Honda EG5000CL, EG4000CL, EG6500CL Owner's Manual

Owner’s Manual

GENERATOR

EG4000CL • EG5000CL • EG6500CL

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

See page 67 for
Initial Use Instructions

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductiveharm.

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.

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
understand its coverage and your responsibilities of ownership. The

Distributor’s Limited Warranty

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.

Distributor’s Limited Warranty

is a separate document that should

to fully

1

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

Safety Messages

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

These signal words mean:

Safety Headings

Safety Section

Instructions

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

−

on the generator.

−

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

such as

−

how to use this generator correctly and safely.

−

be or if

be or if

be if you don’t follow

IMPORTANT SAFETY INFORMATION

GENE R ATOR SAFE TY.

−

.

2

CONTENTS

............................................................................................CONTROLS .13

........................................................................................Starter Grip .13

.......................................................................................Choke Lever .14

.............................................................................................FEATURES .17

System .17

.........................................................................................Fuel Gauge .18

................................................................................GENERATOR SAFETY .6

..................................................IMPORTANT SAFETY INFORMATION .6

......................................................................Operator Responsibility .6

.................................................................Carbon Monoxide Hazards .6

.......................................................................Electric Shock Hazards .7

........................................................................Fire and Burn Hazards .7

.................................................................................Refuel With Care .8

.................................................................SAFETY LABEL LOCATIONS .9

........................................................................CONTROLS & FEATURES .11

...........................................COMPONENT & CONTROL LOCATIONS .11

....................................................................................Engine Switch .13

................................................................................Fuel Valve Lever .14

...................................................................Voltage Selector Switch .15

.............................................................................AC Circuit Breaker .15

.........................................................................AC Circuit Protectors .16

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

.....................................................Automatic Engine Stop Function .17

..............................................................................Oil Alert Function .17

........................................................Overspeed Detection Function .17

............................................Abnormal Voltage Detection Function .17

...............................................................................Ground Terminal .18

...............................................................................BEFORE OPERATION .19

................................................ARE YOU READY TO GET STARTED? .19

.........................................................................................Knowledge .19

..............................................IS YOUR GENERATOR READY TO GO? .19

...............................................................................Check the Engine .20

3

CONTENTS

..............................................................................................OPERATION .21

...................................................................................................Tools .35

.....................................................SAFE OPERATING PRECAUTIONS .21

......................................................................STARTING THE ENGINE .22

......................................................................STOPPING THE ENGINE .25

.....................................................................................AC OPERATION .26

.................................................................................AC Applications .27

...................................................................AC Receptacle Selection .28

.................................................................Power Producing Circuits .28

...................................................................Voltage Selector Switch .29

................................................................................STANDBY POWER .31

...............................Connections to a Building’s Electrical System .31

.................................................................................System Ground .31

.......................................................................Special Requirements .32

.............................................................SERVICING YOUR GENERATOR .33

.............................................THE IMPORTANCE OF MAINTENANCE .33

......................................................................MAINTENANCE SAFETY .34

............................................................................Safety Precautions .34

................................................................MAINTENANCE SCHEDULE .35

...........................................................................................REFUELING .36

...............................................................FUEL RECOMMENDATIONS .37

..................................................................ENGINE OIL LEVEL CHECK .38

...........................................................................ENGINE OIL CHANGE .39

....................................................ENGINE OIL RECOMMENDATIONS .40

........................................................................AIR CLEANER SERVICE .41

..................................................AIR CLEANER ELEMENT CLEANING .43

.........................................................................SPARK PLUG SERVICE .44

................................................................SPARK ARRESTER SERVICE .46

.................................................................SEDIMENT CUP CLEANING .47

4

..................................................................................................STORAGE .48

....................................................................STORAGE PREPARATION .48

.............................................................................................Cleaning .48

.....................................................................................................Fuel .48

..........................................................................................Engine Oil .51

