Honda EM3500SX Owner's Manual

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

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 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.

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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.

Page 4

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

−

Safety Headings

such as

−

You WILL KILLED SERIOUSLY HURT

you don’t follow instructions.

You CAN KILLED SERIOUSLY HURT

you don’t follow instructions.

You CAN HURT

tions.

be or if

be if you don’t follow instruc-

IMPORT ANT SAFET Y

INFORMATION.

such as

Safety Section Instructions

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

−

how to use this generator correctly and safely.

−

GENERATOR SAFETY.

−

Page 5

......................................................................................................SAFETY . 5

..............................................................SAFETY LABEL LOCATIONS . 5

.....................................................................SAFETY INFORMATION . 7

..............................................................COMPONENT IDENTIFICATION . 9

..............................................................................................CONTROLS . 11

....................................................................................Engine Switch . 11

.....................................................................................Recoil Starter . 11

................................................................................Fuel Valve Lever . 12

..........................................................................................Choke Rod . 12

...................................................................................Circuit Breaker . 13

................................................................................Circuit Protector . 13

...............................................................................Ground Terminal . 13

System . 14

..........................................................................................Pilot Lamp . 15

..........................................................................................Volt Meter . 15

..........................................................................................Engine Oil . 25

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

........................................................................Auto-throttle System . 14

............................Voltage Selector Switch (Dual Voltage System) . 15

.....................................................................................DC Terminals . 16

..........................................................................DC Circuit Protector . 16

...................................................................................GENERATOR USE . 17

..................................Connections to a Building Electrical System . 17

.................................................................................Ground System . 17

.................................................................................AC Applications . 18

.....................................................................................AC Operation . 19

...................................................................AC Receptacle Selection . 20

.....................................................................................DC Operation . 21

....................................................Disconnecting the battery cables . 22

........................................................................Auto-throttle System . 23

....................................................................High Altitude Operation . 24

.......................................................................PRE-OPERATION CHECK . 25

.....................................................................Fuel Recommendation . 26

........................................................................STARTING THE ENGINE . 29

........................................................................STOPPING THE ENGINE . 30

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......................................................................................MAINTENANCE . 31

......................................................The Importance of Maintenance . 31

..........................................................................Maintenance Safety . 32

............................................Emission Control System Information . 33

.............................................................................................Air Index . 36

.....................................................................Maintenance Schedule . 37

............................................................................Engine Oil Change . 38

...........................................................................Air Cleaner Service . 39

...........................................................Fuel Sediment Cup Cleaning . 40

............................................................................Spark Plug Service . 41

............................................................Spark Arrester Maintenance . 42

..................................................................TRANSPORTING/STORAGE . 43

.............................................................................TROUBLESHOOTING . 45

.................................................................................WIRING DIAGRAM . 47

....................................................................................SPECIFICATIONS . 48

.................................................INSTALLATION OF OPTIONAL PARTS . 49

.................................................WARRANTY SERVICE INFORMATION . 55

......................................................................................................INDEX . 56

Page 7

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.

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Page 9

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 exhaust can cause loss of consciousness and may lead to death.

If you run the generator in an area that is confined, or even partially enclosed, the air you breathe could contain a dangerous amount of exhaust gas. To keep exhaust gas from accumulating, provide adequate ventilation.

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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 electrical components on the control panel, before each use. Moisture or ice can cause a malfunction or short circuit in electrical components which could result in electrocution.

Do not connect to a building 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.

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.

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CHOKE ROD

FUEL VALVE LEVER

VOLT METER PILOT LAMP

ENGINE SWITCH

COMPONENT IDENTIFICATION

VOLTAGE SELECTOR SWITCH

AC CIRCUIT BREAKER

AC CIRCUIT PROTECTOR

AIR CLEANER

RECOIL STARTER GRIP

DC CIRCUIT PROTECTOR

DC OUTPUT TERMINAL

ENGINE SERIAL NUMBER

AUTO-THROTTLE SWITCH

OIL DRAIN PLUG

GROUND TERMINAL

OIL FILLER CAP

AC RECEPTACLES

Page 12

FUEL TANK CAP FUEL METER

SPARK PLUG CAP

FRAME SERIAL NUMBER

MUFFLER

Record the engine and frame serial numbers for your future

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

Frame serial number:

Engine serial number:

Page 13

CONTROLS

ENGINE SWITCH

To start and stop the engine.

Key position: OFF: ON: START:

ENGINE SWITCH

Return the key to the ON position once the engine has started. Do not use the starter for more than 5 seconds at a time. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.

To stop the engine. Key can be removed/inserted. To run the engine after starting. To start the engine by operating the starter motor.

