Owner’s Manual GENERATOR EM4000SX • EM5000SX • EM6500SX AHM.35.2011.02

Owner’s Manual GENERATOR EM4000SX • EM5000SX • EM6500SX AHM.35.2011.02

Owner’s Manual

GENERATOR

EM4000SX • EM5000SX • EM6500SX

CY

CMY

CM

MY

K

C

M

Y

31Z23600

00X31-Z23-6000

Printed on

Recycled Paper

AHM.35.2011.02

PRINTED IN U.S.A.

© 2011 Honda Motor Co., Ltd.—All Rights Reserved

See page 82 for

Initial Use Instructions

10/10/12 14:15:12 31Z23600_001

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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.

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.

10/10/12 14:15:18 31Z23600_002

INTRODUCTION

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 all 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

Distributor’s Limited Warranty

to fully understand its coverage and your responsibilities of ownership. The

Distributor’s Limited Warranty

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 and is supported by the parts and service divisions of American Honda. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes,

Honda Motor Co., Ltd.

1

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A FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this generator safely is an important responsibility.

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:

Safety Labels

− on the generator.

Safety Messages

− preceded by a safety alert symbol of three signal words, DANGER, WARNING, or CAUTION.

and one

These signal words mean:

You WILL be

KILLED or

SERIOUSLY HURT you don’t follow instructions.

if

You CAN be KILLED or SERIOUSLY HURT you don’t follow instructions.

if

You CAN be HURT instructions.

if you don’t follow

Safety Headings

− such as

IMPORTANT SAFETY INFORMATION

.

Safety Section

− such as

GENERAT OR SAF ET Y .

Instructions

− how to use this generator correctly and safely.

This entire book is filled with important safety information − please read it carefully.

2

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CONTENTS

GENERATOR SAFETY ................................................................................

.6

IMPORTANT SAFETY INFORMATION ..................................................

.6

Operator Responsibility ......................................................................

.6

Carbon Monoxide Hazards .................................................................

.6

Electric Shock Hazards

Fire and Burn Hazards

.......................................................................

.7

........................................................................

.7

Refuel With Care .................................................................................

SAFETY LABEL LOCATIONS .................................................................

.8

.9

CONTROLS & FEATURES ........................................................................

.10

COMPONENT & CONTROL LOCATIONS ...........................................

.10

CONTROLS ............................................................................................

.12

Engine Switch ....................................................................................

.12

Starter Grip ........................................................................................

Fuel Valve Lever ................................................................................

.12

.13

Voltage Selector Switch ...................................................................

.13

Auto Throttle System ......................................................................

.14

AC Circuit Breaker .............................................................................

.14

AC Circuit Protectors .........................................................................

.15

DC Terminals .....................................................................................

.16

DC Circuit Protector

Folding Handle

..........................................................................

..................................................................................

.16

.17

FEATURES .............................................................................................

.18

Oil Alert System ..............................................................................

.18

Automatic Engine Stop Function .....................................................

.18

Oil Alert Function ..............................................................................

Overspeed Detection Function ........................................................

.18

.18

Abnormal Voltage Detection Function ............................................

.18

Auto Choke and Throttle Control System .......................................

.19

iAVR (Intelligent Auto Voltage Regulator) ......................................

.19

Fuel Gauge .........................................................................................

.20

Ground Terminal ...............................................................................

.20

BEFORE OPERATION ...............................................................................

ARE YOU READY TO GET STARTED?

................................................

.21

.21

Knowledge .........................................................................................

.21

IS YOUR GENERATOR READY TO GO?

..............................................

.21

Check the Engine ...............................................................................

.22

3

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CONTENTS

OPERATION ..............................................................................................

SAFE OPERATING PRECAUTIONS .....................................................

.23

.23

STARTING THE ENGINE

STOPPING THE ENGINE

......................................................................

......................................................................

.24

.27

AC OPERATION .....................................................................................

.28

AC Applications .................................................................................

.29

AC Receptacle Selection ...................................................................

.30

Power Producing Circuits .................................................................

.30

Voltage Selector Switch ...................................................................

.31

DC OPERATION .....................................................................................

.33

AUTO THROTTLE SYSTEM ................................................................

.35

STANDBY POWER ................................................................................

.36

Connections to a Building’s Electrical System ...............................

.36

System Ground .................................................................................

.36

Special Requirements .......................................................................

.37

SERVICING YOUR GENERATOR .............................................................

.38

THE IMPORTANCE OF MAINTENANCE .............................................

.38

MAINTENANCE SAFETY ......................................................................

.39

Safety Precautions ............................................................................

.39

MAINTENANCE SCHEDULE ................................................................

.40

REFUELING ...........................................................................................

FUEL RECOMMENDATIONS ...............................................................

.41

.42

ENGINE OIL LEVEL CHECK ..................................................................

.43

ENGINE OIL CHANGE ...........................................................................

.44

ENGINE OIL RECOMMENDATIONS ....................................................

.45

AIR CLEANER SERVICE ........................................................................

.46

AIR CLEANER ELEMENT CLEANING ..................................................

.48

SPARK PLUG SERVICE .........................................................................

.49

SPARK ARRESTER SERVICE ................................................................

.51

SEDIMENT CUP CLEANING .................................................................

.52

BATTERY SERVICE ...............................................................................

.53

FUSE ......................................................................................................

.57

STORAGE ..................................................................................................

.58

STORAGE PREPARATION ....................................................................

.58

Cleaning .............................................................................................

.58

Fuel .....................................................................................................

.58

Engine Oil ..........................................................................................

.61

STORAGE PRECAUTIONS ...................................................................

.62

REMOVAL FROM STORAGE ................................................................

.62

TRANSPORTING ......................................................................................

.63

4

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CONTENTS

TAKING CARE OF UNEXPECTED PROBLEMS .......................................

.64

ENGINE WILL NOT START ...................................................................

.64

ENGINE LACKS POWER .......................................................................

.65

NO POWER AT THE AC RECEPTACLES ..............................................

.66

NO POWER AT THE DC TERMINALS ..................................................

.66

TECHNICAL INFORMATION ....................................................................

.67

Serial Number Location .......................................................................

.67

Carburetor Modification for High Altitude Operation

Emission Control System Information

.......................

...............................................

.68

.69

Air Index ................................................................................................

.71

Specifications ........................................................................................

.72

Wiring Diagram .....................................................................................

.73

CONSUMER INFORMATION ...................................................................

.75

Dealer Locator Information ..................................................................

.75

Honda Publications ..............................................................................

Customer Service Information ............................................................

.75

.76

ASSEMBLY ...............................................................................................

.77

SAFETY ..................................................................................................

.77

The Importance of Proper Assembly

Important Safety Precautions

..............................................

..........................................................

.77

.78

ASSEMBLY ............................................................................................

.79

Unpacking ..........................................................................................

.79

Loose Parts ........................................................................................

.79

Wheel Kit Installation ........................................................................

.80

Handle Installation ............................................................................

.81

INITIAL USE INSTRUCTIONS ..................................................................

.82

ENGINE OIL ...........................................................................................

.82

FUEL .......................................................................................................

.83

BATTERY ...............................................................................................

.84

BEFORE OPERATION ...........................................................................

.85

REGISTRATION .....................................................................................

.85

OPTIONAL PARTS ....................................................................................

Remote Control Kit ...............................................................................

.86

.86

Remote Control Box .............................................................................

.87

Hanger Kit ..............................................................................................

.88

INDEX ........................................................................................................

QUICK REFERENCE INFORMATION .............................

.89

.Inside back cover

5

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GENERATOR SAFETY

IMPORTANT SAFETY INFORMATION

Honda generators are designed for use with electrical equipment that has suitable power requirements. Other uses can result in injury to the operator or damage to the generator and other property.

Most injuries or property damage can be prevented if you follow all instructions in this manual and on the generator. The most common hazards are discussed below, along with the best way to protect yourself and others.

Operator Responsibility

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.