...................................................................STORAGE PRECAUTIONS .52

................................................................REMOVAL FROM STORAGE .52

CONTENTS

......................................................................................TRANSPORTING .53

.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54

...................................................................ENGINE WILL NOT START .54

.......................................................................ENGINE LACKS POWER .55

..............................................NO POWER AT THE AC RECEPTACLES .56

..........................................TECHNICAL & CONSUMER INFORMATION .57

................................................................TECHNICAL INFORMATION .57

...................................................................Serial Number Location .57

....................Carburetor Modification for High Altitude Operation .58

............................................Emission Control System Information .59

.............................................................................................Air Index .61

....................................................................................Specifications .62

.................................................................................Wiring Diagram .63

...............................................................CONSUMER INFORMATION .65

..............................................................Dealer Locator Information .65

...........................................................................Honda Publications .65

.........................................................Customer Service Information .66

..................................................................INITIAL USE INSTRUCTIONS .67

...........................................................................................ENGINE OIL .67

.......................................................................................................FUEL .68

...........................................................................BEFORE OPERATION .69

.....................................................................................REGISTRATION .69

....................................................................................OPTIONAL PARTS .70

.....................................................................HANDLE INSTALLATION .70

.................................................................WHEEL KIT INSTALLATION .71

........................................................................................................INDEX .72

.............................QUICK REFERENCE INFORMATION .Inside back cover

5

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

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

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

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

GENERATOR SAFETY

10

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

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

ENGINE SWITCH

AC CIRCUIT BREAKER

VOLTAGE SELECTOR SWITCH

AC CIRCUIT PROTECTORS

120V/240V AC

＊

112200VV RREECCEEPPTTAACCLLEESS

RECEPTACLE

GROUND TERMINAL

＊

:

Except EG4000CL

11

CONTROLS & FEATURES

CHOKE LEVER

FUEL VALVE LEVER

AIR CLEANER

SEDIMENT CUP

FUEL GAUGE

STARTER GRIP

OIL DRAIN PLUG

OIL FILLER CAP/
DIPSTICK

12

FUEL TANK CAP

SPARK PLUG

MUFFLER

CONTROLS

Engine Switch

The engine switch controls the
ignition system.

CONTROLS & FEATURES

OOFFFF

−

OFF Stops the engine.

−

ON Running position, and for
starting.

Starter Grip

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

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.

ENGINE SWITCH

DDiirreeccttiioonn ttoo ppuullll

OONN

ST

ARTER GRIP

13

CONTROLS & FEATURES

Fuel Valve Lever

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

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

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

Choke Lever

The choke is used to provide
proper starting mixture when the
engine is cold. It can be opened
and closed by operating the choke
lever manually. Move the choke
lever to the CLOSED position to
enrich the mixture for cold
starting.

CCLLOOSSEEDD

OONN

FU

EL VALVE LEVER

OOFFFF

CHOKE LEVER

14

O

PEN

CONTROLS & FEATURES

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

VOLTAGE SELECTOR SWITCH

120V/240V

120V ONLY

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.

ON

OFF

AC CIRCUIT BREAKER

15

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

＊

120V 30A

AC CIRCUIT PROTECTOR
for Receptacle

AC CIRCUIT PROTECTOR
for Receptacle

16

120V 20A

120V 20A

＊

: Except EG4000CL

120V/240V 20A (EG4000CL)
120V/240V 30A (EG5000CL, EG6500CL)

AC CIRCUIT PROTECTOR

ON

OFF

PUSH

FEATURES

CONTROLS & FEATURES

Oil Alert

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 ) 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.

System

38

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.

17

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

FULL EMPTY

Ground Terminal

FUEL TANK CAP

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

18

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 ).27

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.

19

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 ). 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 ). A dirty air cleaner element will
restrict air flow to the carburetor, reducing engine and generator
performance.

Check the fuel level (see page ). Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.

38

41

36

20

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, review chapters

GENERATOR SAFETY

page ).

19

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.

(see page ) and

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.

6

BEFORE OPERATION

(see

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.

21

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
IS YOUR GENERATOR READY TO GO
AC OPERATION

Make sure that the AC circuit

1.

