HONDA EB6500X User Manual

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.

The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the generator get wet, and do not operate it with wet hands.

Keep this owner’s manual handy so that you can refer to it at any time. This owner’s manual is considered a permanent part of the generator and should remain with the generator if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase of one of the finest generators on the market.

We want to help you get the best results from your new generator and to operate it safely. This manual contains the information on how to do that; please read it carefully.

As you read this manual, you will find information preceded by a

symbol. That information is intended to help you avoid

damage to your generator, other property, or the environment.

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.

When your generator needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators. Your authorized Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes, Honda Motor Co., Ltd.

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:

on the generator.

Safety Labels

Safety Messages

of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

−

preceded by a safety alert symbol and one

−

You WILL KILLED SERIOUSLY HURT

you don’t follow instructions.

You CAN KILLED SERIOUSLY HURT

you don’t follow instructions.

You CAN HURT

instructions.

such as

Safety Headings

Safety Section

Instructions

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

−

such as

−

how to use this generator correctly and safely.

GEN E RATOR SAF E T Y.

be or if

be if you don’t follow

IMPORTANT SAFETY INFORMATION

−

..............................................................................GENERATOR SAFETY . 5

.......................................................................Safety Label Locations . 5

............................................................Important Safety Information . 6

..............................................................COMPONENT IDENTIFICATION . 8

..............................................................................................CONTROLS . 10

....................................................................................Engine Switch . 10

........................................................................................Starter Grip . 10

................................................................................Fuel Valve Lever . 11

..........................................................................................Choke Rod . 11

............................Voltage Selector Switch (Dual Voltage System) . 12

...............................................................................Ground Terminal . 12

System . 13

..........................................................................................Engine Oil . 31

............................................................................................Refueling . 32

..............................................................................Oil Alert

System . 13

...................................................................................Circuit Breaker . 14

...................................................................................GENERATOR USE . 20

..................................................................................Ground System .20

.................................................................................AC Applications . 21

.....................................................................................AC Operation . 22

System . 29

......................................................................................MAINTENANCE . 36

......................................................................Auto Throttle

................................................................................Circuit Protector . 15

...........................................Ground Fault Circuit Interrupter (GFCI) . 16

...............................Connections to a Building’s Electrical System . 20

.......................................................................Special Requirements . 20

...................................................................AC Receptacle Selection . 23

......................................................................Auto Throttle

....................................................................High Altitude Operation . 30

.......................................................................PRE-OPERATION CHECK . 31

....................................................................Fuel Recommendations . 33

..............................STARTING THE ENGINE/STOPPING THE ENGINE . 34

......................................................The Importance of Maintenance . 36

..........................................................................Maintenance Safety . 37

.....................................................................Maintenance Schedule . 38

............................................................................Engine Oil Change . 39

...........................................................................Air Cleaner Service . 40

...........................................................Fuel Sediment Cup Cleaning . 41

............................................................................Spark Plug Service . 42

............................................................Spark Arrester Maintenance . 43

................................................................................................STORAGE . 44

..........................................................................Storage Preparation . 44

...........................................................................................Cleaning . 44

...................................................................................................Fuel . 44

.........................................................................................Engine Oil . 47

.........................................................................Storage Precautions . 48

....................................................................Removal From Storage . 48

.....................................................................................TRANSPORTING . 49

.............................................................................TROUBLESHOOTING . 50

..................................................................TECHNICAL INFORMATION . 52

............................................Emission Control System Information . 52

.............................................................................................Air Index . 54

.................................................................................WIRING DIAGRAM . 55

....................................................................................SPECIFICATIONS . 57

..............................................................................................ASSEMBLY . 60

.................................................WARRANTY SERVICE INFORMATION . 68

.................................................DEALER LOCATOR INFORMATION . 68

............................................CUSTOMER SERVICE INFORMATION . 68

.....................................................................Honda PUBLICATIONS . 69

......................................................................................................INDEX . 70

GENERATOR SAFETY

SAFETY LABEL LOCATION

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.

California type

Non-California type

IMPORTANT SAFETY INFORMATION

Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls and by observing safe operating procedures.

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 and odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

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

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

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 the ground-fault circuit Interrupter (GFCI), and all other 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.

