Spec
HONDA
POWER PRODUCTS
GENERATOR
OWNER'S MANUAL
Honda EX7
OWNER'S MANUAL
The e-SPEC" "mark symbolizes environmentally
responsible technologies applied to Honda power
equipment, which contains our wish to “preserve
nature for generations to come.”
ECOLOGY CONSCIOUS TECHNOLOGY
Thank you for purchasing a Honda generator.
This manual covers operation and maintenance of the EX7 generator.
All information in this publication is based on the latest product
information available at the time of approval for printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time
without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
This manual should be considered a permanent part of the generator
and should remain with it if it is resold.
Pay special attention to statements preceded by the following words:
Indicates a strong possibility of severe personal injury or
death if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment
damage if instructions are not followed.
NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about the
generator, consult an authorized Honda dealer.
AWARNING
Honda generator is designed to give safe and dependable service if
operated according to instructions. Read and understand the Owner's
Manual before operating the generator. Failure to do so could result
in personal injury or equipment damage.
* The illustration may vary according to the type.
CONTENTS
Na
apo
—
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11.
12.
13.
SAFETY INSTRUCTIONS cco rrr esses enteraron. 3
SAFETY LABEL LOCATIONS .....….…..……rsrrcsrresannare nas enracanrenne nana nana nana une 5
CE mark and noise label lOCAtlONS..…..................….….….csarsrenerensesseennen re 6
COMPONENT IDENTIFICATION .....….…….……ssorcrrrcsaren are rss esse n ane canes 7
PRE-OPERATION CHECK...............e.e.ecneneucaceonecanerenerenzarceneneo renace. 9
STARTING THE ENGINE.............ecececarmenriconcarero rene eo nana ee neacerereneme. 13
* Carburetor Modification for High Altitude Operation
GENERATOR USE ..........e...ee.neeraerricenarerereecearanerenoonrenareaseeoneeneore eee 17
STOPPING THE ENGINE.............e.enereencrcecerecaaoine eee ener 24
MAINTENANCE ®…...…..…..….…rerssrrossrensrensarenaren sente nren ane n anna nan een ee nana nan e nes 26
TRANSPORTING/STORAGE................e.erecerneareeororeenracesreccereaeconeen.. 31
TROUBLESHOOTING........….………sssrrssrenserennren asian arenanen nana nana nes an an eu aa 33
O (07: [0] nanas an nan nen ue 35
WIRING DIAGRAM ..............e.evnrerecorcenerenorerarennenzareacanenenanerenenvanenenene. 37
MAJOR Honda DISTRIBUTOR ADDRESSES ..............e.ereeeverevereceeea 41
1. SAFETY INSTRUCTIONS
AWARNING
To ensure safe operation —
Г Y
* Honda generator is designed to give safe and
dependable service if operated according to
instructions.
A LL] Read and understand the Owner's Manual
before operating the generator. Failure to do
so could result in personal injury or equipment
damage.
e 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.
* The engine exhaust system will be heated
during operation and remain hot immediately
after stopping the engine.
To prevent scalding, pay attention to the
warning marks attached to the generator.
Ant
Ne
= = ; в
* Gasoline is extremely flammable
and explosive under certain
DARRTEZ LE MOTEUR AVANT DE REFARE LE PLEIN conditions. Refuel in a well
OARRESTARE IL MOTORE PRIMA DI FARE REORNIMENTO. ventilated area with the engine
A OPARE EL MOTOR ANTES DE REPOSTAR nn stopped.
®DESLIGUE O MOTOR ANTES DE ABASTECER. .
@ ETAMATATE TH MHXANH TIPIN TON ANEGOAIA EMO ME KAY £IMA. © Keep away from cigarette, smoke
OSTNG AV MOTORN FORE BRNSLEPFYLLNING. =
®STOP MOTOREN FIR BRENDSTOFPFYLDNING. and sparks when refueling the
@SL AV MOTOREN FIR PFYLLING. .
@SAMMUTA MOOTTORI ENNEN TANKKAUSTA. generator. Always refuel in a well-
ventilated location.
« * Wipe up spilled gasoline at once.
AWARNING
To ensure safe operation —
7
N
e Exhaust gas contains poisonous carbon
monoxide. Never run the generator in an
enclosed area. Be sure to provide adequate
No ventilation.
When installed inside, adequate ventilation
should be provided.
(
\_
* Connections for standby power to a building's
electrical system must be made by a qualified
electrician and must comply with all
applicable laws and electrical codes. Improper
connections can allow electrical current from
the generator to back feed into the utility lines.