(see page ) for connecting loads to the generator.

26

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

2.

ON position.

on page and perform the

checks (see page ). Refer to

CIRCUIT BREAKER

AC

FUEL VALVE LEVER

21

19

OFF

OONN

22

To start a cold engine, move the

3.

choke lever to the CLOSED
position.
To restart a warm engine, leave
the choke lever in the OPEN
position.

Turn the engine switch to the

4.

ON position.

OPERATION

CHOKE LEVER

CCLLOOSSEEDD

OOPPEENN

OONN

Pull the starter grip lightly until

5.

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.

E

NGINE SWITCH

DDiirreeccttiioonn ttoo ppuullll

STARTER GRIP

23

OPERATION

If the choke lever was moved to

6.

the CLOSED position to start
the engine, gradually move it to
the OPEN position as the
engine warms up.

CHOKE LEVER

OOPPEENN

24

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.

Turn off or disconnect all appliances that are connected to the

1.

generator.

Move the AC circuit breaker to

2.

the OFF position.

AC CIRCUIT BREAKER

OOFFFF

Turn the engine switch to the

3.

OFF position.

OOFFFF

Turn the fuel valve lever to the

4.

OFF position.

EL VALVE

FU
LEVER

E

NGINE SWITCH

OOFFFF

25

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.

Turn the voltage selector switch

1.

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 the 120V/240V receptacle,
then select the ‘‘120V ONLY’’
position.

VOLTAGE SELECTOR SWITCH

120V/240V

120V ONLY

Start the engine (see page ).

2.

Switch ON the AC circuit breaker.

3.

Plug in the appliance.

4.

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

Turn on the appliance.

5.

22

AC CIRCUIT BREAKER

ON

PLUG

＊

: Except EG4000CL

AC CIRCUIT PROTECTORS

＊

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.

26

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:

EG4000CL:
EG5000CL:
EG6500CL:

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

EG4000CL:
EG5000CL:
EG6500CL:

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.

4.0 kVA

5.0 kVA

6.5 kVA

3.6 kVA

4.5 kVA

5.5 kVA

27

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.

＊

: Except EG4000CL

＊

4B

○

○

4A

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

4A 4B

& 120V/240V 20A (EG4000CL)

○○

120V/240V 30A (EG5000CL, EG6500CL)

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.

120V/240V 120V ONLY

POWER
CIRCUIT 1

POWER
CIRCUIT 2

28

POWER CIRCUIT 2

POWER CIRCUIT 1

OPERATION

Voltage Selector Switch

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

Switch

Position

120V ONLY

120V/240V

Receptacle

1

2

3

4A

4B

1

2

3

4A-4B

EG4000CL EG5000CL EG6500CL

30A at 120V

20A at 120V

20A at 120V

20A at 120V

None

15.0A at 120V

15.0A at 120V

15.0A at 120V

15.0A at 240V

Available Power

30A at 120V

20A at 120V

20A at 120V

30A at 120V

None

18.8A at 120V

18.8A at 120V

18.8A at 120V

18.8A at 240V

30A at 120V

20A at 120V

20A at 120V

30A at 120V

None

22.9A at 120V

20A at 120V

20A at 120V

22.9A at 240V

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 below and the total load does not exceed the total
current available.

Total Current Available:

30.0 A

37.5 A

45.8 A

(EG4000CL)
(EG5000CL)
(EG6500CL)

29

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

(EG4000CL)
(EG5000CL)
(EG6500CL)

＊

Set of

Receptacles

＋＋

134B

＋

24A

Total Current Available

15.0A

15.0A

18.8A

18.8A

EG6500CLEG5000CLEG4000CL

22.9A

22.9A

Power Producing

Circuit

1

2

30

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.

31

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.

32

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.

33

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.

34

MAINTENANCE SCHEDULE

SERVICING YOUR GENERATOR

REGULAR SERVICE PERIOD (3)
Perform at every indicated month
or operating hour interval,

whichever comes first.
ITEM
Engine oil

Air cleaner

Sediment cup
Spark plug

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

(1)

Service more frequently when used in dusty areas.