Do not connect to swimming pool equipment installed before adoption of the 1965 national electric code.

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.

Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks where the generator is refueled or where gasoline is stored. Refuel in a wellventilated area with the engine stopped.

Fuel vapors are extremely flammable and may ignite after the engine has started. Make sure that any spilled fuel has been wiped up before starting the generator.

COMPONENT IDENTIFICATION

CHOKE ROD

AIR CLEANER

FUEL VALVE LEVER

STARTER GRIP

ENGINE SERIAL NUMBER

CONTROL PANEL

＊

1: Except EB3800X

GFCI TEST BUTTON

GFCI RESET BUTTON

ENGINE SWITCH

AC CIRCUIT PROTECTORS

CONTROL PANEL

OIL FILLER CAP/DIPSTICK

OIL DRAIN PLUG

120 ONLY 120/240 VOLTAGE SELECTOR SWITCH

−

AUTO THROTTLE SWITCH

CIRCUIT BREAKER

＊

120V AC RECEPTACLES

120/240V AC RECEPTACLE

GROUND TERMINAL

FUEL TANK CAP

FUEL GAUGE

LIFTING HANGER

WHEEL

TRANSPORT HANDLE

SPARK PLUG CAP

FRAME SERIAL NUMBER

STAND

MUFFLER

Record the engine and frame serial numbers and date of purchase

for your future reference. Refer to these serial numbers when ordering parts and when making technical or warranty inquiries (see page ).

Engine serial number:

Frame serial number:

Date of purchase:

CONTROLS

Engine Switch

To start and stop the engine.

Switch position: OFF: ON:

Starter Grip

To start the engine, pull the starter grip lightly until resistance is felt, and then pull briskly.

To stop the engine. To run the engine.

ENGINE SWITCH

OOFFFF

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

RECOIL STARTER

STARTER GRIP

Fuel Valve Lever

The fuel valve is located between the fuel tank and carburetor. When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the OFF position after stopping the engine.

FUEL VALVE LEVER

OFF

Choke Rod

The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually. Pull the rod out toward CLOSED to enrich the mixture for cold starting.

OPEN

CCLLOOSSEEDD

CHOKE ROD

Voltage Selector Switch (Dual Voltage System)

The voltage selector switch switches the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position.

Switch Position 120/240V:

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

120V ONLY:

ONLY the 120V receptacles can be used. Do not use the 120/240V receptacle in this position. The most power will be available at the 30A 120V locking plug receptacle.

VOLTAGE SELECTOR SWITCH

112200//224400VV

112200VV OONNLLYY

120V ONLY

GROUND TERMINAL

120/240V

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.

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). The Oil Alert system should not take the place of checking the oil level before each use. If the engine stops and will not restart, check the engine oil level (see page ) before troubleshooting in other areas.

Auto Throttle

The Auto Throttle

System

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 reduce noise levels when no load is applied to the generator.

OFF:

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

OFF

Circuit Breaker

The circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle, or if the ground fault circuit interrupter (GFCI) detects a ground fault current.

Check the following if the circuit breaker switches OFF automatically:

When the GFCI RESET button is extended (page 18):

Unplug all appliances from the receptacles and check the

−

appliance for any defects as described in TROUBLESHOOTING (page 50).

After making repairs, push the GFCI RESET button then turn the circuit breaker ON.

When the GFCI RESET button is not extended:

Check that the appliance is working properly and does not exceed

−

the rated load capacity of the circuit before switching the circuit breaker ON again.

The circuit breaker may be used to switch the generator power on or off.

GFCI RESET BUTTON

CIRCUIT BREAKER

OFF

Circuit Protector

The circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at the 20A 120V, 30A 120V locking plug, or 120/240V locking plug receptacle. If a 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 circuit protector ON.

CIRCUIT PROTECTORS

＊

OFF

＊

1: Except EB3800X

Ground Fault Circuit Interrupter (GFCI)

Using the generator in rain or snow or near water can lead to death from electric shock. Keep the generator dry.

All receptacles on the generator are protected by a ground fault circuit interrupter (GFCI) for protection against the shock hazard of ground fault current. The GFCI has TEST and RESET buttons and is connected to the circuit breaker.