Such back feed may electrocute utility
company workers or others who contact the
lines during a power outage, and when utility
power is restored, the generator may explode,
burn, or cause fires in the building's electrical
system.
N J
* Always make a pre-operation inspection (page 9 ) before you start
the engine. You may prevent an accident or equipment damage.
* Place the generator at least 1 m (3 ft) away from buildings or other
equipment during operation.
* Operate the generator on a level surface.
If the generator is tilted, fuel spillage may result.
* Know how to stop the generator quickly and understand operation
of all the controls. Never permit anyone to operate the generator
without proper instructions.
* Keep children and pets away from the generator when it is in
operation.
* Keep away from rotating parts while the generator is running.
* The generator is a potential source of electrical shocks when
misused; do not operate with wet hands.
* Do not operate the generator in rain or snow and do not let it get
wet.
4
2. SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause serious
injury. Read the labels and safety notes and precautions described in
this manual carefully.
If a label comes off or becomes hard to read, contact your Honda
dealer for a replacement.
[For European model: G, GW, B, F, W types]
HOT CAUTION
=
CONNECT CAUTION
FUEL CAUTION/PARALLEL OPERATION CAUTION
( | Y >
G STOP THE ENGINE BEFORE REFUELING. (P) DESLIGUE O MOTOR ANTES DE ABASTECER.
(E) AMAÉTEZ LE MOTEUR AVANT DE NEFAIRE LE PLEIN, @ ETAMATATE TH MEDAL MN TON ANEOOAIAZIO ME KAY END. 4
(© VOR AUFTANKEN MOTOR ABSTELLEN. (O) STÁNG AV MOTORN FORE BRANSLEPAFYLLNING.
A D ARRESTARE IL MOTORE PRIMA Di FARE RIFORNIMENTO. (8) STOP MOTOREN FOR BRÆNOSTOFPAFYLDNING.
@ STOP DE MOTOR ALVORENS BL) TE TANKEN. (Y SLA AV MOTOREN FOR PÁFYLUNG.
(E) PARE El MOTOR ANTES DE REPOSTAR. CE SAMMUTA MOOTTOR! ENNEN TANKKAUSTA.
EX 7
Generating set Honda Motor Co., Ltd.
an ISO 8528 Tekyo, Japa syama, Minate-k
| | с em 1 50 Hz[Max. «OT G1
— «> 1.07 230 V ]Max. 1000 m
К
=== sex | 26A [Mass 12.0 kg|!P23S
Saver CAUTION
READ OWNER'S MANUAL
e CE mark and noise label locations
[For European model: G, GW, B, F, W types]
* CE MARK
NOISE LABEL
~~
Manufacturer and address |
Maximum ambient
я я я temperature
e : 2 a a a
Rated power COP 0.6 kW] 50Hz|Max. 40 a Performance class
[Rated power factor 1.0 | 230 V |Max., 1000 m|
[Year of Mfg. x x x x 2.6 A |Mass 12.0 kg 1235 IP code
Maximum altitude
Dry weight
3. COMPONENT IDENTIFICATION
FUEL CAP VENT LEVER
CHOKE LEVER
FUEL FILLER CAP
CONTROL PANEL
LEFT SIDE
MAINTENANCE COVER
STARTER GRIP
ENGINE SWITCH FRAME SERIAL NUMBER
SPARK PLUG
MAINTENANCE COVER
MUFFLER
Record the frame serial number in the space below. You will need this
serial number when ordering parts.
Frame serial number:
CONTROL PANEL
G, GW, F, W types
AC RECEPTACLE
ECO THROTTLE SWITCH
GROUND TERMINAL
OIL ALERT INDICATOR LIGHT
OUTPUT INDICATOR LIGHT
DC RECEPTACLE
DC CIRCUIT PROTECTOR
B type U type
AC RECEPTACLE o AC RECEPTACLE
4. PRE-OPERATION CHECK
CAUTION:
Be sure to check the generator on a level surface with the engine
stopped.
1. Check the engine oil level.
CAUTION:
Using nondetergent oil or 2-stroke engine oil could shorten the
engine's service life.
Use high-detergent, premium quality 4-stroke engine oil, certified to
meet or exceed U.S. automobile manufacturer's requirements for API
Service Classification SG, SF.
Select the appropriate viscosity for the average temperature in your
area.