(2)

These items should be serviced by your Honda servicing dealer, unless you have the proper
tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.
For commercial use, log hours of operation to determine proper maintenance intervals.

(3)

Check level
Change
Check
Clean
Clean
Check-adjust
Replace
Clean
Check-adjust
Check-adjust
Clean

Clean
Check
Check
Check
Check

Each

Every 2 years (Replace if necessary) (2)

First

month

use

After every 1,000 Hrs. (2)

months

or

20 Hrs.

50 Hrs.

Every 2 years (2)
Every 2 years (2)
Every 2 years (2)

Every

3

or

(1)

Every

months

100 Hrs.

Every

year

6

or

300 Hrs.

or

(2)
(2)

(2)

page

38
39
41
43
47
44
44
46

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

Tools

A box wrench and wrench handle are supplied with the generator.
Use the supplied tools to perform maintenance tasks. Using an
incorrect tool may damage the generator.

35

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.

36

FUEL GAUGE

SERVICING YOUR GENERATOR

UPPER LEVEL MARK (RED)

FUEL TANK CAP

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 ) for

48

additional information regarding fuel deterioration.

37

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.

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

1.

Insert and remove the dipstick without screwing it into the oil filler

2.
hole. Check the oil level shown on the dipstick.

If the oil level is low, fill to the outer edge of the oil filler hole with

3.
the recommended oil (see page ).

Screw in the oil filler cap/dipstick securely.

4.

OIL FILLER CAP/DIPSTICK

40

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.

38

SERVICING YOUR GENERATOR

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 used oil,

1.
and then remove the oil filler cap/dipstick, 12 15 mm drain plug,
and sealing washer.

×

Allow the used oil to drain completely, and then reinstall the 12 15

2.
mm drain plug and a new sealing washer. Tighten the plug securely.

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

3.
to the outer edge of the oil filler hole (see page ).

Screw in the oil filler cap/dipstick securely.

4.

UPPER LIMIT

SEALING
WASHER

12 15 mm

×

OIL DRAIN PLUG

OIL FILLER CAP/DIPSTICK

38

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.

39

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.

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.

−

AMBIENT TEMPERATURE

40

SERVICING YOUR GENERATOR

AIR CLEANER SERVICE

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

1.

Free the hooks from the setting pins on the air cleaner case and

2.
remove the air cleaner cover to the right side of the frame pipe,
taking care not to damage the air cleaner cover.

Remove the air cleaner element from the air cleaner case.

3.

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 .
Replace the air cleaner element if it is damaged.

HOOK

AIR CLEANER CASE

43

SETTING PIN

AIR CLEANER COVER

FRAME PIPE

AIR CLEANER ELEMENT

CLIP

41

SERVICING YOUR GENERATOR

Reinstall the air cleaner element in the air cleaner case.

5.

Set the hooks of the air cleaner cover to the setting pins securely,

6.
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

GOOD NO GOOD

Distributor’s Limited Warranty.

HOOK

SETTING PIN

42

AIR CLEANER CASE

AIR CLEANER ELEMENT

AIR CLEANER COVER

CLIP

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.

Wash the air cleaner element in a solution of household detergent

1.
and warm water and 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

2.
excess oil. The engine will smoke during initial startup if too much
oil is left in the air cleaner element.

4. Squeeze1. Soak 3. Oil2. Squeeze to Dry

Do not twist.Do not twist.

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

3.
Be careful to prevent dirt from entering the air duct that leads to the
carburetor.

43

SERVICING YOUR GENERATOR

SPARK PLUG SERVICE

Recommended spark plugs:

To ensure proper engine operation, the spark plug must be properly
gapped and free of deposits.

BPR5ES (NGK)

An incorrect spark plug can cause engine damage.

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

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

1.
spark plug area.

Remove the spark plug with a spark plug wrench.

2.