An example of ground fault current is the current that would flow through a person who is using an appliance with faulty insulation and, at the same time, is in contact with an electrical ground such as a plumbing fixture, wet floor, or earth.

The ground fault circuit interrupter will not protect against short circuits or overloads. The circuit breaker in the control panel that supplies power to the circuit provides that protection (refer to circuit breaker on page ).14

GFCI TEST BUTTON

GFCI RESET BUTTON CIRCUIT BREAKER

Observe the following precautions to ensure proper GFCI operation and to reduce shock hazards:

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

Inspect cords and plugs, and replace if damaged.

Do not use cord lengths greater than 164 feet (50 meters), and do not use multiple tools and appliances with built-in noise filters. Such use may activate the GFCI and trip the circuit breaker.

Inspection:

Always check GFCI operation before using the generator.

You risk electric shock if you operate this generator with a faulty GFCI (ground fault circuit interrupter).

Test GFCI before use.

If the GFCI fails testing, do not use your generator. Contact your Honda dealer.

Unplug all tools and appliances from the generator.

Start the engine.

Turn the circuit breaker to the ON position.

Turn the Auto Throttle switch to the OFF position.

Press the GFCI TEST button. The RESET button should extend, and the circuit breaker should switch to the OFF position.

If the GFCI and circuit breaker do not function as described, take the generator to an authorized Honda generator dealer for repair.

GFCI RESET BUTTON GFCI TEST BUTTON

CIRCUIT BREAKER

OFF

Press the GFCI RESET button. The RESET button should stay in, flush with its base plate.

With the RESET button in and engine running, turn the circuit breaker to the ON position. The circuit breaker should remain in the ON position. The circuit breaker will not remain in the ON position if the RESET button is extended.

If the GFCI and circuit breaker do not function as described, take the generator to an authorized Honda generator dealer for repair.

GFCI RESET BUTTON

CIRCUIT BREAKER

During generator use, if the GFCI RESET button extends and the circuit breaker trips, this usually indicates a faulty power tool, appliance, or cord.

If that occurs, perform test steps 1 through 6 to verify that the GFCI and circuit breaker are in proper working order. If the GFCI and circuit breaker test correctly, then you will know that the fault is in the power tool, appliance, or cord. Repair or replace the faulty power tool, appliance, or cord before further use.

GENERATOR USE

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. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers.

Improper connections to a building’s electrical system can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored. Consult the utility company or a qualified electrician.

Ground System

Honda portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire. If the generator is tested by a receptacle tester, it will show the same ground circuit condition as for a home receptacle.

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.

AC Applications

Before connecting an appliance or power cord to the generator:

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

If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance or the rated load capacity of the generator has been exceeded.

Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

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

Limit operation requiring maximum power to 30 minutes. Maximum power is:

EB3800X: EB5000X:

EB6500X: For continuous operation (longer than 30 minutes), do not exceed the rated power. Rated power is:

EB3800X:

EB5000X:

EB6500X: The total power requirements (VA) of all appliances connected must be considered. Appliance and power tool manufacturers usually list rating information near the model number or serial number.

3.8 kVA

5.0 kVA

6.5 kVA

3.3 kVA

4.5 kVA

5.5 kVA

AC Operation

Check GFCI operation before each use (see page 18 ).

Start the engine (see page ).

Turn the voltage selector switch to either position.

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

use the 120V and 120/240V receptacles simultaneously. If you are

NOT using the 120/240V receptacle, then select the ‘‘120V ONLY’’

position.

Make sure that the GFCI RESET button is pushed in (flush with its

base plate).

Switch ON the AC circuit breaker.

Plug in the appliance.

Be sure that all appliances are in good working order before connecting them to the generator. If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn off the ignition switch lever immediately. Then disconnect the appliance and examine it for signs of malfunction.

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

VOLTAGE SELECTOR SWITCH

GFCI RESET BUTTON

AACC CCIIRRCCUUIITT PPRROOTTEECCTTOORRSS

＊

1: Except EB3800X

AC CIRCUIT BREAKER

Do not exceed the current limit specified for any one receptacle. If an overloaded circuit causes the AC circuit breaker or circuit protector to switch OFF, reduce the electrical load on the circuit, wait a few minutes and then reset the circuit breaker or circuit protector.