OIL FILLER CAP SAE Viscosity Grades
(GE te oy UPPER LEVEL
© ZA A ||
15W-40
EE EN EO o
10W-40
a e NN ЛО
10W-30
a > y
onl
= - - - 0 de
DIPSTICK > bd e 6 me
OIL FILLER HOLE AMBIENT TEMPERATURE
7
Loosen the cover screw and remove the left side maintenance cover.
(see page 27 )
Remove the oil filler cap, and wipe the dipstick with a clean rag. Check
the oil level by inserting the dipstick in the filler hole without screwing
it in.
If the oil level is below the end of the dipstick, refill with recommended
oil up to the top of the oil filler neck.
CAUTION:
Running the engine with insufficient oil can cause serious engine
damage.
NOTE:
The Oil Alert System will automatically stop the engine before the oil
level falls below the safe limit. However, to avoid the inconvenience of
an unexpected shutdown, it is still advisable to visually inspect the oil
level regularly.
9
2. Check the fuel level.
If the fuel level is low, refuel the fuel tank until the level as specified.
After refueling, tighten the fuel filler cap securely.
Use automotive unleaded gasoline with a Research Octane Number of
91 or higher (a Pump Octane Number of 86 or higher).
Never use stale or contaminated gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
AWARNING
e Gasoline is extremely flammable and is explosive under certain
conditions.
e Refuel in a well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
* Do not overfill the fuel tank (there should be no fuel above the
upper limit mark). After refueling, make sure the fuel filler cap is
closed properly and securely.
* Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
starting the engine.
* Avoid repeated or prolonged contact with skin or breathing of
vapor.
KEEP OUT OF REACH OF CHILDREN.
FUEL FILLER CAP
UPPER LIMIT MARK
10
NOTE:
Gasoline spoils very quickly depending on factors such as light
exposure, temperature and time.
In worst cases, gasoline can be contaminated within 1 month.
Using contaminated gasoline can seriously damage the engine
(caburetor clogged, valve stuck).
Such damage due to spoiled fuel is disallowed from coverage by the
warrantry.
To avoid this please strictly follow these recommendations:
* Only use specified gasoline.
» To slow deterioration, keep gasoline in a certified fuel container.
e If long storage (more than 1 month) is foreseen, drain fuel tank and
carburetor (page 31).
Gasolines containing alcohol
If you decide to use a gasoline containing alcohol (gasohol), be sure it's
octane rating is at least as high as that recommended by Honda. There
are two types of “gasohol”: one containing ethanol, and the other
containing methanol.
Do not use gasohol that contains more than 10% ethanol. Do not use
gasoline containing methanol (methyl or wood alcohol) that does not
also contain cosolvents and corrosion inhibitors for methanol. Never
use gasoline containing more than 5% methanol, even if it has
cosolvents and corrosion inhibitors.
NOTE:
* Fuel system damage or engine performance problems resulting
from the use of fuels that contain alcohol is not covered under the
warranty.
Honda cannot endorse the use of fuels containing methanol since
evidence of their suitability is as yet incomplete.
* Before buying fuel from an unfamiliar station, try to find out if the
fuel contains alcohol, if it does, confirm the type and percentage of
alcohol used.
If you notice any undersirable operating symptoms while using a
gasoline that contains alcohol, or one that you think contains
alcohol, switch to a gasoline that you know does not contain alcohol.
11
3. Check the air cleaner.
Check the air cleaner element to be sure it is clean and in good
condition.
Loosen the cover screw and remove the left side maintenance cover.
Press the latch tab on the top of the air cleaner body, remove the air
cleaner cover, check the element.
Clean or replace the element if necessary. (see page 28).
CAUTION:
Never run the engine without the air cleaner element. Rapid engine
wear will result from contaminants, such as dust and dirt, being
drawn through the carburetor, into the engine.
COVER SCREW
LEFT SIDE MAINTENANCE COVER
AIR CLEANER BODY
AIR CLEANER ELEMENT
LATCH TAB
AIR CLEANER COVER
LOWER TAB
12
5. STARTING THE ENGINE
Before starting the engine disconnect any load from the AC receptacle.
1. Turn the fuel cap lever fully clockwise to the ON position.
NOTE:
Turn the fuel cap vent lever to the OFF position when transporting the
generator.
FUEL CAP VENT LEVER
>.
a 2
Г
A 7
2. Turn the engine switch to the ON position.
ENGINE SWITCH
13
3. Move the choke lever to the CLOSED position.
NOTE:
о Оо not use the choke when the engine is warm or the air
temperature is high.