SPARK PLUG WRENCH

44

SPARK PLUG CAP

SERVICING YOUR GENERATOR

Visually inspect the spark plug. Replace it if the electrodes are worn

3.
or if the insulator is cracked, chipped, or fouled.

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

4.
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

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

5.
thread the spark plug in by hand to prevent cross-threading.

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

6.
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.

Attach the spark plug cap.

7.

45

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:

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

1.

SPARK ARRESTER5 mm SCREWS

Use a brush to remove carbon deposits from the spark arrester

2.
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

Install the spark arrester in the reverse order of removal.

3.

46

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.

Turn the engine switch to the OFF position.

1.

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.

Turn the fuel valve lever to the

2.
OFF position; then remove the
sediment cup and the O-ring.
Discard the O-ring.

3.

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

Reinstall the new O-ring and

4.
sediment cup, and tighten the
sediment cup securely.

Turn the fuel valve lever to the

5.
ON position and check for leaks.

FUEL VALVE LEVER

O-RING
(Replace.)

SEDIMENT CUP

OFF

47

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, and/or fuel tank.

48

STORAGE

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 50 ).
Drain the fuel sediment cup (page 47 ).
Fill with fresh gasoline and add gasoline
stabilizer *.
Drain the carburetor float bowl (page 50 ).
Drain the fuel sediment cup (page 47 ).
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.

49

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.

Place a suitable gasoline container below the carburetor, and use a

1.
funnel to avoid spilling fuel.

Remove the drain bolt and sealing washer and drain the gasoline

2.
from the carburetor.

SEALING WASHER

DRAIN BOLT

50

STORAGE

After all the gasoline has drained into the container, tighten the

3.
drain bolt securely.

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

4.
a funnel to avoid spilling gasoline.

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

5.
valve lever to the ON position.

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

6.
cup (see page ).

FUEL VALVE LEVER

47

Engine Oil

47

OONN

Change the engine oil (see page 39).

1.

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

2.
(5 cc) of clean engine oil into the cylinder. Crank the engine several
revolutions to distribute the oil, then reinstall the spark plug.

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

3.
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.

Al

ign the notch on the starter pulley

with the hole at the top of recoil starter.

51

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 ) 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.

25

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 ).

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

51

page ) 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.

19

BEFORE OPERATION

chapter

52

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.

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.

53

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause Correction

Fuel valve lever OFF.
Choke OPEN.

Engine switch OFF.

Out of fuel.
Bad fuel; generator stored
without treating or draining
gasoline, or refueled with bad
gasoline.
Low oil level caused Oil Alert
to stop engine.

Spark plug faulty, fouled, or
improperly gapped.
Spark plug wet with fuel
(flooded engine).
Fuel filter restricted,
carburetor malfunction,
ignition malfunction, valves
stuck, etc.

Turn lever ON (p. 22).
Move to CLOSED unless engine
is warm (p. 23).
Turn engine switch to ON
(p. 23).
Refuel (p. 36).
Drain fuel tank and carburetor
(p. 50).
Refuel with fresh gasoline
(p. 36).
Add oil (p. 38).
Turn engine switch to OFF and
then restart the engine.
Gap or replace spark plug
(p. 44).
Dry and reinstall spark plug.

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

54

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE LACKS POWER

Possible cause Correction

Air filter restricted.

Bad fuel; generator stored
without treating or draining
gasoline, or refueled with bad
gasoline.
Fuel filter restricted,
carburetor malfunction,
ignition malfunction, valves
stuck, etc.

Clean or replace air filter
(p. 41 43).
Drain fuel tank and carburetor
(p. 50).
Refuel with fresh gasoline
(p. 36).
Take the generator to an
authorized Honda servicing
dealer, or refer to the shop
manual.

−

55

TAKING CARE OF UNEXPECTED PROBLEMS

NO POWER AT THE AC RECEPTACLES

Possible Cause Correction

AC circuit breaker left in the
OFF position after starting.
AC circuit protector tripped.

Faulty power tool or
appliance.

Faulty generator.