OFF

START

RECOIL STARTER

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

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

STARTER GRIP

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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.

CHOKE ROD

OPEN

CLOSED

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CIRCUIT BREAKER

The AC circuit breaker will automatically switch OFF if there is a short circuit or an overload of the generator at the AC receptacle. If the AC circuit breaker is switched OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the AC circuit before switching the AC circuit breaker ON again. The AC circuit breaker may be used to switch the generator AC power ON or 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 120V 20A or 120/240V 20A 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 to the ON position.

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.

OOFFFF

GROUND TERMINAL

AC CIRCUIT BREAKER

AC CIRCUIT PROTECTOR

OFF

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OIL ALERT SYSTEM

The Oil Alert

system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert

system will automatically stop the engine (the engine switch will remain in the ON position). If the engine stops and will not restart, check the engine oil level (see page ) before troubleshooting in other areas.

OIL FILLER HOLE

OIL FILLER CAP

UPPER LEVEL

Auto-throttle System

The auto-throttle system automatically reduces engine speed when all loads are turned off or disconnected. When appliances are turned on or reconnected, the engine returns to the rated speed.

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.

AUTO

OFF

AUTO-THROTTLE SWITCH

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Pilot Lamp

The pilot lamp is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the 120 or 120/240 volt receptacles. If the pilot light is illuminated, the volt meter should be displaying 120 or 240 volts depending on the position of the voltage selector switch.

When the auto-throttle is in the AUTO position, and there is no load connected to the generator, the engine will run slower and the pilot light will be dimmer than at normal operating speed.

Volt Meter

The volt meter displays the voltage the generator is producing depending on the position of the voltage selector switch. If the voltage selector switch is in the ‘‘120/240V’’ position, the volt meter will display 240 volts. If the voltage selector switch is in the ‘‘120V ONLY’’ position, the volt meter will display 120 volts.

VOLTAGE SELECTOR SWITCH (DUAL VOLTAGE SYSTEM)

The voltage selector 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.

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. Rated power will be available at the 120V twist lock receptacle.

VOLT METER

PILOT LAMP

120V

112200 224400VV

VOLTAGE SELECTOR SWITCH

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DC Terminals

The DC terminals may ONLY be used for charging 12 volt automotive type batteries. The terminals are colored red to identify the positive ( ) terminal and black to identify the negative ( ) terminal. The battery must be

−

＋

connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal).

DC CIRCUIT PROTECTOR

The DC circuit protector automatically shuts off the DC battery charging circuit when the DC charging circuit is overloaded, when there is a problem with the battery, or when the connections between the battery and the generator are improper.

DC CIRCUIT PROTECTOR

NEGATIVE TERMINAL (BLACK)

POSITIVE TERMINAL (RED)

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GENERATOR USE

CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM

Connections for standby power to a building 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 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 not 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 which must be observed.

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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 if 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 OFF, but will shorten the service life of the generator.

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

3.5 kVA For continuous operation, do not exceed the rated power. Rated power is:

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

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AC OPERATION

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, but require more power from the 120V locking plug receptacle, then select the ‘‘120V ONLY’’ position.

Switch ON the AC circuit breaker.

Plug in the appliance.

VOLTAGE SELECTOR SWITCH

AC CIRCUIT BREAKER

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

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

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AC RECEPTACLE SELECTION

The generator has two separate main power producing circuits. These two circuits supply equal power to different receptacles shown when the voltage selector switch is in the 120/240V position.

When two or more receptacles are used; prevent overloading by dividing the load between the two power circuits.

The chart below shows the rated load in amperes that can be connected to each receptacle to balance the generator.

The total rated ampere draw is 25.0A.

Main power circuit

Receptacles powered

Power distribution

by each main circuit Main Circuit I Main Circuit II

2and3

2 4=12.5A max.

＋

1=12.5A max.

The table shows the specifications when the 120/240V locking

plug receptacle is used for 120V. Example: Receptacle 2 has a 10A load connected to it. Receptacle 3 has a 10

A load connected to it. Both receptacles are powered by main power circuit I. The equation tells us that the total power draw on circuit I is 20A. This is a substantial overload of this circuit. To eliminate the excess power draw on circuit I, the load from receptacle 2 should be switched to receptacle 1. Now circuit I is powering the 10A load (less than 12.5A) and circuit II is powering the 10A load (less than 12.5A).

120V 30A

120V 20A

120/240V 20A

(LOCKING PLUG)

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DC OPERATION

The DC terminals may ONLY be used for charging 12 volt automotive type batteries.

Connecting the battery cables:

Before connecting the battery charging cable to a battery that is

1. installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( ) terminal.