Carbon Monoxide Hazards

Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

If you run the generator in an area that is confined, or even partly enclosed area, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your generator inside a garage, house, or near open windows or doors.

6

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GENERATOR SAFETY

Electric Shock 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.

Fire and Burn Hazards

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.

7

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GENERATOR SAFETY

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.

Allow the engine to cool if the generator has been in operation. Refuel only outdoors in a well-ventilated area with the engine off. Do not overfill the fuel tank. Never smoke near gasoline, and keep other flames and sparks away. Always store gasoline in an approved container. Make sure that any spilled fuel has been wiped up before starting the engine.

8

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GENERATOR SAFETY

SAFETY LABEL LOCATIONS

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.

9

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CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

Use the illustrations on these pages to locate and identify the most frequently used controls.

AC CIRCUIT PROTECTORS

VOLTAGE SELECTOR SWITCH

AC CIRCUIT BREAKER

DC CIRCUIT PROTECTOR

ENGINE SWITCH

120 V/240 V AC

RECEPTACLE

GROUND

TERMINAL

120 V

RECEPTACLES

AUTO THROTTLE SWITCH

DC TERMINALS

10

: Except EM4000SX

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AIR CLEANER

FUEL VALVE LEVER

SEDIMENT CUP

STARTER GRIP

CONTROLS & FEATURES

CONTROL PANEL

BATTERY COVER

FUEL TANK CAP

FUEL GAUGE

OIL FILLER CAP/DIPSTICK

OIL DRAIN PLUG

HANDLE

SPARK PLUG

WHEEL

STAND

MUFFLER

MANUAL CHOKE LEVER

11

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CONTROLS & FEATURES

CONTROLS

Engine Switch

The engine switch controls the ignition system, and it operates the electric starter.

OFF − Stops the engine. The engine switch key can be removed/inserted.

ON − Running position, and for starting with the recoil starter.

START − Operates the electric starter.

Starter Grip

Used when the battery voltage is too low to turn the starter motor.

Pulling the starter grip operates the recoil starter to crank the engine.

O F F

ENGINE SWITCH

O N

Do not allow the starter grip to snap back against the generator.

Return it gently to prevent damage to the starter.

Do not let the starter rope rub against the generator body, or the rope will wear out prematurely.

Be careful not to hit your hand against the handle when pulling the starter grip.

D i r e c t i o n t o p u l l

S T A R T

STARTER

GRIP

12

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CONTROLS & FEATURES

Fuel Valve Lever

The fuel valve lever is located between the fuel tank and carburetor.

The fuel valve must be in the ON position for the engine to run.

After stopping the engine, turn the fuel valve to the OFF position.

O N

O F F

FUEL VALVE LEVER

Voltage Selector Switch

The voltage selector switch switches generator output to produce

‘‘120V ONLY’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the

4-prong receptacle, the switch must be in the ‘‘120V/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position.

Select the voltage before starting the engine.

Switch Position

120V/240V:

The 120V and 120V/240V receptacles can be used simultaneously.

120V ONLY:

ONLY 120 volts is available in this position; 240 volts is not available. The most power will be available at the 30A 120V locking plug receptacle.

VOLTAGE SELECTOR SWITCH

120 V/240 V

120 V ONLY

13

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CONTROLS & FEATURES

Auto Throttle System

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.

Switch Position

AUTO:

Recommended to minimize fuel consumption and further

OFF:

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 startup power equipments.

AUTO THROTTLE SWITCH

O F F

O F F

O N

O N

AC Circuit Breaker

The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload at the receptacles.

The AC circuit breaker may be used to switch the generator power ON or OFF.

O N

14

AC CIRCUIT BREAKER

O F F

10/10/12 14:16:53 31Z23600_016

CONTROLS & FEATURES

AC Circuit Protectors

The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at each 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.

AC CIRCUIT PROTECTOR for Receptacle

AC CIRCUIT PROTECTOR for Receptacle

AC CIRCUIT PROTECTOR for Receptacle

120 V/240 V 20 A (EM4000SX)

120 V/240 V 30 A (EM5000SX,

EM6500SX)

AC CIRCUIT PROTECTOR for Receptacle

ON

120 V 30 A

1 2 0 V 2 0 A

OFF

120 V 20 A

PUSH

: Except EM4000SX

15

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CONTROLS & FEATURES

DC Terminals

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).

DC CIRCUIT PROTECTOR

POSITIVE DC TERMINAL

(RED)

OFF

ON

NEGATIVE DC TERMINAL

(BLACK)

DC Circuit Protector

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. However, the DC circuit protector does not prevent overcharging.

16

10/10/12 14:17:07 31Z23600_018

CONTROL & FEATURES

Folding Handle

The foldable handle is intended for ease of transportation and should be folded when the generator is stationary. Do not rest objects on the extended handle.

To Extend The Handle

Lift handle upward. Lock lever will lock and secure the handle into place.

To Fold The Handle

1.

2.

Press handle lock lever downward.

Lower the handle.

HANDLE

Handle transport position

Generator stationary position

HANDLE LOCK LEVER

17

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CONTROLS & FEATURES

FEATURES

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 can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position).

If the engine stops and will not restart, check the engine oil level (see

page 43 ) before troubleshooting in other areas.

Automatic Engine Stop Function

Oil Alert Function

During operation, the engine will automatically stop if there is not enough oil in the tank. Moreover, if the generator is on a slope, the oil alert function may operate and stop the engine.

Overspeed Detection Function

To protect the engine from exceeding the engine load, the engine will automatically stop if the engine speed becomes abnormal.

Abnormal Voltage Detection Function

The engine will automatically stop during generation when it detects abnormal voltage.

If the engine stops, make sure the oil level is correct. Wait a few minutes, and then try to restart the engine. If the engine still won’t start, take the generator to your authorized servicing Honda power equipment dealer.

18

10/10/12 14:17:22 31Z23600_020

CONTROLS & FEATURES

Auto Choke and Throttle Control System

The ECM of this engine controls the choke valve and throttle automatically.

When starting and warming up the engine, you do not need to operate the choke lever unless the engine is hard to start using the normal starting procedure.

ECM

MANUAL CHOKE LEVER

ECM: Engine Control Module iAVR (Intelligent Auto Voltage Regulator)

This generator is equipped with an intelligent, automatic voltage regulator. The iAVR provides power in excess of the maximum rating for up to ten seconds to start appliances that require high startup current.

The total amount of power available for each generator model is:

EM4000SX 5,000 watts for up to 10 seconds

EM5000SX

EM6500SX

7,000 watts for up to 10 seconds

7,000 watts for up to 10 seconds

19

10/10/12 14:17:29 31Z23600_021

CONTROLS & FEATURES

Fuel Gauge

The fuel gauge is a mechanical device that measures the fuel level in the tank. The red indicator in the window will reference the level in relation to full or empty. To provide increased operating time, start with a full tank before beginning operation. Check the fuel level with the generator on a level surface. Always refuel with the engine OFF and cool.

FUEL GAUGE FUEL TANK CAP

FULL EMPTY

Ground Terminal

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.

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.

GROUND TERMINAL

20

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BEFORE OPERATION

ARE YOU READY TO GET STARTED?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual. Know what the controls do and how to operate them.

Familiarize yourself with the generator and its operation before you begin using it. Know how to quickly shut off the generator in case of an emergency.

If the generator is being used to power appliances, be sure that they

do not exceed the generator’s load rating (see page 29 ).

IS YOUR GENERATOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the generator to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the generator.

Improperly maintaining this generator, or failing to correct a problem before operation, could cause a malfunction in which you could be seriously injured.

Always perform a pre-operation inspection before each operation, and correct any problem.

21

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BEFORE OPERATION

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.

Before beginning your pre-operation checks, be sure the generator is on a level surface and the engine switch is in the OFF position.

Check the Engine

Check the oil level (see page

43

). A low oil level will cause the Oil Alert

system to shut down the engine or prevent it from starting.