Switch AC circuit breaker ON
(p. 26).
Check AC load and reset AC
circuit protector (p. 16).
Replace or repair power tool or
appliance.
Stop and restart the engine.
Take the generator to an
authorized Honda servicing
dealer, or refer to the shop
manual.

56

TECHNICAL & CONSUMER INFORMATION

TECHNICAL INFORMATION

Serial Number Location

FRAME SERIAL NUMBERENGINE SERIAL NUMBER

Record the engine and frame serial numbers 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:

57

TECHNICAL & CONSUMER 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.

58

TECHNICAL & CONSUMER 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.

59

TECHNICAL & CONSUMER 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
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.

MAINTENANCE SCHEDULE

on page . Remember that

35

60

TECHNICAL & CONSUMER 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
information.

Emission Control System Warranty

for additional

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)

−

−

−

61

TECHNICAL & CONSUMER INFORMATION

Specifications

Dimensions

Model
Type
Description code
Length
Width
Height
Dry mass [weight]

Engine

Model

Engine type
Displacement

〔× 〕

Bore Stroke

Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug

EG4000CL

147.7 lbs
(67.0 kg)

GX270T2

4-stroke, overhead valve, single cylinder

16.5 cu-in (270 cm )

〔×

3.03 2.28 in

×〕

(77.0 58.0 mm)

8.5:1

EG5000CL

AT type

EBEC

26.8 in (681 mm)

20.9 in (530 mm)

22.5 in (571 mm)

173.1 lbs
(78.5 kg)

GX390T2

23.7 cu-in (389 cm

〔×

3.46 2.52 in

×〕

(88.0 64.0 mm)

8.2:1
3,600 rpm
Forced air

CDI magneto

1.2 US qt (1.1 L)

6.34 US gal (24.0 L)
BPR5ES (NGK)

EG6500CL

EBBCEBGC

178.6 lbs
(81.0 kg)

)

Generator

Model

Type

Rated voltage
AC
output

Tuneup

Spark plug gap

Valve clearance (cold)

Other specifications

Rated frequency

Rated current

Rated output

Maximum output

ITEM

30.0 A/15.0 A

3.6 kVA

4.0 kVA

−

0.028 0.031 i n

−

(0.7 0.8 mm)
IN: 0.15 0.02 mm
EX: 0.20 0.02 mm

±

±

No other adjustments needed.

37.5 A/18.8 A

AT type

120 V/240 V

60 Hz

4.5 kVA

5.0 kVA

Refer to page 44

See your authorized
Honda dealer.

EG6500CLEG4000CL EG5000CL

45.8 A/22.9 A

5.5 kVA

6.5 kVA

MAINTENANCESPECIFICATION

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

62

TECHNICAL & CONSUMER INFORMATION

Wiring Diagram

Abbreviations Wire color code

Symbol
AC O
AC CB
CBB
D-AVR

D-CDI
ESw
EgB
EX W
FrB
Fu
FW
GeB
GND
GT
IgC
J/B
MW
OLSw
PoC
SP
VSSw

Part name
AC Outlet
AC Circuit Breaker
Control Box Block
Digital-Automatic
Voltage Regulator
Digital-CDI
Engine Switch
Engine Block
Exciter Winding
Frame Block
Fuse
Field Winding
Generator Block
Ground
Ground Terminal
Ignition Coil
Junction Box
Main Winding
Oil Level Switch
Power Coil
Spark Plug
Voltage Selector
Switch

Bl
Y
Bu
G
R
W
Br
Lg
Gr
Lb
O
P

Engine switch

OFF
ON

BLACK
YELLOW
BLUE
GREEN
RED
WHITE
BROWN
LIGHT GREEN
GRAY
LIGHT BLUE
ORANGE
PINK

DC12VIG

63

TECHNICAL & CONSUMER INFORMATION

EG4000CL: 1 · EG5000CL, EG6500CL: 2

2

＊

＊＊

1

＊

64

TECHNICAL & CONSUMER INFORMATION

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 [phone] 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.