−

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using batteries.

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

Connect the positive ( ) battery cable to the battery positive ( )

Wash hands after handling.

＋＋

terminal. Connect the other end of the positive ( ) battery cable to the

3. generator positive ( ) terminal.

DC CIRCUIT PROTECTOR

＋

POSITIVE TERMINAL (RED)

NEGATIVE TERMINAL (BLACK)

Connect the negative ( ) battery cable to the battery negative ( )

−−

terminal. Connect the other end of the negative ( ) battery cable to the

5. generator negative ( ) terminal. Start the generator.

−

Do not start the vehicle while the battery charging cable is connected and the generator is running. The vehicle or the generator may be damaged.

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

Disconnecting the battery cables:

Stop the engine.

Disconnect the negative ( ) battery cable from the generator negative ( ) terminal.

Disconnect the other end of the negative ( ) battery cable from the battery negative ( ) terminal.

Disconnect the positive ( ) battery cable from the generator positive ( ) terminal.

Disconnect the other end of the positive ( ) battery cable from the battery positive ( ) terminal.

Connect the vehicle ground battery cable to the battery negative ( )

−

＋

−

＋

−

terminal.

Reconnect the vehicle grounded battery cable.

DC CIRCUIT PROTECTOR

NEGATIVE TERMINAL (BLACK)

POSITIVE TERMINAL (RED)

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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. Turn the auto-throttle 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. Turn the auto-throttle to the OFF position and connect the appliance to the generator. If the engine still will not reach normal operating speed, check that the appliance does not exceed the rated load capacity of the generator. To avoid extended warm-up periods, keep the switch OFF until the engine reaches operating temperature.

The auto-throttle system is not effective for use with appliances that require only momentary power. If the tool or appliance will be turned ON and OFF quickly, the auto-throttle switch should be in the OFF position.

AUTO

OFF

AUTO-THROTTLE SWITCH

Page 26

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 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.

Page 27

PRE-OPERATION CHECK

ENGINE OIL

Engine oil is a major factor affecting engine performance and service life. Non detergent and 2-stroke engine oils will damage the engine and are not recommended.

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 classification SJ. Always check the API SERVICE label on the oil container to be sure it includes the letters SJ.

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 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 top of the oil filler neck with the recommended oil.

SAE Viscosity Grades

AMBIENT TEMPERTURE

OIL FILLER HOLE

OIL FILLER CAP

UPPER LEVEL

Page 28

FUEL RECOMMENDATION

Check the fuel level gauge.

Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer.

Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored. Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely. Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine. Avoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN.

Fuel tank capacity:

4.49 US gal (17.0

, 3.74 Imp gal)

FUEL STRAINERFUEL TANK CAP

FUEL LEVEL GAUGE

Use unleaded gasoline with a pump octane rating of 86 or higher.

This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

Page 29

Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern.

If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda generator dealer.

Running the engine with persistent spark knock or pinging can cause engine damage.

Running the engine with persistent spark knock or pinging is misuse, and the by misuse.

Distributor’s Limited Warranty

does not cover parts damaged

Page 30

Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.

If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump.

The following are the EPA approved percentages of oxygenates:

ETHANOL

MTBE

METHANOL

If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline.

Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.

(ethyl or grain alcohol) 10% by volume You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name ‘‘Gasohol’’.

(methyl tertiary butyl ether) 15% by volume You may use gasoline containing up to 15% MTBE by volume.

(methyl or wood alcohol) 5% by volume Youmayusegasolinecontainingupto5% methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.

Page 31

STARTING THE ENGINE

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.

2. The automatic choke will be closed if the engine is cold. If you want

3. to operate the choke manually, pull the choke rod out to the CLOSED position. Make sure the auto-throttle switch is in the OFF position, or more

4. time will be required for warm up. Turn the engine switch to the ON position.

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

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

With electric starter: Connect the battery cables to the generator. (page )

1. Turn the engine switch to the START position and hold it there for 5

2. seconds or until the engine starts.

(Optional kit)

Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again. If the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged.

When the engine starts, allow the engine switch to return to the ON position.

If you have manually closed the choke, push it to the OPEN position

7. as the engine warms up. If you wish to use the auto-throttle system, turn the auto-throttle

8. switch to the AUTO position after the engine has warmed up for 2 or 3 minutes.

Page 32

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. Disconnect DC battery charging cables.

Turn the engine switch to the OFF position.

Turn the fuel valve lever to the OFF position.

Page 33

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.

Page 34

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.

−

Be sure there is adequate ventilation whenever you operate the engine.