Check the air cleaner (see page 46 ). A dirty air cleaner element will

restrict air flow to the carburetor, reducing engine and generator performance.

Check the fuel level (see page 41 ). Starting with a full tank will help to

eliminate or reduce operating interruptions for refueling.

22

10/10/12 14:17:52 31Z23600_024

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, review chapters

GENERATOR SAFETY

(see page 6 ) and

BEFORE OPERATION

(see

page 21 ).

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.

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.

Before connecting an AC appliance or power cord to the generator:

Use grounded 3-prong extension cords, tools, and appliances, or double-insulated tools and appliances.

Inspect cords and plugs, and replace if damaged.

Make sure that the appliance is in good working order. Faulty appliances or power cords can create a potential for electric shock.

Make sure 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.

Operate the generator at least 3 feet (1 meter) away from buildings and other equipment.

Do not operate the generator in an enclosed structure.

23

10/10/12 14:17:59 31Z23600_025

OPERATION

STARTING THE ENGINE

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

SAFE OPERATING PRECAUTIONS

on page 23

and perform the

IS YOUR GENERATOR READY TO GO

checks (see page 21 ). Refer to

AC OPERATION

(see page 28 ) or

DC OPERATION

(see page 33 ) for

connecting loads to the generator.

1.

Make sure that the AC circuit breaker is in the OFF position.

The generator may be hard to start if a load is connected.

AC CIRCUIT BREAKER

2.

Turn the fuel valve lever to the

ON position.

FUEL VALVE LEVER

O N

O F F

24

10/10/12 14:18:08 31Z23600_026

OPERATION

AUTO THROTTLE SWITCH

3.

Make sure the Auto Throttle switch is in the OFF position, or more time will be required for warm up.

OFF

4.

Start the engine.

Using the electric starter:

Turn the engine switch to the

START position, and hold it there until the engine starts.

When the engine starts, release the key, allowing the switch to return to the ON position.

If the engine fails to start within

5 seconds, release the key, and wait at least 10 seconds before operating the starter again.

O F F

O N

S T A R T

ENGINE SWITCH

Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

Do not leave the engine switch in the ON position when the generator is not operating as the battery will discharge. Turn the engine switch to the OFF position when not in use.

25

10/10/12 14:18:16 31Z23600_027

OPERATION

Using the recoil starter: a.

Turn the engine switch to the

ON position.

O N

ENGINE SWITCH

b.

Pull the starter grip lightly until you feel resistance; then pull briskly in the direction of the arrow as shown.

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

Do not let the starter rope rub against the generator body, or the rope will wear out prematurely.

Be careful not to hit your hand against the handle when pulling the starter grip.

5.

If you wish to use the Auto

Throttle system, turn the Auto

Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes.

D i r e c t i o n t o p u l l

AUTO THROTTLE SWITCH

O N

STARTER

GRIP

26

10/10/12 14:18:24 31Z23600_028

OPERATION

STOPPING THE ENGINE

To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure.

1.

Turn off or disconnect all appliances that are connected to the generator.

2.

Move the AC circuit breaker to the OFF position.

3.

Turn the engine switch to the

OFF position.

AC CIRCUIT BREAKER

O F F

O F F

4.

Turn the fuel valve lever to the

OFF position.

ENGINE SWITCH

O F F

FUEL VALVE LEVER

27

10/11/04 13:05:17 31Z23600_029

OPERATION

AC OPERATION

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 in the appliance or the rated load capacity of the generator has been exceeded.

Substantial overloading may damage the generator. Marginal overloading may shorten the service life of the generator.

1.

Turn the voltage selector switch to either position.

With the voltage selector switch in the ‘‘120V/240V’’ position, you can use the 120V and 120V/

240V receptacles simultaneously. If you are NOT using 240 volts, then select the

‘‘120V ONLY’’ position.

VOLTAGE SELECTOR SWITCH

120 V/240 V

120 V ONLY

AC CIRCUIT PROTECTORS

2.

Start the engine (see page 24 ).

AC CIRCUIT

BREAKER

3.

Switch ON the AC circuit breaker.

4.

Plug in the appliance.

Most motorized appliances require more than their rated wattage for startup.

O N

5.

Turn on the appliance.

PLUG

: Except EM4000SX

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.

If the generator is overloaded and the internal circuit is overheated, current to the connected appliance(s) may shut off, even though the

AC circuit breaker stays ON and the engine keeps running.

Stop the engine and correct the problem. Allow the generator to cool

for a few minutes, and then restart the engine (see page 24 ).

28

10/10/12 14:18:45 31Z23600_030

OPERATION

AC Applications

Before connecting an appliance or power cord to the generator:

Make sure that it is in good working order. A faulty appliance or power cord 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 combined electrical rating of the tools or appliances do 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.

Substantial overloading will open the AC circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the AC circuit breaker OFF, but will shorten the service life of the generator.

Limit operation requiring maximum power to 30 minutes.

Maximum power is:

EM4000SX:

EM5000SX:

EM6500SX:

4.0 kVA

5.0 kVA

6.5 kVA

For continuous operation (longer than 30 minutes), do not exceed the rated power.

Rated power is:

EM4000SX: 3.6 kVA

EM5000SX:

EM6500SX:

4.5 kVA

5.5 kVA

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.

29

10/10/12 14:18:53 31Z23600_031

OPERATION

AC Receptacle Selection

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.

120 V 30 A

120 V 20 A

120 V 20 A

&

120 V/240 V 20 A (EM4000SX)

120 V/240 V 30 A (EM5000SX, EM6500SX)

Power Producing Circuits

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.

120 V/240 V 120 V ONLY

POWER

CIRCUIT B

POWER

CIRCUIT A

POWER CIRCUIT A

POWER CIRCUIT B

30

10/10/12 14:19:02 31Z23600_032

OPERATION

Voltage Selector Switch

The power available to each receptacle depends on the position of the voltage selector switch.

Switch

Position

120V ONLY

Receptacle

1

EM4000SX

30A at 120V

Available Power

EM5000SX

30A at 120V

EM6500SX

30A at 120V

2 20A at 120V

3 20A at 120V

20A at 120V

20A at 120V

20A at 120V

20A at 120V

120V/240V 1

2

4A

4B

3

4A-4B

20A at 120V

None

15.0A at 120V

15.0A at 240V

30A at 120V

None

15.0A at 120V 18.8A at 120V

15.0A at 120V 18.8A at 120V

18.8A at 120V

18.8A at 240V

30A at 120V

None

22.9A at 120V

20A at 120V

20A at 120V

22.9A at 240V

120V ONLY Position

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 table above and the total load does not exceed the total current available.

Total Current Available:

30.0 A (EM4000SX)

37.5 A

45.8 A

(EM5000SX)

(EM6500SX)

31

10/10/12 14:19:09 31Z23600_033

OPERATION

120V/240V Position

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 amps( * ).

* :

15.0 A

18.8 A

22.9 A

(EM4000SX)

(EM5000SX)

(EM6500SX)

Set of Total Current Available

Receptacles EM4000SX EM5000SX EM6500SX

1 + + 4B 15.0A

18.8A

22.9A

Power Producing

Circuit

B

2 + 4A 15.0A

18.8A

22.9A

A

32

10/10/12 14:19:18 31Z23600_034

OPERATION

DC OPERATION

The DC receptacle should ONLY be used for charging 12-volt automotive type batteries. The DC charging output is not regulated.

Connecting the battery charging cable (optional equipment):

1.

Before connecting the battery charging cable (optional equipment) to a battery that is installed in a vehicle, disconnect the vehicle battery ground cable from the negative ( − ) battery terminal.

The battery gives off explosive hydrogen gas during normal operation.

A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you.

Wear protective clothing and a face shield, or have a skilled mechanic perform the battery maintenance.

WARNING:

Battery posts, terminals, and related accessories contain lead and lead components.

Wash hands after handling.

2.