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.

EB3800X:

○

120V 30A 120V 20A (in total) 120V 20A (in total)

4A 4B

& 120/240V 20A

○

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.

POWER CIRCUIT 1

120V/240V

120V ONLY

POWER CIRCUIT 2

POWER CIRCUIT 1

Voltage Selector Switch

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

Available Power

27.5A at 120V

20A at 120V

None

13.8A at 120V

13.8A at 240V

120V ONLY

120V/240V

ReceptacleSwitch Position

4A-4B

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 preceding table and the total load does not exceed 27.5 amps.

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 13.8 amps.

Set of

Receptacles

134B

＋＋

24A

＋

Total Current

Available

13.8A

Power Producing

Circuit

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.

EB5000X:

○

120V 30A 120V 20A (in total) 120V 20A (in total)

4A 4B

& 120/240V 30A

○○

Power Producing Circuits

POWER CIRCUIT 1

120V/240V

120V ONLY

POWER CIRCUIT 2

POWER CIRCUIT 1

Voltage Selector Switch

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

Available Power

30A at 120V

20A at 120V

30A at 120V

None

18.8A at 120V

18.8A at 240V

120V ONLY

120V/240V

ReceptacleSwitch Position

4A-4B

120V ONLY Position

120V/240V Position

Set of

Receptacles

134B

＋＋

24A

＋

Total Current

Available

18.8A

Power Producing

Circuit

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.

EB6500X:

○

120V 30A 120V 20A (in total) 120V 20A (in total)

4A 4B

& 120/240V 30A

○○

Power Producing Circuits

POWER CIRCUIT 1

120V/240V

120V ONLY

POWER CIRCUIT 2

POWER CIRCUIT 1

Voltage Selector Switch

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

Available Power

30A at 120V

20A at 120V

30A at 120V

None

22.9A at 120V

20A at 120V

22.9A at 240V

120V ONLY

120V/240V

ReceptacleSwitch Position

4A-4B

120V ONLY Position

120V/240V Position

Set of

Receptacles

134B

＋＋

24A

＋

Total Current

Available

22.9A

Power Producing

Circuit

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.

OFF

AUTO THROTTLE SWITCH

OFF

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 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.

PRE-OPERATION CHECK

Engine Oil

ChecktheoillevelBEFORE EACH USE with the generator on a level surface and the engine stopped.

Use 4-stroke motor oil that meets or exceeds the requirements for API service category SJ or later (or equivalent). Always check the API SERVICE label on the oil container to be sure it includes the letters SJ or later (or equivalent).

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

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

Check the oil level by inserting the dipstick into the filler neck without screwing it in.

If the level is low, fill to the upper limit of the oil filler neck with the recommended oil.

AMBIENT TEMPERATURE

OIL FILLER HOLE

OIL FILLER CAP/DIPSTICK

UPPER LEVEL

Refueling

With the engine stopped, check the fuel level 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 engine and keep heat, sparks, and flame away.

Refuel only outdoors.

Wipe up spills immediately.

Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Refuel carefully to avoid spilling fuel. Do not fill above the upper limit mark.

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.

FUEL GAUGE

FUEL TANK CAP

UPPER LIMIT MARK

NON-CALIFORNIA TYPE CALIFORNIA TYPE

UPPER LIMIT MARK

TETHER

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.

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.

STARTING THE ENGINE/STOPPING THE ENGINE

Starting the Engine

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.

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 generator.

1. 31

Perform the

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

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

Turn the fuel valve lever to the ON position.

Pull the choke rod to the CLOSE position.

Make sure the Auto Throttle switch is in the OFF position, or more

time will be required for warm up.

Move the engine switch to the ON position.

Pull the starter grip lightly until resistance is felt, then pull briskly.

AC Operation

(see page ) for connecting loads to the

PRE-OPERATION CHECK

(see page ).

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

Push the choke rod to the OPEN position as the engine warms up.

If you wish to use the Auto Throttle system, turn the Auto Throttle

switch to the AUTO position after the engine has warmed up for 2 or

3 minutes.

Stopping the Engine In an emergency:

To stop the engine in an emergency, move the engine switch to the OFF position.

In normal use:

Turn the AC circuit breaker to the OFF position.