65

TECHNICAL & 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: [phone]:30 am to 7:00 pm ET

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

Model and serial numbers (see page )
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

57

66

INITIAL USE INSTRUCTIONS

ENGINE OIL

The generator is shipped in the engine.

Place the generator on a level surface.

1.

Remove the oil filler cap/dipstick.

2.

Add enough SAE 10W-30 API service category SJ or later (or

3.
equivalent) oil to bring the oil level to the upper limit of the oil filler
hole. SAE 10W-30 oil is recommended for general use; for additional
recommendations, see page .

Do not overfill the engine with oil.

excess oil may be transferred to the air cleaner housing and air filter.

Screw in the oil filler cap/dipstick securely.

4.

WITHOUT OIL

40

If the engine is overfilled, the

OIL FILLER CAP/DIPSTICK

UPPER LIMIT

OIL FILLER HOLE

67

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 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.

37

Remove the fuel tank cap.

1.

Fuel carefully to avoid spilling fuel. Do not fill the fuel tank above the

2.
upper level mark (red) on the fuel strainer.

After refueling, reinstall the fuel tank cap securely.

3.

FUEL TANK CAP

FUEL STRAINER

UPPER LEVEL MARK (RED)

UPPER LEVEL MARK

68

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.

BEFORE OPERATION

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

GENERATOR SAFETY

CONTROLS & FEATURES

BEFORE OPERATION

OPERATION

STARTING THE ENGINE

STOPPING THE ENGINE

MAINTENANCE SCHEDULE

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.

(page )

(pages )

(pages )

21

(pages )

(page )

−

610

(pages )

19 20

(page )

11 18

−

−

22 24

25

35

−

69

OPTIONAL PARTS

HANDLE INSTALLATION

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

−− −

TORQUE:

LEFT UPPER HANDLE ASSY RIGHT UPPER HANDLE ASSY

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

×

8 16 mm FLANGE BOLT (4)

RIGHT HANDLE
BRACKET

LEFT HANDLE BRACKET

70

OPTIONAL PARTS

WHEEL KIT INSTALLATION

Install the two wheels on the axle shaft using the plain washers and

1.
split pins.

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

2.

×

flange bolts and 8 mm flange nuts.

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

3.

×

flange bolts.

TORQUE:

−− −

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

×

8 16 mm FLANGE BOLT (8)

LONGER

UNDER FLAME

AXLE SHAFT

GENERATOR
SIDE

20 mm
PLAIN WASHER (2)

WHEEL (2)

STAND (2)

8 mm FLANGE NUT (4)

×

428mm
SPLIT PIN (2)

71

INDEX

A

B

C

..............................................Abnormal Voltage Detection Function . 17

...................................................................................AC Applications . 27

...............................................................................AC Circuit Breaker . 15

..........................................................................AC Circuit Protectors . 16

...................................................................................AC OPERATION . 26

....................................................................AC Receptacle Selection . 28

................................................AIR CLEANER ELEMENT CLEANING . 43

......................................................................AIR CLEANER SERVICE . 41

...............................................................................................Air Index . 61

...............................................ARE YOU READY TO GET STARTED? . 19

......................................................Automatic Engine Stop Function . 17

....................................................................BEFORE OPERATION . 19, 69

..................................................................Carbon Monoxide Hazards . 6

......................Carburetor Modification for High Altitude Operation . 58

................................................................................Check the Engine . 20

.........................................................................................Choke Lever . 14

...............................................................................................Cleaning . 48

..........................................COMPONENT & CONTROL LOCATIONS . 11

.................................Connections to a Building’s Electrical System . 31

..............................................................CONSUMER INFORMATION . 65

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

..........................................................................................CONTROLS . 13

..................................................................CONTROLS & FEATURES . 11

..........................................................Customer Service Information . 66

D

72

................................................................Dealer Locator Information . 65

E

F

G

INDEX

.........................................................................Electric Shock Hazards . 7

..............................................Emission Control System Information . 59