Connect the red lead of battery charging cable into the positive ( + )

DC terminal of the generator.

POSITIVE DC TERMINAL

(RED)

NEGATIVE DC TERMINAL

(BLACK)

BATTERY POSITIVE

(

) TERMINAL

BATTERY NEGATIVE

(

) TERMINAL

33

10/10/12 14:19:28 31Z23600_035

OPERATION

3.

Connect the black lead of battery charging cable into the negative

( − ) DC terminal of the generator.

4.

Connect the red lead of the battery charging cable to the positive

( + ) battery terminal and the black lead to the negative ( − ) battery terminal.

5.

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.

An overloaded DC circuit, excessive current drawn by the battery, or a wiring problem will trip the DC circuit protector (the yellow indicator inside the clear circuit protector button will pop out). If this happens, wait a few minutes before pushing in the circuit protector button to resume operation. If the circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer.

The DC circuit protector does not prevent overcharging the battery.

DC CIRCUIT PROTECTOR

OFF

ON

Disconnecting the battery charging cable:

1.

2.

Stop the engine.

Disconnect the black lead of the battery charging cable from the

3.

4.

negative ( − ) battery terminal.

Disconnect the red lead of the battery charging cable from the positive ( + ) battery terminal.

Disconnect the battery charging cables from the DC terminals of the

5.

generator.

Connect the vehicle battery ground cable to the negative ( − ) battery terminal.

34

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OPERATION

AUTO THROTTLE SYSTEM

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.

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.

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.

AUTO THROTTLE SWITCH

OFF

OFF

ON

ON

35

10/10/14 10:10:38 31Z23600_037

OPERATION

STANDBY POWER

Connections to a Building’s Electrical System

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.

Improper connections to a building’s electrical system can allow 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 prior to making any power connections.

In some areas, generators are required by law to be registered with local utility companies. Check local regulations for proper registration and use procedures.

System Ground

Honda portable generators have a system ground that connects the 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 with a receptacle tester, it will not show the same ground circuit condition as for a home receptacle.

36

10/10/12 14:19:44 31Z23600_038

OPERATION

Special Requirements

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.

If the generator is used at a construction site, there may be additional regulations that must be observed.

37

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SERVICING YOUR GENERATOR

THE IMPORTANCE OF MAINTENANCE

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 unusual conditions, such as sustained high-load or high-temperature operation, or use it in dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

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.

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 and replacement.

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.

38

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SERVICING YOUR GENERATOR

MAINTENANCE SAFETY

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.

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.

Safety Precautions

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust.

Operate outside away from open windows or doors.

Burns from hot parts.

Let the engine and exhaust system cool before touching.

Injury from moving parts.

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.

39

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SERVICING YOUR GENERATOR

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

Engine oil Check level

Change

Air cleaner

Sediment cup

Spark plug

Check

Clean

Clean

Check-adjust

Replace

Clean Spark arrester

Idle speed

Valve clearance

Combustion chamber

Fuel tank and filter

Fuel tube

Canister

Purge tube

Charge tube

Check-adjust

Check-adjust

Clean

Clean

Check

Check

Check

Check

Each use

First month or

20 Hrs.

Every

3 months or

50 Hrs.

Every

6 months or

100 Hrs.

Every year or

300 Hrs.

page

(1)

52

49

49

51

43

44

46

48

(2)

(2)

After every 1,000 Hrs. (2)

(2)

Every 2 years (Replace if necessary) (2)

Every 2 years (2)

Every 2 years (2)

Every 2 years (2)

(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 the Honda shop manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

Failure to follow this maintenance schedule could result in non-warrantable failures.

40

10/10/12 14:20:19 31Z23600_042

SERVICING YOUR GENERATOR

REFUELING

With the engine stopped, check the fuel gauge. Refill the fuel tank if the fuel level is low.

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.

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.

Refuel in a well-ventilated area before starting the engine. If the engine has been running, allow it to cool. Refuel carefully to avoid spilling fuel.

Do not fill above the upper level mark.

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.

41

10/10/12 14:20:28 31Z23600_043

SERVICING YOUR GENERATOR

UPPER LEVEL MARK (RED)

FUEL TANK CAP

FUEL GAUGE

FUEL STRAINER

FULL EMPTY

UPPER LEVEL MARK (RED)

After refueling, reinstall the fuel tank cap securely.

FUEL RECOMMENDATIONS

This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher.

Never use stale or contaminated gasoline or an oil/gasoline mixture.

Avoid getting dirt or water in the fuel tank.

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.

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.

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.

If your equipment will be used on an infrequent or intermittent basis, please refer to the fuel section of the

STORAGE

chapter (page 58 ) for additional information regarding fuel deterioration.

42

10/10/12 14:20:37 31Z23600_044

SERVICING YOUR GENERATOR

ENGINE OIL LEVEL CHECK

Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped.

1.

Remove the oil filler cap/dipstick and wipe it clean.

2.

Insert and remove the dipstick without screwing it into the oil filler hole. Check the oil level shown on the dipstick.

3.

If the oil level is low, fill with the recommended oil to the upper limit

on the oil filler cap/dipstick (see page 45 ).

4.

Screw in the oil filler cap/dipstick securely.

OIL FILLER CAP/DIPSTICK UPPER LIMIT

OIL FILLER HOLE

The Oil Alert system will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, check the oil level regularly.

43

10/10/12 14:20:46 31Z23600_045

SERVICING YOUR GENERATOR

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid and complete draining.

1.

Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap/dipstick, 12 × 15 mm drain plug, and sealing washer.

2.

Allow the used oil to drain completely, and then reinstall the 12 × 15 mm drain plug and a new sealing washer. Tighten the plug securely.

3.

With the generator in a level position, fill with the recommended oil

to the upper limit on the oil filler cap/dipstick (see page 43 ).

4.

Screw in the oil filler cap/dipstick securely.

UPPER LIMIT

SEALING

WASHER

OIL FILLER CAP/DIPSTICK 12

×

15 mm

OIL DRAIN PLUG

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.

44

10/10/12 14:20:51 31Z23600_046

SERVICING YOUR GENERATOR

ENGINE OIL RECOMMENDATIONS

Oil is a major factor affecting performance and service life. Use

4-stroke automotive detergent oil.

SAE 10W − 30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range.

AMBIENT TEMPERATURE

The SAE oil viscosity and service category are in the API label on the oil container. Honda recommends that you use API service category

SJ or later (or equivalent) oil.

45

10/10/12 14:20:59 31Z23600_047

SERVICING YOUR GENERATOR

AIR CLEANER SERVICE

1.

Unsnap the air cleaner cover clips and open the air cleaner cover.

2.

Free the hooks from the setting pins on the air cleaner case and remove the air cleaner cover to the right side of the frame pipe, taking care not to damage the air cleaner cover.

3.

Remove the air cleaner element from the air cleaner case.

4.

Check the air cleaner element to be sure it is clean and in good condition.

If the air cleaner element is dirty, clean it as described on page 48

.

Replace the air cleaner element if it is damaged.

HOOK

AIR CLEANER CASE

SETTING PIN

46

FRAME PIPE

AIR CLEANER ELEMENT

AIR CLEANER COVER

CLIP

10/10/12 14:21:05 31Z23600_048

SERVICING YOUR GENERATOR

5.

Reinstall the air cleaner element in the air cleaner case.

6.

Set the hooks of the air cleaner cover to the setting pins securely, and then push the air cleaner cover to lock the clips.

Be sure that the cover is set securely. There must be no clearance between the air cleaner cover and air cleaner case.

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.

SETTING PIN

GOOD

HOOK

NO GOOD

AIR CLEANER CASE

AIR CLEANER COVER

AIR CLEANER ELEMENT

CLIP

47

10/10/12 14:21:12 31Z23600_049

SERVICING YOUR GENERATOR

AIR CLEANER ELEMENT CLEANING

A dirty air cleaner element will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in very dusty areas, clean the air cleaner element more frequently than specified in the Maintenance Schedule.