Move the engine switch to the OFF position.

Turn the fuel valve lever to the OFF position.

MAINTENANCE

The Importance of Maintenance

Good maintenance is essential for safe, economical, and trouble free operation. It will also help reduce air pollution.

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.

To help you properly care for your generator, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your generator under severe conditions, such as sustained high-load or high-temperature operation, or use it in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

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.

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.

Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, Honda Genuine parts or their equivalents for repair or replacement.

Maintenance Schedule

REGULAR SERVICE PERIOD (3)

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

Engine oil

Air cleaner

GFCI Canister (California type) Purge tube (California type) Charge tube (California type) Sediment cup Spark plug

Spark arrester Idle speed Valve clearance Combustion chamber Fuel tank and filter Fuel tube

Service more frequently when used in dusty areas.

(1)

These items should be serviced by an authorized Honda generator dealer, unless the owner

(2)

has the proper tools and is mechanically proficient. See the Honda Shop Manual. For commercial use, log hours of operation to determine proper maintenance intervals.

(3)

Check level Change Check Clean Check Check

Check

Clean Check-adjust Replace Clean Check-adjust Check-adjust Clean

Clean Check

Each

use

First

month

20 Hrs.

After every 500 Hrs.(2)

Every 2 years (Replace if necessary)(2)

Every

3 months

50 Hrs.

(1)

Every 2 years (2)

Every

6 months

100 Hrs.

(2)

Every

year

300 Hrs.

(2) (2)

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

Engine Oil Change

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

Place a suitable container below the engine to catch the oil, then

remove the oil drain plug and sealing washer, remove the oil filler

cap/dipstick, and drain the oil.

Reinstall the oil drain plug and a new sealing washer. Tighten the

plug securely.

Refill with the recommended oil (see page ) and check the oil level.

3. 31

SEALING WASHER

OIL DRAIN PLUG

OILFILLER CAP/DIPSTICK

UPPER LEVEL

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.

Air Cleaner Service

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas.

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

Unsnap the two air cleaner cover clips, remove the air cleaner cover,

Distributor’s Limited Warranty.

and remove the element.

CLIP (2)

ELEMENT

AIR CLEANER COVER

Wash the air cleaner element in a solution of household detergent

ELEMENT

and warm water, then rinse thoroughly, or wash in nonflammable or

high flashpoint solvent. Allow the air cleaner element to dry

thoroughly.

Soak the air cleaner element in clean engine oil and squeeze out the

excess oil. The engine will smoke during initial startup if too much

oil is left in the air cleaner element.

Reinstall the air cleaner element and the cover.

• properly hooked

• improperly hooked

ELEMENT

AIR CLEANER COVER

CLIP (2)

Fuel 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.

Turn the fuel valve lever to the OFF position. Remove the sediment

1. cup, O-ring, and filter. Clean the sediment cup and filter in nonflammable or high flash

2. point solvent. Reinstall the filter, new O-ring, and sediment cup.

3. Turn the fuel valve lever ON and check for leaks.

FUEL VALVE LEVER

OOFFFF

FUEL FILTER

O-RING (Replace)

SEDIMENT CUP

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 has been running, let it to cool before servicing the spark plug.

Remove the spark plug cap.

1. Clean any dirt from around the spark plug base.

2. Use a spark plug wrench to remove the spark plug.

SPARK PLUG WRENCH

SPARK PLUG CAP

Visually inspect the spark plug. Discard it if the insulator is cracked, chipped, or fouled.

Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefullybendingtheside electrode. The gap should be:

0.028 0.031 in (0.7 0.8 mm)

−−

0.028 0.031 in

−

(0.7 0.8 mm)

−

SEALING WASHER

Check that the spark plug sealing washer is in good condition, and

6. thread the spark plug in by hand to prevent cross-threading.

Afterthesparkplugisseated,tightenwithasparkplugwrenchto compress the washer.

If installing a new spark plug, tighten 1/2 turn after the spark plug

−

seats to compress the washer. If reinstalling a used spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the

−

washer.

A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

Spark Arrester Maintenance

If the generator has been running, the muffler will be very hot. Allow it to cool before proceeding.

The spark arrester must be serviced every 100 hours to maintain its efficiency.