.....................................................................ENGINE LACKS POWER . 55

......................................................................................Engine Oil . 51, 67

.........................................................................ENGINE OIL CHANGE . 39

................................................................ENGINE OIL LEVEL CHECK . 38

..................................................ENGINE OIL RECOMMENDATIONS . 40

.....................................................................................Engine Switch . 13

.................................................................ENGINE WILL NOT START . 54

...........................................................................................FEATURES . 17

..........................................................................Fire and Burn Hazards . 7

.................................................................................................Fuel . 48, 68

..........................................................................................Fuel Gauge . 18

.............................................................FUEL RECOMMENDATIONS . 37

..................................................................................Fuel Valve Lever . 14

..........................................................................GENERATOR SAFETY . 6

.................................................................................Ground Terminal . 18

H

...................................................................HANDLE INSTALLATION . 70

.............................................................................Honda Publications . 65

I

................................................IMPORTANT SAFETY INFORMATION . 6

............................................................INITIAL USE INSTRUCTIONS . 67

............................................IS YOUR GENERATOR READY TO GO? . 19

K

...........................................................................................Knowledge . 19

73

INDEX

M

N

O

P

Q

R

....................................................................MAINTENANCE SAFETY . 34

..............................................................MAINTENANCE SCHEDULE . 35

............................................NO POWER AT THE AC RECEPTACLES . 56

................................................................................Oil Alert Function . 17

System . 17

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

.........................................................................................OPERATION . 21

.......................................................................Operator Responsibility . 6

..............................................................................OPTIONAL PARTS . 70

..........................................................Overspeed Detection Function . 17

...................................................................Power Producing Circuits . 28

........................QUICK REFERENCE INFORMATION . Inside back cover

..........................................................................................REFUELING . 36

...................................................................................Refuel With Care . 8

.....................................................................................REGISTRATION .69

..............................................................REMOVAL FROM STORAGE . 52

74

INDEX

S

...................................................SAFE OPERATING PRECAUTIONS . 21

................................................................SAFETY LABEL LOCATIONS . 9

...............................................................SEDIMENT CUP CLEANING . 47

..............................................................................Safety Precautions . 34

.....................................................................Serial Number Location . 57

.......................................................SERVICING YOUR GENERATOR . 33

..............................................................SPARK ARRESTER SERVICE . 46

.......................................................................SPARK PLUG SERVICE . 44

........................................................................Special Requirements . 32

......................................................................................Specifications . 62

..............................................................................STANDBY POWER . 31

..........................................................................................Starter Grip . 13

....................................................................STARTING THE ENGINE . 22

....................................................................STOPPING THE ENGINE . 25

............................................................................................STORAGE . 48

.................................................................STORAGE PRECAUTIONS . 52

..................................................................STORAGE PREPARATION . 48

...................................................................................System Ground . 31

T

.................................TAKING CARE OF UNEXPECTED PROBLEMS . 54

....................................TECHNICAL & CONSUMER INFORMATION . 57

...............................................................TECHNICAL INFORMATION . 57

............................................THE IMPORTANCE OF MAINTENANCE . 33

....................................................................................................Tools . 35

.................................................................................TRANSPORTING . 53

V

W

...............................................................Voltage Selector Switch . 15, 29

...............................................................WHEEL KIT INSTALLATION . 71

...................................................................................Wiring Diagram . 63

75

QUICK REFERENCE INFORMATION

Fuel

Engine Oil

Spark Plug

Maintenance

Type

Type

Type
Electrode Gap
Before each
use
First 20 hours
Subsequent

Regular unleaded gasoline with
apumpoctaneratingof86or
higher
SAE 10W-30, API SJ or later (or
equivalent), for general use
(page 40)
BPR5ES (NGK)

−−

0.028 0.031 in (0.7 0.8 mm)
Check engine oil level.
Check air cleaner element.
Change engine oil.
See Maintenance Schedule
(page 35)

31Z30600
00X31-Z30-6000

Printed on

Recycled Paper

AHM.35.2011.02

PRINTED IN U.S.A.