1.

Wash the air cleaner element in a solution of household detergent and warm water and rinse thoroughly, or wash in nonflammable or high flashpoint solvent. Allow the air cleaner element to dry thoroughly.

2.

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.

1. Soak 2. Squeeze to Dry

Do not twist.

3. Oil 4. Squeeze

Do not twist.

3.

Wipe dirt from the air cleaner housing and cover using a moist rag.

Be careful to prevent dirt from entering the air duct that leads to the carburetor.

48

10/10/12 14:21:20 31Z23600_050

SERVICING YOUR GENERATOR

SPARK PLUG SERVICE

In order to service the spark plug, you will need a spark plug wrench

(commercially available).

Recommended spark plugs:

BPR5ES (NGK)

W16EPR-U (DENSO)

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 is hot, allow it to cool before servicing the spark plug.

1.

Disconnect the spark plug cap, and remove any dirt from around the spark plug area.

2.

Remove the spark plug with a spark plug wrench.

SPARK PLUG WRENCH

SPARK PLUG CAP

49

10/10/12 14:21:28 31Z23600_051

SERVICING YOUR GENERATOR

3.

Visually inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked, chipped, or fouled.

4.

Measure the spark plug electrode gap with a wire-type feeler gauge.

Correct the gap, if necessary, by carefully bending the side electrode.

The gap should be:

0.028

− 0.031 in (0.7

− 0.8 mm)

SIDE ELECTRODE

0.028

0.031 in (0.7

0.8 mm)

SEALING WASHER

5.

Check that the spark plug sealing washer is in good condition, and thread the spark plug in by hand to prevent cross-threading.

6.

After the spark plug is seated, tighten with a spark plug wrench to 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.

7.

Attach the spark plug cap.

50

10/10/12 14:21:37 31Z23600_052

SERVICING YOUR GENERATOR

SPARK ARRESTER SERVICE

The spark arrester must be serviced every 100 hours to keep it functioning as designed.

If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester.

Clean the spark arrester as follows:

1.

Remove the two 5 mm screws, and remove the spark arrester.

5 mm SCREWS SPARK ARRESTER

2.

Use a brush to remove carbon deposits from the spark arrester screen.

Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and tears. Replace the spark arrester if it is damaged.

SPARK ARRESTER SCREEN

3.

Install the spark arrester in the reverse order of removal.

51

10/10/12 14:21:46 31Z23600_053

SERVICING YOUR GENERATOR

SEDIMENT CUP CLEANING

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.

1.

Turn the engine switch to the

OFF position and remove the key.

KEY

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.

2.

Turn the fuel valve lever to the

OFF position; then remove the sediment cup and the O-ring.

Discard the O-ring.

FUEL VALVE LEVER

3.

Clean the sediment cup in nonflammable solvent, and dry it thoroughly.

O-RING

(Replace)

4.

Reinstall the new O-ring and sediment cup, and tighten the sediment cup securely.

SEDIMENT CUP

5.

Turn the fuel valve lever to the

ON position and check for leaks.

52

O F F

10/10/12 14:21:54 31Z23600_054

SERVICING YOUR GENERATOR

BATTERY SERVICE

Your generator’s engine charging system charges the battery while the engine is running. However, if the generator is only used periodically, the battery must be charged monthly to maintain the battery service life.

The battery contains sulfuric acid

(electrolyte), which is highly corrosive and poisonous. Getting electrolyte in your eyes or on your skin can cause serious burns.

Wear protective clothing and eye protection when working near the battery.

KEEP CHILDREN AWAY FROM THE

BATTERY.

Emergency Procedures

Eyes

− Flush with water from a cup or other container for at least fifteen minutes. (Water under pressure can damage the eye.)

Immediately call 911 (USA only) or a physician.

Skin

− Remove contaminated clothing. Flush the skin with large quantities of water. Call a physician immediately.

Swallowing

− Drink water or milk. Call your local Poison Control

Center (USA only) or a physician immediately.

53

10/10/12 14:22:02 31Z23600_055

SERVICING YOUR GENERATOR

Battery Removal

WARNING:

Battery posts, terminals, and related accessories contain lead and lead components.

Wash hands after handling.

1.

Loosen the cover screw and remove the battery cover.

COVER SCREW

BATTERY COVER

2.

Remove the negative ( − ) cable from the battery negative ( − ) terminal, and then remove the positive ( + ) cable from the battery positive ( + ) terminal.

3.

Remove the battery holder band.

BATTERY HOLDER BAND

NEGATIVE (

) CABLE

POSITIVE (

) CABLE

4.

Remove the battery from the battery tray.

BATTERY

54

10/10/12 14:22:08 31Z23600_056

SERVICING YOUR GENERATOR

Battery Charging

The battery will expel explosive hydrogen gas when overcharged.

A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you.

Always use a regulated charger that provides the correct charging current to prevent overcharging.

Wear protective clothing and a face shield, or have a skilled mechanic perform the battery maintenance.

The battery is rated at 11.2 Ah (ampere-hours). Charging current should equal 10% of the battery’s ampere-hour rating. A battery charger should be used that can be adjusted to deliver 1.1 amps.

1.

Connect the battery charger following the manufacturer’s instructions.

2.

Charge the battery 5 − 10 hours.

3.

Clean the outside of the battery and the battery tray compartment with a solution of baking soda and water.

55

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SERVICING YOUR GENERATOR

Battery Installation

1.

Install the battery in the generator.

2.

Connect the battery positive ( + ) cable to the battery positive ( + ) terminal first and tighten the bolt securely.

3.

Slide the battery boot over the positive ( + ) cable and terminal.

4.

Connect the battery negative ( − ) cable to the battery negative ( − ) terminal, and tighten the bolt securely.

5.

Install the battery holder band.

6.

Install the battery cover in the reverse order of removal (see page

54 ).

Never operate the generator without the battery cover in place, as poor engine and generator performance will result.

BATTERY HOLDER BAND

NEGATIVE (

)

CABLE

POSITIVE (

)

CABLE

56

10/10/12 14:22:25 31Z23600_058

SERVICING YOUR GENERATOR

FUSE

If the fuse is blown, the starter motor won’t operate.

In the event of fuse failure, locate the cause of failure and repair it before you continue operation. If the fuse continues to fail, discontinue generator use and consult an authorized Honda generator dealer.

1.

Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse.

2.

Remove the fuse holder cover and pull the fuse out.

FUSE HOLDER COVER

FUSE (20 A)

3.

Replace the fuse with a fuse of the same type and rating.

Specified fuse:

20 A

Never use a fuse with a different rating from that specified. Serious damage to the electrical system or fire may result.

4.

Install the fuse holder cover in the reverse order of removal.

57

10/10/12 14:22:33 31Z23600_059

STORAGE

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.

Cleaning

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.

Fuel

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 Distributor’s Limited Warranty 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, and/or fuel tank.

58

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STORAGE

Service according to the table below:

STORAGE TIME

Less than 1 month

1 to 2 months

RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

No preparation required

Fill with fresh gasoline and add gasoline

2 months to 1 year

Fill with fresh gasoline and add gasoline

Drain the carburetor float bowl (page 60 ).

Drain the fuel sediment cup (page 54 ).

Fill with fresh gasoline and add gasoline

1 year or more

Drain the carburetor float bowl (page 60 ).

Drain the fuel sediment cup (page 52 ).

Remove the spark plug. Put a teaspoon of engine oil into the cylinder. Turn the engine slowly with the pull rope to distribute the oil.

Reinstall the spark plug.

Change the engine oil (page 44 ).

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.

59

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STORAGE

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.

1.

Turn the fuel valve lever to the OFF position.

2.

Place a suitable gasoline container below the carburetor, and use a funnel to avoid spilling fuel.

3.

Loosen the carburetor drain screw and drain the gasoline from the carburetor.

DRAIN SCREW

60

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STORAGE

4.