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 nonflammable 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, genuine Honda parts or their equivalents for repair or replacement.

Page 35

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 lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

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.

Page 36

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.

Page 37

Replacement Parts

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

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

Maintenance

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

Page 38

AIR INDEX

An Air Index Information hang tag/label was applied to this engine 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 Warranty

Applicable to Emissions Durability PeriodDescriptive Term

for additional

Moderate

Intermediate

Extended

The Air Index Information hang tag must remain on the generator until it is sold. Remove the hang tag before operating the generator.

50 hours (0 65 cc)

125 hours (greater than 65 cc)

125 hours (0 65 cc) 250 hours (greater than 65 cc)

300 hours (0 65 cc) 500 hours (greater than 65 cc)

−

Page 39

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3) Every

ITEM

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

Engine oil

Air cleaner

Sediment Cup Spark pulg

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

Emission related items.

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 Change Check Clean Clean Clean-Adjust Replace Clean Clean-Adjust Check-Adjust Clean

Clean Check

Before

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

6 months

100 Hrs.

(2)

year

300 Hrs.

(2) (2)

Page 40

ENGINE OIL CHANGE

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

Remove the drain plug and sealing washer, remove the oil filler cap, and drain the oil.

Reinstall the drain plug and sealing washer. Tighten the plug securely.

3. 25

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

Oil capacity:

OIL DRAIN PLUG UPPER LEVEL

1.2 US qt (1.1

, 1.0 Imp qt)

Wash your hands with soap and water after handling used oil.

Please dispose of used motor oil and containers in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station or recycling center for reclamation. Do not throw it in the trash, pour it on the ground or down a drain.

Page 41

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.

Never run the generator without the air filter. Rapid engine wear will result.

Unsnap the air cleaner cover clips,

AIR CLEANER COVER

CLIP

remove the air cleaner cover, and remove the element.

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

CLIP

Soak the air filter in clean engine oil and squeeze out the excess oil.

AIR CLEANER ELEMENT

The engine will smoke during initial startup if too much oil is left in the air filter.

Reinstall the air cleaner element

4. and the cover.

ELEMENT

Page 42

FUEL SEDIMENT CUP CLEANING

The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned.

Turn the fuel valve lever to the OFF position. Remove the sediment cup, O-ring, and filter.

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

Reinstall the filter, O-ring, and sediment cup.

Turn the fuel valve lever ON and check for leaks.

FUEL VALVE LEVER

SEDIMENT CUP

OFF

FUEL FILTER

O-RING

SEDIMENT CUP

Page 43

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.

If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

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.

PLUG WRENCH

PLUG CAP

Visually inspect the spark plug. Discard it if the insulator is cracked

4. or chipped. Clean the spark plug with a wire brush if it is to be reused. Measure the plug gap with a feeler gauge.

5. Correct as necessary by carefully bending the side electrode.

The gap should be:

0.028 0.031 in (0.70 0.80 mm)

−−

0.028 0.031 in (0.70 0.80 mm)

−−

Page 44

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

6. the spark plug in by hand to prevent cross-threading. Afterthesparkplugisseated,tightenwithasparkplugwrenchto

7. 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.

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and could damage the engine. Never use spark plugs which have an improper heat range. Use only the recommended spark plugs or equivalent.

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

1. 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

SPARK ARRESTER

Page 45

TRANSPORTING/STORAGE

When transporting the generator, turn the engine switch OFF and 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.

Before storing the unit for an extended period:

1. Be sure the storage area is free of excessive humidity and dust.

2. 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

No preparation required

Fill with fresh gasoline and add gasoline

conditioner .

Fill with fresh gasoline and add gasoline

conditioner .

＊

Drain the carburetor float bowl. (page 44 ).

Drain the fuel sediment cup. (page 40 ).

Fill with fresh gasoline and add gasoline

conditioner .

＊

Drain the carburetor float bowl. (page 44 ). 1 year or more

Drain the fuel sediment cup. (page 40 ).

Remove the spark plug. Put a tablespoon 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 38 ).

After removal from storage, drain the stored

gasoline into a suitable container, and fill

with fresh gasoline before starting.

＊

Use gasoline conditioners that are formulated to extend storage life. Contact your authorized Honda generator dealer for conditioner recommendations.

Page 46

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

Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.

DRAIN SCREW

Change the engine oil. (page )

Remove the spark plug, and pour about a tablespoon of clean

engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug.

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.

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

Page 47

When the engine will not start:

TROUBLESHOOTING

Is there fuel in the tank?

YES

Is there enough oil in the engine?

YES

Isthereaspark from the spark plug?

Be sure there is no spilled fuel around the spark plug. Spilled fuel may ignite.