Clean the spark arrester as follows:

Loosen the screw by the exhaust port of the muffler and remove the spark arrester.

Use a brush to remove carbon deposits from the spark arrester screen. Inspect the screen for breaks or tears and replace it if necessary.

Install the spark arrester in the reverse order of removal.

SPARK ARRESTER SCREEN

SCREW

SPARK ARRESTER

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.

Distributor’s Limited Warranty

The does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the carburetor, sediment cup (if applicable) and/ or fuel tank.

Service according to the table below:

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

Less than 1 month 1 to 2 months

2 months to 1 year

1 year or more

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.

No preparation required Fill with fresh gasoline and add gasoline stabilizer *. Fill with fresh gasoline and add gasoline stabilizer *. Drain the carburetor float bowl (page 46 ). Drain the fuel sediment cup (page 41 ). Fill with fresh gasoline and add gasoline stabilizer *. Drain the carburetor float bowl (page 46 ). Drain the fuel sediment cup (page 41 ). 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 39 ). After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting.

Draining the Fuel Tank and Carburetor

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container.

DRAIN SCREW

Place a suitable gasoline container below the sediment cup, and use

2. a funnel to avoid spilling gasoline.

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

3. valve lever to the ON position.

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

4. cup (see page ).

Engine Oil

Change the engine oil (see page ).

Remove the spark plug (see page ).

Pour a teaspoon (5 10 cc) of clean engine oil into the cylinder.

Pull the starter grip several times to distribute the oil in the cylinder.

Reinstall the spark plug.

Slowly pull the starter grip until resistance is felt. At this point, the

−

piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion. Return the starter grip gently.

STARTER GRIP

Align the notch on the starter pulley with the hole at the top of recoil starter.

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 fuel valve in the OFF position to reduce the possibility of leakage.

Place the generator on a level surface. Tilting 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 chapter of this manual (see page ).31

If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting.

If the cylinder was coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

PRE-OPERATION CHECK

TRANSPORTING

When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite.

Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator.

Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.

When transporting the generator by loading it on to a vehicle, secure to the generator frame as shown.

TROUBLESHOOTING

When the engine will not start:

Is there fuel in the tank?

YES

Is there enough oil in the engine?

YES

Is the spark plug in good condition?

YES

Is the fuel reaching the carburetor?

YES

If the engine still does not start, take the generator to an authorized Honda generator dealer.

Refill the fuel tank. (page 32)

Add the recommended oil. (page 31)

Readjust gap and dry the spark plug. Replace it if necessary. (page 42)

Clean the fuel sediment cup. (page 41)

To check:

Turn off the engine switch and loosen the drain screw. (page 46)

Turn the fuel valve to ON. Fuel should flow from the drain when the fuel valve is turned ON.

No electricity at the AC receptacles:

〈〉

When the GFCI RESET button is extended

Unplug all appliances and equipment, and inspect the GFCI operation. (refer to page 18)

The GFCI RESET button is not extended.

When the GFCI RESET button is not extended

〈〉

Is the AC circuit breaker ON?

YES

Is the AC circuit protector ON?

The GFCI RESET button is extended again.

Take the generator to an authorized Honda generator dealer.

Replace the electrical appliance or equipment. Take the electrical appliance or equipment to an electrical shop for repair.

Turn the AC circuit breaker ON. (page 14)

Reset the circuit protector. (page 15)

YES

Check the electrical appliance or equipment for any defects.

DEFECTS

NO DEFECTS

Take the generator to an authorized Honda generator dealer.

Replace the electrical appliance or equipment. Take the electrical appliance or equipment to an electrical shop for repair.

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 are very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

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 emissions from your Honda engine 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 the intake, fuel, or exhaust systems.

Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters.

Problems That May Affect Emissions

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

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with applicable emission regulations. We recommend the use of Honda Genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

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

Maintenance Schedule

on page . Remember that this

Air Index

(Models certified for sale in California)

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 information.