CHOKE LEVER
| >
CLOSED
CLOSED
4. Pull the starter grip lightly until you feel resistance, then pull the
starter grip briskly toward the arrow as shown below.
CAUTION:
Do not allow the starter grip to snap back. Return it slowly by hand.
STARTER GRIP
14
5. Move the choke lever to the OPEN position as the engine warms up.
CHOKE LEVER
NI y OPEN
NOTE:
If the engine stops and will not restart, check the engine oil level (see
page 9 ) before troubleshooting in other areas.
15
» Carburetor Modification for High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will be too
rich. Performance will decrease, and fuel consumption will increase. À
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.
High altitude performance can be improved by specific modifications
to the carburetor. If you always operate your generator at altitudes
above 1,500 meters (5,000 feet), have your authorized Honda servicing
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.
Even with carburetor modification, engine horsepower will decrease
about 3.5% for each 300-meter (1,000-foot) increase in altitude. The ef-
fect of altitude on horsepower will be greater than this if no carburetor
modification is made.
CAUTION:
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 1,500 meters (5,000 feet) 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.
16
6. GENERATOR USE
Be sure to ground the generator when the connected equipment is
grounded.
AWARNING
Connections for standby power to a building's electrical system must
be made by a qualified electrician and must comply with all applicable
laws and electrical codes. Improper connections 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 when utility power is
restored, the generator may explode, burn, or cause fires in the
building's electrical system.
GROUND TERMINAL
1
— EARTH MARK
CAUTION:
* For continuous operation, do not exceed the rated power (see page
35 ).
In either case, the total wattage of all appliances connected must be
considered.
* Do not exceed the current limit specified for any one receptacle.
* Do not connect the generator to a household circuit. This could
cause the damage to the generator or to electrical appliances in the
house.
* Do not modify or use the generator for other purposes than it is
intended for. Also observe the following when using the generator.
* Do not connect generators in parallel.
* Do not connect an extension to the exhaust pipe.
* When an extension cable is required, be sure to use a tough rubber
sheathed flexible cable (IEC 245 or equivalent).
* Limit length of extension cables; 60 m for cables of 1.5 mm? and 100
m for cables of 2.5 mm”. Long extension cables will lower usable
power due to resistance in the extension cable.
* Keep the generator away from other electric cables or wires such as
commercial power supply lines.
17
NOTE:
* The DC receptacle can be used while the AC power is in use.
If you use both at the same time, be sure not to exceed 500 VA for
the AC power.
* Most appliance motors require more than their rated wattage for
startup.
18
AC applications
1. Start the engine and make sure the output indicator (green) comes
on.
2. Confirm that the appliance to be used is switched off, and plug in the
appliance.
OUTPUT INDICATOR OVERLOAD INDICATOR
LIGHT (GREEN) LIGHT (RED) PLUG
CAUTION:
* Substantial overloading will switch off the circuit protector.
Marginal overloading may not switch off the circuit protector, but it
will shorten the service life of the generator.
e 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
generator engine switch immediately. Then disconnect the
appliance, and examine it for signs of malfunction.
NOTE:
If an overloaded circuit trips the AC circuit protector, reduce the
electrical load on the circuit, and wait a few minutes before resuming
operation.
The yellow indicator inside the circuit protector button will pop out to
show that the circuit protector has switched off. Push the button in to
reset the circuit protector.
19
Output Indicator
The Output indicator (green) will remain ON during normal operating
conditions.
If the output indicator (green) blinks, current to the connected
appliance(s) will shut off.
When this happens, stop the engine and disconnect the appliance(s).
Then restart the engine.
If the output indicator (green) blinks again, consult your Honda
generator dealer.
OUTPUT INDICATOR
(GREEN)
20
DC application
The DC receptacle may be used for charging 12 volt automotive-type
batteries only.
1. Connect the charging cable to the DC receptacle of the generator
and then to the battery terminals.
CHARGING CABLE
(SOLD SEPARATELY)
AWARNING
* To prevent the possibility of creating a spark near the battery,
connect charging cable first to the generator, then to the battery.
Disconnect cable first at the battery.
* Before connecting charging cable to a battery that is installed in a
vehicle, disconnect the vehicle's battery cable. Reconnect the
vehicle's battery cable after the charging cables are removed. This
procedure will prevent the possibility of a short circuit and sparks if
you make accidental contact between a battery terminal and the
vehicle's frame or body.
CAUTION:
* Do not attempt to start an automobile engine with the generator
still connected to the battery. The generator may be damaged.
* Connect the positive battery terminal to the positive charging cord.