After all the gasoline has drained into the container, tighten the drain screw securely.

5.

Place a suitable gasoline container below the sediment cup, and use a funnel to avoid spilling gasoline.

6.

Remove the sediment cup (see page 52 ), and then turn the fuel

valve lever to the ON position.

7.

Allow the gasoline to drain completely, and then install the sediment

cup (see page 52 ).

FUEL VALVE LEVER

ON

Engine Oil

1.

Change the engine oil (see page 44).

2.

Remove the spark plug, and pour between one and two teaspoons

(5 cc) of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug.

3.

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.

Battery

Charge the battery before storing the generator (see page 55 ).

61

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STORAGE

STORAGE PRECAUTIONS

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.

Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.

Also avoid any area with a spark-producing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that promotes rust and corrosion.

Unless all fuel has been drained from the fuel tank, leave the engine switch in the OFF position, and the fuel valve lever in the OFF position

(see page 27 ) to reduce the possibility of leakage.

Place the generator on a level surface. Tilting or laying it on its side can cause fuel or oil leakage.

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.

Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the generator, promoting rust and corrosion.

REMOVAL FROM STORAGE

Check your generator as described in the

of this manual (see page 21 ).

BEFORE OPERATION

chapter

If the generator was stored for 1 year or longer, drain the fuel tank (see

page 60 ) and refuel 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.

62

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TRANSPORTING

Do not lay the generator on its side when moving, storing, or operating it. Oil or fuel may leak and damage the engine or your property.

If the generator has been running, allow the engine to cool for at least

15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

Keep the generator level when transporting to reduce the possibility of fuel leakage. Move the fuel valve lever to the OFF position. Do not use the generator while it is being transported.

When using ropes or tie-down straps to secure the generator for transportation, be sure to only use the frame bars as attachment points. Do not fasten ropes or straps to any portions of the generator body.

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TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause

Fuel valve lever OFF.

Correction

Turn lever ON (p. 24).

Engine switch OFF.

Out of fuel.

Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline.

Drain fuel tank and carburetor

(p. 60).

Refuel with fresh gasoline

(p. 41).

Low oil level caused Oil Alert to stop engine.

Spark plug faulty, fouled, or improperly gapped.

Spark plug wet with fuel

(flooded engine).

Turn engine switch to ON

(p. 25).

Refuel (p. 41).

Add oil (p. 43).

Turn engine switch to OFF and then restart the engine.

Gap or replace spark plug

(p. 49).

Dry and reinstall spark plug.

Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.

Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.

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10/11/04 13:10:17 31Z23600_066

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE LACKS POWER

Possible cause

Air filter restricted.

Correction

Clean or replace air filter

(p. 46 − 48).

Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline.

Drain fuel tank and carburetor

(p. 60).

Refuel with fresh gasoline

(p. 41).

Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.

Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.

65

10/11/04 13:05:48 31Z23600_067

TAKING CARE OF UNEXPECTED PROBLEMS

NO POWER AT THE AC RECEPTACLES

Possible Cause Correction

AC circuit breaker left in the

OFF position after starting.

Switch AC circuit breaker ON.

AC circuit protector tripped.

Faulty power tool or appliance.

Internal circuit overheated.

Faulty generator.

Check AC load and reset AC

circuit protector (p. 15).

Replace or repair power tool or appliance.

Stop and restart the engine.

Stop the engine. Reduce the electrical load. Wait a few minutes for the internal circuit to cool down. Restart the engine.

Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.

NO POWER AT THE DC TERMINALS

Possible Cause Correction

DC circuit protector OFF.

Turn DC circuit protector ON

(p. 16).

Faulty generator.

Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.

66

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TECHNICAL INFORMATION

Serial Number Location

ENGINE SERIAL NUMBER

FRAME SERIAL NUMBER

Record the frame serial number and date purchased in the spaces below. You will need this information when ordering parts and when making technical or warranty inquiries.

Engine serial number:

Frame serial number:

Date purchased:

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TECHNICAL INFORMATION

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. 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.

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 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 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

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.

68

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TECHNICAL INFORMATION

Emission Control System Information

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is 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.

Honda utilizes appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

Additionally, Honda fuel systems utilize components and control technologies to reduce evaporative emissions.

The U.S. and California Clean Air Acts

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 Honda engine emissions within the emission standards.

Tampering and Altering

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 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.

69

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TECHNICAL INFORMATION

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your authorized Honda servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your new 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.

Maintenance

Follow the

MAINTENANCE SCHEDULE

on page 40 . Remember that

this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or hightemperature operation, or use in dusty conditions, will require more frequent service.

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TECHNICAL INFORMATION

Air Index

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.

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)

71

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TECHNICAL INFORMATION

Specifications

Dimensions

Model

Type

Description code

Length

Width

Height

Dry mass [weight]

EM4000SX

203.9 lbs (92.5 kg)

EM5000SX

AT type

EBRC EBMC

41.1 in (1,043 mm)

27.8 in (706 mm)

28.3 in (719 mm)

228.2 lbs (103.5 kg)

EM6500SX

EBJC

41.4 in (1,051 mm)

233.7 lbs (106.0 kg)

Engine

Model

Engine type

Displacement

〔 Bore × Stroke 〕

Compression ratio

Engine speed

Cooling system

Ignition system

Oil capacity

Fuel tank capacity

Spark plug iGX270

4-stroke, overhead valve, single cylinder

16.5 cu-in (270 cm )

23.7 cu-in (389 cm )

〔 3.03

× 2.28 in

〔 3.46

× 2.52 in

(77.0

× 58.0 mm) 〕

(88.0

× 64.0 mm) 〕

8.5:1 iGX390

8.2:1

3,600 rpm

Forced air

CDI magneto

1.2 US qt (1.1 L)

6.21 US gal (23.5 L)

BPR5ES (NGK)

·

W16EPR-U (DENSO)

Generator

Model

Type

AC output

Rated voltage

Rated frequency

Rated current

Rated output

Maximum output

DC output

EM4000SX EM5000SX

AT type

120 V/240 V

60 Hz

EM6500SX

30.0 A/15.0 A

3.6 kVA

37.5 A/18.8 A

4.5 kVA

45.8 A/22.9 A

5.5 kVA

4.0 kVA 5.0 kVA 6.5 kVA

Only for charging 12V automotive batteries.

Maximum charging output = 8.3 A

Tuneup

ITEM

Spark plug gap

Valve clearance (cold)

SPECIFICATION

0.028

− 0.031 in (0.7

− 0.8 mm)

MAINTENANCE

Refer to page 49

IN: 0.15

EX: 0.20

±

±

0.02 mm

0.02 mm

See your authorized

Honda dealer.

No other adjustments needed.

Other specifications

Specifications may vary according to the types, and are subject to change without notice.

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10/10/12 14:24:26 31Z23600_074

D-CDI

DC D

DC CP

DC T

DC W

ECU

ESw

EgB

EX W

FrB

Fu

FW

GeB

GND

GT

J/B

MW

OLSw

OP

PoC

RCBB

Symbol

AC O

AC CB

Au Sw

BAT

CBB

ChC

CT

D1

D2

D-AVR

RCBX

RCCa

SP

SSw

St

Stp Sw

VSSw

Wiring Diagram

Abbreviations

Part name

AC Outlet

AC Circuit Breaker

Auto Throttle Switch

Battery

Control Box Block

Charge Coil

Current Transformer

Diode (MMB)

Diode (196)

Digital-Automatic

Voltage Regulator

Digital-CDI

DC Diode

DC Circuit Protector

DC Terminal

DC Winding

Engine Control Unit

Engine Switch

Engine Block

Exciter Winding

Frame Block

Fuse

Field Winding

Generator Block

Ground

Ground Terminal

Junction Box

Main Winding

Oil Level Switch

Option

Power Coil

Remote Control Box

Block

Remote Control Box

Remote Control Cable

Spark Plug

Start Switch

Starter

Stop Switch

Voltage Selector

Switch

TECHNICAL INFORMATION

Wire color code

Bl

Y

Bu

G

R

W

Br

Lg

Gr

Lb

O

P

BLACK

YELLOW

BLUE

GREEN

RED

WHITE

BROWN

LIGHT GREEN

GRAY

LIGHT BLUE

ORANGE

PINK

Engine Switch

EXT

( + )

EXT

( − )

LO BAT ST

OFF

ON

ST

73

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TECHNICAL INFORMATION

EM4000SX:

1 · EM5000SX, EM6500SX:

2

74

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CONSUMER INFORMATION

Dealer Locator Information

To find an authorized Honda Servicing Dealer anywhere in the United

States, visit our website: www.hondapowerequipment.com/ dealerlocator/

Honda Publications

Shop Manual

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/products/ manuals/

Parts Catalog

This manual provides complete, illustrated parts lists. Available through your Honda dealer.

