNICAL INFORMATION . 52
.............................................................................................Air Index . 54
............................................Emission Control System Information . 52
.....................................................................................TRANSPORTING . 49
.............................................................................TROUBLESHOOTING . 50
.................................................WARRANTY SERVICE INFORMATION . 72
............................................CUSTOMER SERVICE INFORMATION . 72
.................................................DEALER LOCATOR INFORMATION . 72
.....................................................................Honda PUBLICATIONS . 73
.................................................................................WIRING DIAGRAM . 55
09/02/10 12:55:24 31Z21600_076
76
MEMO
09/02/10 12:55:26 31Z21600_077
EM3800SX•EM5000SX•EM6500SX
K2:EM5000SX
See page 57 for instructions
on assembling your generator.
00X31-Z21-6050
… 46 …

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