Do not reverse the charging cables, or serious damage to the
generator and/or battery may occur.
21
AWARNING
» Batteries produce explosive gases: If ignited, and explosion can
cause serious injury or blindness. Provide adequate ventilation
when charging.
CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.
Contact with eyes or skin, even through clothing, may cause severe
burns. Wear a faceshield and protective clothing.
* Keep flames and sparks away, and do not smoke in the area.
ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with
warm water for at least 15 minutes and call a physician
immediately. |
* POISON: Electrolyte is poison.
ANTIDOTE
— External: Flush thoroughly with water.
— Internal: Drink large quantities of water or milk.
Follow with milk of magnesia or vegetable oil, and call a
physician immediately.
KEEP OUT OF REACH OF CHILDREN.
2. Start the engine.
NOTE:
* The DC receptacle can be used while the AC power is in use.
* An overload DC circuit will trip the DC circuit protector (push button
comes out).
If this happens, walt a few minutes before pushing in the circuit
protector to resume operation.
pe) BO
ON OFF
DC CIRCUIT PROTECTOR
22
Oil alert system
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 falls below a safe limit, the Oil Alert system will
automatically shut down the engine (the engine switch will remain in
the ON position).
If the Oil Alert system shuts down the engine, the Oil Alert indicator
(red) will come on when you operate the starter, and the engine will
not run. If this occurs, check the engine oil level (see page 9 ).
OIL ALERT INDICATOR
LIGHT (RED)
23
7.STOPPING THE ENGINE
To stop the engine in an emergency, turn the engine switch to the OFF
position.
IN NORMAL USE:
1. Switch off the connected equipment and pull the inserted plug.
2. Turn the engine switch to the OFF position.
ENGINE SWITCH
24
3. Turn the fuel cap vent lever fully counterclockwise to the “OFF”
position.
FUEL CAP VENT LEVER
OFF
CAUTION:
Be sure the fuel cap vent lever and the engine switch are “OFF” when
stopping, transporting and/or storing the generator.
25
8. MAINTENANCE
The purpose of the maintenance and adjustment schedule is to keep
the generator in the best operating condition.
Inspect or service as scheduled in the table below.
AWARNING
Shut off the engine before performing any maintenance. If the engine
must be run, make sure the area is well ventilated. The exhaust
contains poisonous carbon monoxide gas.
CAUTION:
Use genuine Honda parts or their equivalent. The use of replacement
parts which are not of equivalent quality may damage the generator.
Maintenance Schedule
REGULAR SERVICE PERIOD (3) Each use | First Every Every Every
Item month |3 months | 6 months | 2 years
Performed at every indicated or or or or
month or operating hour interval, 10 hrs. 50 hrs. | 100 hrs. | 300 hrs.
| whichever comes first.
Engine oil Check level O
Change O O
Air cleaner Check O
Clean O (1)
Spark plug Check-adjust O
Replace O
Spark arrester Clean O a
Valve Clearance Check-adjust O (2)
Combustion Clean After every 300 hrs (2)
chamber
Fuel tank & filter Clean Every year (2)
Fuel line Check Every 2 years (Replace if necessary) (2)
NOTE: (1)Service more frequently when used in dusty areas.
(2)These items should be serviced by your servicing dealer, unless you have the
proper tools and are mechanically proficient. Refer to Honda shop manual for
service procedures.
(3)For commercial use, log hours of operation to determine proper maintenance
intervals.
26
1. CHANGING OIL
Drain the oil while the engine is still warm to assure rapid and
complete draining.
CAUTION:
Make sure to turn the engine switch and the fuel cap vent lever OFF
before draining.
1. Loosen the cover screw and remove the left side maintenance cover.
2. Remove the oil filler cap.
3. Drain dirty oil into a container thoroughly.
4. Refill with the recommended oil (see page 9 } and check the oil level.
5. Reinstall the left side maintenance cover and tighten the cover
screw securely.
ENGINE OIL CAPACITY: 0.25 2 (0.26 US gt, 0.22 Imp qt)
COVER SCREW _—_
UPPER LEVEL
CO
OIL FILLER CAP
“J
OIL FILLER HOLE Y
Wash your hands with soap and water after handling used oil.
A;
N
NOTE:
Please dispose of used motor oil in a manner that is compatible with
the environment. We suggest you take it in a sealed container to your
local service station for reclamation. Do not throw it in the trash or
pour it on the ground.
27
2. AIR CLEANER SERVICE
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.