Accessories Catalog

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/products/accessories/ and click on Generators and Welders to see the entire catalog of accessories.

75

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CONSUMER INFORMATION

Customer Service Information

Honda Power Equipment dealership personnel are trained professionals. They should be able to answer any question 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:

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 numbers (see page 67 )

Name of the dealer who sold the generator to you

Name and address of the dealer who services your generator

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

76

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ASSEMBLY

SAFETY

The Importance of Proper Assembly

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.

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.

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.

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.

77

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ASSEMBLY

Important Safety Precautions

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:

□ Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.

Make sure the engine is off before you begin any assembly, maintenance, or repairs. This will help eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust.

Operate outside away from open windows or doors.

Burns from hot parts.

Let the engine and exhaust system cool before touching.

Injury from moving parts.

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.

78

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ASSEMBLY

Ref. No.

1

2

3

4

5

6

7

8

9

10

11

12

13

ASSEMBLY

Unpacking

1.

Remove the generator and loose parts box from the carton.

2.

Compare the loose parts with the inventory list below.

Tools Required:

12 mm wrench (2), pliers

Loose Parts (Wheel kit and handle)

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.

Description

Wheel

Axle Shaft

Handle Assembly

Handle Lower bracket

Handle Bush B

Handle Bush A

Stand

8 × 16 mm Flange bolt

20 mm Plain Washer

4.0

× 28 mm Split pin

8 mm Flange nut

Handle Folder Assembly

8 × 18 mm Flange bolt

16

2

2

4

1

2

2

2

2

2

Qty.

2

1

1

79

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ASSEMBLY

Wheel Kit Installation

1.

Install the two wheels on the axle shaft using the plain washers and split pins.

2.

Install the axle assembly on the generator using four 8 × 16 mm flange bolts and 8 mm flange nuts.

3.

Install the two stands on the under frame using four 8 × 16 mm flange bolts.

TORQUE:

17 − 22 lbf·ft (24 − 29 N·m , 2.4

− 3.0 kgf·m)

8

×

16 mm FLANGE BOLT (8)

GENERATOR

SIDE

SHORTER

UNDER FRAME

AXLE SHAFT

20 mm

PLAIN WASHER (2)

4.0

×

28 mm

SPLIT PIN (2)

80

STAND (2)

WHEEL (2)

8 mm FLANGE NUT (4)

10/10/12 14:25:32 31Z23600_082

ASSEMBLY

Handle Installation

1.

Install the handle folder assembly on the generator upper frame

2.

using the 8 × 18 mm flange bolts.

Install the handle assembly on the generator upper frame pipe using the 8 × 16 mm flange bolts, handle bush A, handle bush B, and handle lower bracket.

TORQUE:

17 − 22 lbf·ft (24 − 29 N·m , 2.4

− 3.0 kgf·m)

8

×

18 mm FLANGE BOLT (2)

8

×

16 mm FLANGE BOLT (8)

HANDLE ASSEMBLY

HANDLE BUSH A (2)

HANDLE BUSH B (2)

HANDLE FOLDER ASSEMBLY

FRAME PIPE

HANDLE LOWER BRACKET (2)

Operation must be checked after attaching the handle.

Check that the handle can be folded smoothly.

Check that the handle does not hang down by its own weight.

To extend handle:

Raise the handle to the horizontal position. The handle will click into place when locked.

HANDLE

HANDLE LOCK LEVER

81

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INITIAL USE INSTRUCTIONS

ENGINE OIL

The generator is shipped

WITHOUT OIL

in the engine.

1.

Place the generator on a level surface.

2.

Remove the oil filler cap/dipstick.

3.

Add enough SAE 10W-30 API service category SJ or later (or equivalent) oil to bring the oil level to the upper limit on the oil filler cap/dipstick. SAE 10W-30 oil is recommended for general use; for

additional recommendations, see page 45 .

Do not overfill the engine with oil.

If the engine is overfilled, the excess oil may be transferred to the air cleaner housing and air filter.

4.

Screw in the oil filler cap/dipstick securely.

OIL FILLER CAP/DIPSTICK

UPPER LIMIT

OIL FILLER HOLE

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INITIAL USE INSTRUCTIONS

FUEL

Add fuel to the generator in a well-ventilated area. 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.

This engine is certified to operate on unleaded gasoline with a pump

octane rating of 86 or higher. Refer to page

41

for additional fuel recommendations.

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.

1.

Remove the fuel tank cap.

2.

Fuel carefully to avoid spilling fuel. Do not fill the fuel tank above the upper level mark (red) on the fuel strainer.

3.

After refueling, reinstall the fuel tank cap securely.

FUEL TANK CAP

FUEL STRAINER UPPER LEVEL MARK (RED)

UPPER LEVEL MARK (RED)

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INITIAL USE INSTRUCTIONS

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.

Move the generator at least 10 feet (3 meters) away from the fueling source and site before starting the engine.

BATTERY

WARNING:

Battery posts, terminals, and related accessories contain lead and lead components.

Wash hands after handling.

The battery is disconnected for shipment.

1.

Remove the cover (see page 54 )

2.

Connect the battery positive ( + ) cable to the battery positive ( + ) terminal first, and tighten the bolt securely.

3.

Slide the battery boot over the positive ( + ) cable and terminal.

4.

Connect the battery negative (

) cable to the battery negative (

) terminal, and tighten the bolt securely.

5.

Install the battery holder band.

6.

Install the battery cover in the reverse order of removal (see page

54 ).

Never operate the generator without the battery cover in place, as poor engine and generator performance will result.

BATTERY HOLDER BAND

BATTERY BOOT

NEGATIVE (

) CABLE

84

POSITIVE (

)

CABLE

10/10/12 14:26:06 31Z23600_086

INITIAL USE INSTRUCTIONS

BEFORE OPERATION

Before using the generator, all generator operators must read the following chapters and sections:

GENERATOR SAFETY

(pages 6 − 9 )

CONTROLS & FEATURES

(pages 10 − 20 )

BEFORE OPERATION

(pages 21

22 )

OPERATION

(page 23 )

STARTING THE ENGINE

(pages 24 − 26 )

STOPPING THE ENGINE

(page 27 )

MAINTENANCE SCHEDULE

(page 40 )

REGISTRATION

Please Register Your Generator

If your dealer did not collect registration information from you, please take a few minutes and register your purchase with Honda. This allows us to contact you with any important updates regarding your generator. Please note registration is not required to obtain warranty service. You can register your generator by visiting the Honda Power

Equipment website, www.hondapowerequipment.com and selecting

Product Registration. Your information will remain confidential. It will not be released to any other company or organization.

85

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OPTIONAL PARTS

Remote Control Kit

1.

Remove the plug from the 6-pin connector.

PLUG

2.

Connect the remote control cable to the back of the control panel and remote control box.

REMOTE CONTROL

CABLE

86

REMOTE CONTROL

CABLE

REMOTE CONTROL BOX

When the remote control is not being used, replace it with the plug on the connector.