Descriptive Term Applicable to Emission Durability Period

Emission Control System Warranty

for additional

Moderate 50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)

Intermediate 125 hours (0 80 cc, inclusive)

250 hours (greater than 80 cc)

Extended 300 hours (0 80 cc, inclusive)

500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

−

EB3800X

WIRING DIAGRAM

EB5000X, EB6500X

Dimensions

Type

Description code Length Width Height Dry mass [weight]

Engine

Type

Engine type Displacement [Bore Stroke] Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug

Model

SPECIFICATIONS

EB3800X

California type

(AC type)

40.9 in (1,040 mm)

27.2 in (691 mm)

30.4 in (773 mm)

186.3 lbs (84.5 kg)

California type

(AC type)

4-stroke, overhead valve, single cylinder

14.8 cu-in (242 cm

×××

[2.9 2.3 in (73.0 58.0 mm)]

Forced air cooling

Transistorized magneto

1.2 US qt (1.1 L)

6.21 US gal (23.5 L)

BPR5ES (NGK) W16EPR-U (DENSO)

Non-California type

(AN type)

EAJC

185 lbs (84 kg)

GX240

Non-California type

(AN type)

)

8.2 : 1

3,600 rpm

Generator

Model

Rated voltage Rated frequency

AC output Rated current

Rated output Maximum output

EB3800X

120/240 V

60 Hz

27.5/13.8 A

3.3 kVA

3.8 kVA

Tuneup Specifications

ITEM SPECIFICATION MAINTENANCE

−−

Spark plug gap Valve clearance

Other specifications

0.028 0.031 in (0.7 0.8 mm)

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

No other adjustments needed.

Refer to page 42 See your authorized Honda dealer.

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

Dimensions

Type

Description code Length Width Height Dry mass [weight]

Engine

Type

Engine type Displacement

[Bore Stroke] Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug

Model

EB5000X

California type

(AC, ACH type)

41.3 in (1,049 mm)

27.2 in (691 mm)

30.4 in (773 mm)

215.6 lbs (97.8 kg) 214.5 lbs (97.3 kg)

California type

(AC, ACH type)

4-stroke, overhead valve, single cylinder

20.6 cu-in (337 cm

××

[3.2 2.5 in (82.0 64.0 mm)]

Forced air cooling

Transistorized magneto

1.2 US qt (1.1 L)

6.21 US gal (23.5 L)

BPR5ES (NGK) W16EPR-U (DENSO)

Non-California type

(AN, ANH type)

EAKC

GX340

Non-California type

(AN, ANH type)

)

8.0 : 1

3,600 rpm

Generator

Model

Rated voltage Rated frequency

AC output Rated current

Rated output Maximum output

EB5000X

120/240 V

60 Hz

37.5/18.8 A

4.5 kVA

5.0 kVA

Tuneup Specifications

ITEM MAINTENANCESPECIFICATION

−−

Spark plug gap Valve clearance

Other specifications No other adjustments needed.

0.028 0.031 in (0.7 0.8 mm)

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

Refer to page 42 See your authorized Honda dealer.

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

Dimensions

Type

Description code Length Width Height Dry mass [weight]

Engine

Type

Engine type Displacement

[Bore Stroke] Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug

Model

EB6500X

California type

(AC, ACH type)

41.9 in (1,064 mm)

27.2 in (691 mm)

30.4 in (773 mm)

220.7 lbs (100.1 kg) 219.6 lbs (99.6 kg)

California type

(AC, ACH type)

4-stroke, overhead valve, single cylinder

23.7 cu-in (389 cm

××

[3.5 2.5 in (88.0 64.0 mm)]

Forced air cooling

Transistorized magneto

1.2 US qt (1.1 L)

6.21 US gal (23.5 L)

BPR5ES (NGK)

Non-California type

(AN, ANH type)

EALC

GX390

Non-California type

(AN, ANH type)

)

8.0 : 1

3,600 rpm

W16EPR-U (DENSO)

Generator

Model

Rated voltage Rated frequency

AC output Rated current

Rated output Maximum output

EB6500X

120/240 V

60 Hz

45.8/22.9 A

5.5 kVA

6.5 kVA

Tuneup Specifications

ITEM MAINTENANCESPECIFICATION

−−

Spark plug gap Valve clearance

Other specifications No other adjustments needed.

0.028 0.031 in (0.7 0.8 mm)

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

Refer to page 42 See your authorized Honda dealer.

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

ASSEMBLY

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.

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 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.