AWARNING
Do not use gasoline or low flash point solvents for cleaning. They are
flammable and explosive under certain conditions.
CAUTION:
Never run the generator without the air cleaner. Rapid engine wear
may result.
1. Loosen the cover screw and remove the left side maintenance cover.
2. Press the latch tab on the top of the air cleaner body, and remove
the air cleaner cover.
3. Wash the element in a non-flammable or high flash point solvent
and dry it thoroughly.
4. Soak the element in clean engine oil and squeeze out the excess oil.
5. Reinstall the air cleaner element and the cover.
6. Reinstall the air cleaner cover by inserting the lower tabs, and the
latch tab.
7. Reinstall the left side maintenance cover and tighten the cover
screw securely.
COVER SCREW
AIR CLEANER COVER
LEFT SIDE MAINTENANCE
COVER
MT
28
3. SPARK PLUG SERVICE
RECOMMENDED SPARK PLUG: CR4HSB (NGK)
U14FSR-UB (DENSO)
To ensure proper engine operation, the spark plug must be properly
gapped and free of deposits.
1. Remove the spark plug maintenance cover.
SPARK PLUG MAINTENANCE COVER
2. Remove the spark plug cap.
3. Clean any dirt from around the spark plug base.
4. Use a spark plug wrench to remove the spark plug.
HANDLE BAR
SPARK PLUG CAP
PLUG WRENCH
29
5. Visually inspect the spark plug. Discard it if the insulator is cracked
or chipped. Clean the spark plug with a wire brush if it is to be
reused.
6. Measure the plug gap with a feeler gauge.
Correct as necessary by carefully bending the side electrode.
The gap should be:
0.60—0.70 mm (0.024 — 0.028 in)
0.60 — 0.70 mm
(0.024 — 0.028 in)
7. Install the spark plug carefully, by hand, to avoid cross-threading.
8. After a new spark plug has been seated by hand, it should be
tightened 1/2 turn with a wrench to compress its washer.
If a used plug is being reinstalled, it should only require 1/8 to 1/4
turn after being seated.
9. Reinstall the spark plug cap on the spark plug securely.
10. Reinstall the spark plug maintenance cover.
CAUTION:
* The spark plug must be securely tightened. An improperly
tightened plug can become very hot and possibly damage the
generator.
Never use a spark plug with an improper heat range.
30
9. TRANSPORTING/STORAGE
To prevent fuel spillage when transporting or during temporary
storage, the generator should be secured upright in its normal
operating position, with the engine switch OFF.
The fuel cap vent lever is turned fully counterclockwise to the “OFF”
position.
AWARNING
When transporting the generator:
e Do not overfill the tank (there should be no fuel in the filler neck).
e Do not operate the generator while it is on a vehicle. Take the
generator off the vehicle and use it in a well ventilated place.
e Avoid a place exposed to direct sunlight when putting the
generator on a vehicle. If the generator is left in an enclosed vehicle
for many hours, high temperature inside the vehicle could cause
fuel to vaporize resulting in a possible explosion.
Do not drive on a rough road for an extended period with the
generator on board. If you must transport the generator on a rough
road, drain the fuel from the generator beforehand.
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Drain the fuel.
AWARNING
Gasoline is extremely flammable and is explosive under certain
conditions. Perform this task in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the area during
this procedure.
a.Drain all gasoline from the fuel tank into an approved gasoline
container.
31
b. Turn the engine switch ON, and loosen the carburetor drain screw
and drain the gasoline from the carburetor into a suitable container.
c. With the drain screw loosened remove the spark plug cap, and pull
the starter grip 3 to 4 times to drain the gasoline from the fuel pump.
d. Turn the engine switch to the OFF position, and tighten the drain
screw securely.
e. Reinstall the spark plug cap on the spark plug securely.
3. Change the engine oil.
4. Remove the spark plug and pour about a tablespoon of clean engine
oil into the cylinder. Crank the engine several revolutions to
distribute the oil, then reinstall the spark plug.
5. 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.
STARTER GRIP
32
10. TROUBLESHOOTING
When the engine will not start:
Is there fuel in NO
the tank?
| YES
Is the engine NO
_ | Refill the fuel
tank.
switch on?
| YES
Is the enough oil NO
Turn the engine
switch on.
in the engine?
| YES
Is the spark plug NO
Add the
recommended
oil.
in good
condition?
YES
Ÿ
If the engine still
does not start,
take the
generator to an
authorized
Honda dealer.
Clean, readjust
gap and dry the
spark plug.
Replace it if
necessary.