10/10/12 14:26:20 31Z23600_088

Remote Control Box

PILOT LAMP

OPTIONAL PARTS

START BUTTON STOP BUTTON

Starting the engine with remote control

1.

Turn the fuel valve on the generator to the ON position.

2.

Turn the Auto Throttle switch on the generator to the OFF position.

3.

4.

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

1.

Press the stop button.

2.

3.

Turn the engine switch on the generator to the OFF position.

Turn the fuel valve lever on the generator to the OFF position.

87

10/10/12 14:26:27 31Z23600_089

OPTIONAL PARTS

Hanger Kit

1.

Position the hanger at the generator’s balance point as shown below.

2.

Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely.

TORQUE:

17 − 22 lbf·ft (24 − 29 N·m , 2.4

− 3.0 kgf·m)

8

×

16 mm FLANGE BOLT (4) HANGER

HANGER BRACKET (2)

88

HANGER

11 in (280 mm)

GENERATOR

SIDE

10/10/12 14:26:32 31Z23600_090

INDEX

A

Abnormal Voltage Detection Function

AC Applications

..............................................

...................................................................................

. 18

. 29

AC Circuit Protectors

AC Circuit Breaker

..........................................................................

...............................................................................

. 15

. 14

AC OPERATION ...................................................................................

AC Receptacle Selection ....................................................................

. 28

. 30

AIR CLEANER ELEMENT CLEANING

AIR CLEANER SERVICE

................................................

......................................................................

. 48

. 46

Air Index ...............................................................................................

ARE YOU READY TO GET STARTED?

...............................................

. 71

. 21

ASSEMBLY ..........................................................................................

Automatic Engine Stop Function ......................................................

. 77

. 18

AUTO THROTTLE SYSTEM ........................................................

Auto Choke and Throttle Control System

. 14, 35

.........................................

. 19

B

BATTERY SERVICE .............................................................................

BEFORE OPERATION ....................................................................

. 53

. 21, 85

C

Carbon Monoxide Hazards ..................................................................

. 6

Carburetor Modification for High Altitude Operation

Check the Engine

......................

................................................................................

. 68

. 22

Cleaning ...............................................................................................

COMPONENT & CONTROL LOCATIONS ..........................................

. 58

. 10

Connections to a Building’s Electrical System

CONSUMER INFORMATION

.................................

..............................................................

. 36

. 75

CONTENTS

CONTROLS

............................................................................................

..........................................................................................

. 3

. 12

CONTROLS & FEATURES ..................................................................

Customer Service Information ..........................................................

. 10

. 76

D

DC Circuit Protector

DC OPERATION

............................................................................

...................................................................................

. 16

. 33

Dealer Locator Information ................................................................

. 75

89

10/11/11 13:00:35 31Z23600_091

INDEX

E

Electric Shock Hazards .........................................................................

Emission Control System Information ..............................................

. 7

. 69

ENGINE LACKS POWER

Engine Oil

.....................................................................

......................................................................................

. 65

. 61, 82

ENGINE OIL CHANGE .........................................................................

ENGINE OIL LEVEL CHECK ................................................................

. 44

. 43

ENGINE OIL RECOMMENDATIONS

Engine Switch

..................................................

.....................................................................................

. 45

. 12

ENGINE WILL NOT START .................................................................

. 64

F

FEATURES ...........................................................................................

Fire and Burn Hazards

. 18

..........................................................................

. 7

Folding Handle

Fuel

....................................................................................

.................................................................................................

. 17

. 58, 83

Fuel Gauge ..........................................................................................

FUEL RECOMMENDATIONS .............................................................

. 20

. 42

Fuel Valve Lever

FUSE

..................................................................................

....................................................................................................

. 13

. 57

G

GENERATOR SAFETY

Ground Terminal

..........................................................................

.................................................................................

. 6

. 20

H

Handle Installation

Hanger Kit

..............................................................................

............................................................................................

. 81

. 88

Honda Publications .............................................................................

. 75

I

iAVR (Intelligent Auto Voltage Regulator)

IMPORTANT SAFETY INFORMATION

........................................

. 19

................................................

. 6

Important Safety Precautions

INITIAL USE INSTRUCTIONS

............................................................

. 78

............................................................

. 82

IS YOUR GENERATOR READY TO GO?

............................................

. 21

90

10/10/12 14:26:45 31Z23600_092

INDEX

K

Knowledge ...........................................................................................

. 21

L

Loose Parts ..........................................................................................

. 79

M

MAINTENANCE SAFETY ....................................................................

MAINTENANCE SCHEDULE ..............................................................

. 39

. 40

N

NO POWER AT THE AC RECEPTACLES

NO POWER AT THE DC TERMINALS

............................................

................................................

. 66

. 66

O

Oil Alert Function

Oil Alert System

................................................................................

................................................................................

. 18

. 18

OPERATION .........................................................................................

Operator Responsibility

. 23

.......................................................................

. 6

Overspeed Detection Function ..........................................................

. 18

P

Power Producing Circuits ...................................................................

. 30

Q

QUICK REFERENCE INFORMATION ........................

. Inside back cover

R

REFUELING ..........................................................................................

Refuel With Care

. 41

...................................................................................

. 8

REGISTRATION ...................................................................................

Remote Control Box ...........................................................................

. 85

. 87

Remote Control Kit .............................................................................

REMOVAL FROM STORAGE ..............................................................

. 86

. 62

91

10/10/12 14:26:50 31Z23600_093

INDEX

S

SAFE OPERATING PRECAUTIONS

SAFETY

...................................................

................................................................................................

. 23

. 77

SAFETY LABEL LOCATIONS

Safety Precautions

................................................................

..............................................................................

. 9

. 39

SEDIMENT CUP CLEANING

Serial Number Location

...............................................................

.....................................................................

. 52

. 67

SERVICING YOUR GENERATOR

SPARK ARRESTER SERVICE

.......................................................

..............................................................

. 38

. 51

SPARK PLUG SERVICE

Special Requirements

.......................................................................

. 49

........................................................................

. 37

Specifications ......................................................................................

STANDBY POWER ..............................................................................

. 72

. 36

Starter Grip ..........................................................................................

STARTING THE ENGINE ....................................................................

. 12

. 24

STOPPING THE ENGINE

STORAGE

....................................................................

............................................................................................

. 27

. 58

STORAGE PRECAUTIONS

STORAGE PREPARATION

System Ground

.................................................................

..................................................................

. 62

. 58

...................................................................................

. 36

T

TAKING CARE OF UNEXPECTED PROBLEMS .................................

. 64

TECHNICAL INFORMATION ...............................................................

THE IMPORTANCE OF MAINTENANCE ............................................

. 67

. 38

The Importance of Proper Assembly

TRANSPORTING

................................................

.................................................................................

. 77

. 63

U

Unpacking ............................................................................................

. 79

V

Voltage Selector Switch ...............................................................

. 13, 31

W

Wheel Kit Installation

Wiring Diagram

..........................................................................

...................................................................................

. 80

. 73

92

10/10/12 14:26:55 31Z23600_094

QUICK REFERENCE INFORMATION

Fuel Type

Engine Oil

Spark Plug

Maintenance

Type

Type

Electrode Gap

Before each use

First 20 hours

Subsequent

Regular unleaded gasoline with a pump octane rating of 86 or higher

SAE 10W-30, API SJ or later (or equivalent), for general use

(page 45)

BPR5ES (NGK)

W16EPR-U (DENSO)

0.028

− 0.031 in (0.7

− 0.8 mm)

Check engine oil level.

Check air filter.

Change engine oil.

See Maintenance Schedule

(page 40)

Owner’s Manual

GENERATOR

EM4000SX • EM5000SX • EM6500SX

CY

CMY

CM

MY

K

C

M

Y

31Z23600

00X31-Z23-6000

Printed on

Recycled Paper

AHM.35.2011.02

PRINTED IN U.S.A.

© 2011 Honda Motor Co., Ltd.—All Rights Reserved

See page 82 for

Initial Use Instructions

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