Unpacking

Remove the generator and loose parts box from the carton.

Compare the loose parts with the inventory list below.

Tools Required:

12 mm wrench (2), pliers

Loose Parts (Wheel kit, hanger 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.

Ref. No.

1 2 3 4 5 6 7 8

9 10 11 12 13

Description Wheel Axle Left upper handle assy Right upper handle assy Left handle bracket Right handle bracket Stand Hanger Hanger bracket

8 16 mm Flange bolt 20 mm Washer

4.0 28 mm Cotter pin 8 mm Flange nut

Qty.

2 1 1 1 1 1 2 1 2

2 2 4

Hanger Kit Installation

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

Fit the end tabs of the hanger through the bracket slots, and bolt the

2. brackets to the hanger and tighten securely.

17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)

TORQUE:

−− −

8 16 mm FLANGE BOLT (4)

HANGER

HANGER BRACKET (2)

280 mm (11 in)

GENERATOR SIDE

Handle Installation

Install the right and left handles on the generator upper frame using the brackets and 6 flange bolts.

TORQUE:

LEFT UPPER HANDLE ASSY

LEFT HANDLE BRACKET

17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)

−− −

8 16 mm FLANGE BOLT (4)

RIGHT UPPER HANDLE ASSY

RIGHT HANDLE BRACKET

Wheel Kit Installation

Apply grease to the axle shaft as shown below, and install the two

1. wheels on the axle shaft using the washers and split pins.

Install the axle assembly on the generator using four 8 16 mm

flange bolts and 8 mm flange nuts.

Install the two stands on the under frame using four 8 16 mm

flange bolts.

−− −

TORQUE:

8 16 mm FLANGE BOLT (4)

17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)

LONGER

8 16 mm FLANGE BOLT (4)

GENERATOR SIDE

20 mm WASHER (2)

STAND (2)

AXLE

8 mm FLANGE NUT (4)

WHEEL (2)

4.0 30 mm COTTER PIN (2)

Engine Oil

The generator is shipped

WITHOUT OIL

in the engine.

Place the generator on a level surface. Add enough of the recommended oil to bring the oil level to the top of the oil filler neck.

Use a 4-stroke motor oil that meets the requirements for API service category SJ or later (or equivalent).

SAE 10W-30 is recommended for general, all-temperature use. Other viscosities in the chart may be used when the temperature in your area is within the indicated range.

Do not overfill the engine with oil. If the engine is overfilled, the excess oil may get transferred to the air cleaner housing and air filter.

AMBIENT TEMPERATURE

OIL FILLER HOLE

OIL FILLER CAP/DIPSTICK

UPPER LEVEL

Fuel

Refer to page .

BEFORE OPERATION

Before using your generator, you should become familiar with information contained in the following chapters and sections:

GENERATOR SAFETY

CONTROLS

GENERATOR USE

STARTING THE ENGINE

STOPPING THE ENGINE

(page )

WARRANTY SERVICE INFORMATION

DEALER LOCATOR INFORMATION

To find an authorized Honda Servicing Dealer anywhere in the United States:

visit our web site:

www.hondapowerequipment.com/dealerlocator/

CUSTOMER SERVICE INFORMATION

Servicing dealership personnel are trained professionals. They should be able to answer most questions you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help. Almost all problems are solved in this way.

If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Power Equipment Customer Relations Office. You can write to:

American Honda Motor Co., Inc. Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400 8:30 am to 7:00 pm ET

When you write or call, please give us this information:

Model and serial number (see pages and )

Name of dealer who sold the generator to you

Name and address of dealer who services your generator

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

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 888292-5395 or visit www.hondapowerequipment.com

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

INDEX

..............................................................................................ASSEMBLY . 57

..............................................................COMPONENT IDENTIFICATION . 8

................................................................................................CONTENTS . 3

..............................................................................................CONTROLS . 10

System . 13

..........................................................................................Choke Rod . 11

...................................................................................Circuit Breaker . 14

....................................................................................Engine Switch . 10

System . 13

........................................................................................Starter Grip . 10

...................................................................................GENERATOR USE . 20

.................................................................................AC Applications . 21

.....................................................................................AC Operation . 22

System . 29

.................................................................................Ground System . 20