33
Appliance does not operate:
Is the Output
NO (Blink) _
indicator ON?
YES (Indicator ON)
YES (Indicator ON)
Disconnect the electrical
appliance or equipment. Stop
and restart the engine.
Y
|
Is the Output NO (Blink)
indicator ON?
Reconnect the electrical
appliance or equipment again.
Take the generator to an
authorized Honda dealer.
Y
Consult an authorized
Honda dealer for the
connected electrical
appliance or equipment.
Turn the AC circuit
protector on.
appliance or
equipment for
any defects.
DEFECTS
Is the Output NO (Blink) _
indicator ON?
Y
Is the AC circuit NO _
protector ON?
| YES
Check the NO DEFECTS
electrical
Take the generator to an
authorized Honda dealer.
No electricity at the DC receptacle:
Is the DC circuit NO
Ba
* Replace the electrical
appliance or eguipment.
* Take the electrical
appliance or equipment to
an electrical shop for repair.
protector on?
YES
Turn the DC circuit protector
on.
34
| Take the generator to an
authorized Honda dealer.
11. SPECIFICATIONS
Dimensions and Weight
Model EX7
Description code EZGG
Length 450 mm (17.7 in)
Width 240 mm (9.4 in)
Height 380 mm (15.0 in)
Dry weight 12.0 Ка (26.5 165)
Engine
Model GXH50
Engine type 4-stroke, overhead valve, single cylinder
Displacement
50 cm? (3.1 cu-in)
Bore X Stroke
41.8 x 36.0 mm (1.64 in X 1.42 in)
Compression ratio 8.0:1
Engine speed 4,500 rpm
Cooling system Forced air
Ignition system
Full transistor
Oil capacity 0.25 £ (0.26 US qt, 0.22 Imp qt)
Fuel tank capacity 2.3 2 (0.61 US gal , 0.51 Imp gal)
Spark plug CR4HSB (NGK)
U14FSR-UB (DENSO)
Generator
Model EX7
Type G, GW, B, F, W U
Rated voltage (V) 230 240
AC Rated frequency (Hz) 50 50
output | Rated current (A) 2.6 2.5
Rated output (VA) 600
Maximum output (VA) 700
DC rated output
Only for charging 12 V
automotive batteries.
12V,8 A
35
Noise
Model EX7
Type G, GW, B, F, W
Sound pressure level (Lpa) 68 dB
According to 98/37/EC
Microphone point
CONTROL i
PANEL
Center >
—— 1 —
у
\ Ï
1.60 т
\
\
=
o
3
Guaranteed sound power 83 dB
level (Lwa)
Tested by 2000/14/EC
NOTE:Specifications are subject to change without notice.
36
12. WIRING DIAGRAM
AC CP AC Circuit Protector
AC NF AC Noise Filter
ACOR AC Output Receptacle
CPB Control Panel Block
CyC Cycloconverter Unit
CyCB Cycloconverter Block
DCCP DC Circuit Protector
DCD DC Diode
DCNF DC Noise Filter
DCOR DC Output Receptacle
DCW DC Winding
EgB Engine Block
EgG Engine Ground
ESw Engine Switch
ExW Exciter Winding
FrB Frame Block
FrG Frame Ground
GB Generator Block
GT Ground Terminal
lgC Ignition Coil
MW Main Winding
OAL Oil Alert Indicator
OLSw Oil Level Switch
PC Pulser Coil
PL Output Indicator
SP Spark Plug
SpU Spark Unit
SW Sub Winding
BI BLACK
Y YELLOW
Bu BLUE
G GREEN
R RED
W WHITE
Br BROWN
Lg LIGHT GREEN
Gr GRAY
Lg LIGHT BLUE
O ORANGE
P PINK
37
G, GW, B, F, W type
0 —*
WT
> Eos |
19 oJ (Mod
1 |
L |
y
4020 a a т
4220 |
— ро.
U type
39
RECEPTACLE
S m z A 5 >
E
E O 0 E
ed dd
O n° x © ®
40
13. MAJOR Honda DISTRIBUTOR ADDRESSES
For European
NAME OF FIRM (COMPANY)
ADDRESS
TEL: FAX:
Honda (U.K.) Limited
470 London Road, Slough,
Berkshire, SL38QY,
United Kingdom
Tel: 01753-590-590
Fax: 01753-590-000
Honda Europe Power Equipment S.A.
Pole 45 Rue des Chataigniers
45140 Ormes
France
Tel: 2-38-65-06-00
Fax: 2-38-65-06-02
Honda Motor Europe (North) GmbH.