YES

Is the fuel reaching the carburetor?

Still NO spark

Replace the spark plug.

To check:

Remove the spark plug cap and clean any dirt from around the spark plug.

Remove the spark plug and install the sparkpluginthe plug cap.

Set the plug side electrode on the cylinder head.

Crank the engine, sparks should jump across the gap.

Refill the fuel tank.

Add the recommended oil.

Take the generator to an authorized Honda generator dealer.

Clean the fuel sediment cup.

YES

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

To check:

Turn off the engine

1) switch and loosen the drain screw. Turn the fuel valve to

2) ON. Fuel should flow from the drain when the fuel valve is turned ON.

DRAIN SCREW

Page 48

No electricity at the AC receptacles:

Is the AC circuit breaker ON.

YES

Check the electrical appliance or equipment for any defects.

DEFECTS

NO DEFECTS

Turn the AC circuit breaker ON.

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.

Page 49

WIRING DIAGRAM

Page 50

SPECIFICATIONS

Dimensions

Model Power product description code Length Width Height Dry weight

Engine

Model Engine type Displacement

〔〕 ××

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

EM3500SX EA6

23.8 in (605 mm)

19.5 in (495 mm)

19.1 in (485 mm)

143.3 lbs (65.0 kg)

GX240K1

4-stroke, overhead valve, single cylinder

14.8 cu-in (242 cm [2.9 2.3 in (73 58 mm)]

8.2 : 1 3,600 r.p.m. Forced air Transistorized magneto

1.2 US qt (1.1

4.49 US gal (17.0 BPR5ES (NGK) W16EPR-U (DENSO)

)

, 1.0 Imp qt)

, 3.74 Imp gal)

Generator

Model

Type

Rated voltage Rated frequency

AC output Rated ampere

Rated output Maximum output

DC output

EM3500SX A 120/240 V 60 Hz 25/12.5 A

3.0 kVA

3.5 kVA

Only for charging 12V automotive batteries. Maximum charging output = 8.3A

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

Tune-up Specifications

ITEM SPECIFICATION MAINTENANCE

−−

Spark plug gap Valve clearance

Other specifications No other adjustments needed.

0.028 0.031 in (0.70 0.80 mm)

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

Refer to page: 41 See your authorized Honda dealer

Page 51

INSTALLATION OF OPTIONAL PARTS

Remote Control Kit

Install the relay box on the right side of the generator.

Remove the blind 8 P connector from the back of the control box and connect the relay box connector instead.

Connect the remote control cable to the remote control and relay box.

REMOTE CONTROL CABLE

RELAY BOX

REMOTE CONTROL BOX

Connect the blind connector when not using the remote control. Engine will not start unless the blind connector is connected.

Page 52

Remote Control Box

PILOT LAMP ENGINE

SWITCH

STARTER BUTTON

Starting the engine with remote control

Turn the fuel valve to the ON position.

1. Turn the auto-throttle switch to the OFF position.

2. Turn off the engine switch at the generator and remove the key.

3. Turn the relay box switch to the ON position.

RELAY BOX

Page 53

Turn the engine switch at the remote control box to the ON position.

Press the starter button untill the pilot lamp comes on.

Stopping the engine

Turn the engine switch at the remote control box to the OFF position.

Turn the relay box switch to the OFF position.

Turn the fuel valve to the OFF position.

Page 54

4 Wheel Kit Installation

Install the four wheels on the axle shaft.

1. Install the axle assembly on the generator using two bolts and nuts.

2. Install the shaft with wheel stopper facing engine side.

Inside

WHEEL STOPPER

Longer end

Shorter end

Page 55

BATTERY TRAY KIT

Install the battery guard on the frame. Set the battery tray on the battery guard and tighten the bolts.

Route the starter cable under the tank and connect it to the starter solenoid.

Connect the ground cable to the generator rear housing.

Set the battery on the battery tray and secure with the battery bracket. Connect the starter cable to the battery positive ( ) terminal first, then to the negative ( ) terminal. When disconnecting, disconnect at the battery negative ( ) terminal first.

Install the battery guard plate on the battery guard.

−

＋

Page 56

BATTERY GUARD

BATTERY

Use a battery rated at 12V-18-35AH or more

STARTER SOLENOID

STARTER CABLE (positive)

GROUND CABLE

STARTER CABLE

BATTERY BRACKET

BATTERY GUARD PLATE

BATTERY TRAY

BATTERY GUARD

Page 57

WARRANTY SERVICE INFORMATION

Servicing 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 to:

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

Or telephone: (770) 497-6400

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

910

Page 58

INDEX