Spredlinger, Landstrafse 166
D-63069 Offenbach/Main
Tel: 069-83-09-0
Fax: 069-83-09-519
Germany
Honda Belgium H.V. Wijngaardveld 1, 9300 Aalst Tel: 053-725-111
Belgium Fax: 053-725-100
Honda Italia Industriale S.P.A. Via della Cecchignola, 5/7 Tel: 06-54928-1
00143 ROMA Fax: 06-54928-400
Honda (Suisse) S.A.
Route des Mouliéres 10
Case postale Ch 1214
Vernier-Geneve, Switzerland
Tel: 022-341-22-00
Fax: 022-341-09-72
Honda Nederland B.V.
Capronilaan 1
1119 NN Schiphol-Rijk
Netherlands
Tel: 020-7070000
Fax: 020-7070001
Honda Austria G.M.B.H.
Honda Strasse 1 A-2351
Tel: 223-66-900
Wiener Neudorf Fax: 223-66-4130
Austria
Honda Power Equipment Sweden AB Vastkustvagen 17 Tel: 040-600 23 00
202 15 Malmo, Fax: 040-600 23 19
Sweden
Honda Produtos De Forga, Portugal, S.A.
Lugar da Abrunheira
S. Pedro de Penaferrim
2710 Sintra, Portugal
Tel: 351-1-9150374
Fax: 351-1-9111021
Berema A/S
Berghagan 5, Langhus
Box 454, 1401 Ski
Norway
Tel: 64-86-05-00
Fax: 64-86-05-49
41
For European (continued)
08530, La Garriga
(Barcelona), Spain
NAME OF FIRM (COMPANY) ADDRESS TEL: FAX:
OY Brandt AB Tuupakantie 4 Tel: 90-895-501
SF-01740, Vantaa Fax: 90-878-5276
Finland
TIMA PRODUCTS A/S Tärnfalkevej 16, Postboks 511 Tel: 31-49-17-00
DK 2650 Hvidovre Fax: 36-77-16-30
Denmark
Greens Polig. Industrial Congost Tel: 93-871-84-50
Fax: 93-871-81-80
Automocion Canarias S.A.
(AUCASA)
Apartado de Correos, num 206
Santa Cruz de Tenerife
Canary Island
Tel: 922-61-13-50
Fax: 922-61-13-44
The Associated Motors Company Ltd.
148, Rue D'Argens, Msida
Malta
Tel: 356-333001
Fax: 356-340473
Two Wheels Ltd.
Crosslands Business Park,
Ballymount Road, Dublin 12,
Ireland
Tel: 4602111
Fax: 4566539
General Automotive Co., S.A.
Р.О. Вох 1200, 101 73 Athens
Greece
Tel: 346-5321
Fax: 346-7329
BG Technik s.r.o
Radlicka 117/520
158 01 Praha 5
Czech Republic
Tel: 2-5694 573
Fax: 2-5694 571
Aries Power Equipment Ltd.
01-493 Warszawa, ul Wroclawska
25a
Tel: 22-685 17 06
Fax: 22-685 16 03
Poland
MO. TOR. PEDO Ltd. 2040 Buda-rs, Kamaraerdei-t 3. Tel: 23-444-971
Hungary Fax: 23-444-972
MDL Motors 140 Dzirnavu Street Tel: 371-7211071
Riga LV 1050 Fax: 371-7821028
Latvia
UAB “Wood Stock” Savanoriu 174 a, LT 2600 Tel: 370-61-606896
Lithuania Fax: 370-52-132756
Honda Slovakia spol. s r.o.
Polus Millennium Tower
Vajnorska ul. 100/A
831 03 Bratislava 3
Slovak Republic
Tel: 42-1-2-4444-1156
Fax: 42-1-2-4444-1150
AS Domzale Moto Center 0.0.0.
Blantnica 3a, 1236 Trzin
Slovenia
Tel: 386-1-562-2242
Fax: 386-1-562-3705
For Australian
NAME OF FIRM (COMPANY)
ADDRESS
TEL: FAX:
Honda Australia Motorcycle and Power
Equipment Pty. Ltd
1954-1956 Hume Highway
Campbellfield Victoria 3061
Tel: (03) 9270 1111
Fax: (03) 9270 1133
42
HONDA
The Povver of Dreams
© Honda Motor Co, Ltd. 2003
367 13708 E U 1 > ED ECHO 500.2007.06
00X36-2T3-7081 hl Printed in Japan
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