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EM3800SX•EM5000SX•EM6500SX
See page 57 for instructions on assembling your generator.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas.
Breathing carbon monoxide can cause unconsciousness or death.
Never run the generator in a closed, or even partly closed area where people may be present.
The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the generator get wet, and do not operate it with wet hands.
Keep this owner’s manual handy so that you can refer to it at any time. This owner’s manual is considered a permanent part of the generator and should remain with the generator if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.
Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase of one of the finest generators on the market.
We want to help you get the best results from your new generator and to operate it safely. This manual contains the information on how to do that; please read it carefully.
As you read this manual, you will find information preceded by a 
symbol. That information is intended to help you avoid
damage to your generator, other property, or the environment.
We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.
When your generator needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators. Your authorized Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.
Best Wishes,
Honda Motor Co., Ltd.
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 on the generator.
Safety Messages preceded by a safety alert symbol 
and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Safety Headings such as IMPORTANT SAFETY INFORMATION.
Safety Section such as GENERAT OR SAF ET Y .
Instructions how to use this generator correctly and safely.
This entire book is filled with important safety information please read it carefully.
2
|
CONTENTS |
GENERATOR SAFETY .............................................................................. |
. 5 |
Safety Label Locations ....................................................................... |
. 5 |
Important Safety Information ............................................................ |
. 6 |
COMPONENT IDENTIFICATION .............................................................. |
. 8 |
CONTROLS .............................................................................................. |
. 10 |
Engine Switch .................................................................................... |
. 10 |
Starter Grip ........................................................................................ |
. 10 |
Fuel Valve Lever ................................................................................ |
. 11 |
Choke Rod .......................................................................................... |
. 11 |
Voltage Selector Switch (Dual Voltage System) ............................ |
. 12 |
Ground Terminal ............................................................................... |
. 12 |
DC Terminal ....................................................................................... |
. 13 |
DC Circuit Protector .......................................................................... |
. 13 |
Oil Alert System .............................................................................. |
. 14 |
Auto Throttle System ...................................................................... |
. 14 |
AC Circuit Breaker ............................................................................. |
. 15 |
AC Circuit Protector .......................................................................... |
. 16 |
GENERATOR USE ................................................................................... |
. 17 |
Connections to a Building’s Electrical System ............................... |
. 17 |
Ground System .................................................................................. |
.17 |
Special Requirements ....................................................................... |
. 17 |
AC Applications ................................................................................. |
. 18 |
AC Operation ..................................................................................... |
. 19 |
AC Receptacle Selection ................................................................... |
. 20 |
DC Operation ..................................................................................... |
. 26 |
Auto Throttle System ...................................................................... |
. 28 |
High Altitude Operation .................................................................... |
. 29 |
PRE-OPERATION CHECK ....................................................................... |
. 30 |
Engine Oil .......................................................................................... |
. 30 |
Refueling ............................................................................................ |
. 31 |
Fuel Recommendations .................................................................... |
. 32 |
STARTING THE ENGINE/STOPPING THE ENGINE .............................. |
. 33 |
3
MAINTENANCE ....................................................................................... |
35 |
The Importance of Maintenance ....................................................... |
35 |
Maintenance Safety ........................................................................... |
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 |
Fuse Replacement .............................................................................. |
43 |
TRANSPORTING/STORAGE ................................................................... |
44 |
TROUBLESHOOTING .............................................................................. |
47 |
TECHNICAL INFORMATION ................................................................... |
49 |
Emission Control System Information ............................................. |
49 |
Air Index .............................................................................................. |
51 |
WIRING DIAGRAM .................................................................................. |
52 |
SPECIFICATIONS ..................................................................................... |
54 |
ASSEMBLY ............................................................................................... |
57 |
WARRANTY SERVICE INFORMATION .................................................. |
69 |
DEALER LOCATOR INFORMATION .................................................. |
69 |
CUSTOMER SERVICE INFORMATION ............................................. |
69 |
Honda PUBLICATIONS ...................................................................... |
70 |
INDEX ....................................................................................................... |
71 |
4
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.
5
IMPORTANT SAFETY INFORMATION
Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating procedures.
Operator Responsibility
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles, and connections.
Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the generator without parental supervision.
Carbon Monoxide Hazards
Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death.
If you run the generator in a confined or even partly enclosed area, the air you breathe could contain dangerous amount of exhaust gas.
Never run your generator inside a garage, house, or near open windows or doors.
6
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.
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.
7
COMPONENT IDENTIFICATION
ENGINE SWITCH
CONTROL PANEL
CHOKE ROD
AIR CLEANER
FUEL VALVE LEVER
STARTER GRIP
OIL FILLER CAP/DIPSTICK
ENGINE SERIAL NUMBER
FUSE
OIL DRAIN PLUG
CONTROL PANEL
1:Except EM3800SX
120 ONLY 120/240
VOLTAGE SELECTOR SWITCH
AC CIRCUIT PROTECTORS
AC CIRCUIT BREAKER
120/240V AC RECEPTACLE
DC CIRCUIT
PROTECTOR
1
DC OUTPUT
TERMINAL
AUTO THROTTLE |
120V AC RECEPTACLES GROUND TERMINAL |
|
SWITCH |
||
|
8
TRANSPORT HANDLE
FUEL TANK CAP
FUEL GAUGE
SPARK PLUG CAP
FRAME SERIAL NUMBER
STAND
WHEEL |
MUFFLER |
*Record the engine and frame serial numbers and date of purchase for your future reference. Refer to these serial numbers when ordering parts and when making technical or warranty inquiries (see page 69 ).
Engine serial number:
Frame serial number:
Date of purchase:
9
CONTROLS
Engine Switch
To start and stop the engine.
Key position:
OFF: To stop the engine. Key can be removed/inserted. ON: To run the engine after starting.
START: To start the engine by operating the starter motor.
ON
OFF START
ENGINE SWITCH
Starter Grip
To start the engine, pull the starter grip lightly until resistance is felt, and then pull briskly.
Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
The recoil starter is used to start the engine if the generator is not equipped with a 12-volt battery to operate the starter motor, or if the battery does not contain adequate charge to operate the starter motor.
RECOIL STARTER
STARTER GRIP
10
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
ON
Choke Rod
The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually. Pull the rod out toward CLOSED to enrich the mixture for cold starting.
OPEN
CLOSED
CHOKE ROD
11
Voltage Selector Switch (Dual Voltage System)
The voltage selector switch switches the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position.
Switch Position
120/240V: The 120V and 120/240V receptacles can be used simultaneously.
120V ONLY: ONLY the 120V receptacles can be used. Do not use the 120/240V receptacle in this position. The most power will be available at the 30A 120V locking plug receptacle.
VOLTAGE SELECTOR SWITCH
120/240V
120/240V
120V ONLY
120V ONLY
GROUND TERMINAL
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.
12
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 |
POSITIVE TERMINAL |
(BLACK) |
(RED) |
13
Oil Alert
System
The Oil Alert
system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position). The Oil Alert system should not take the place of checking the oil level before each use.
If the engine stops and will not restart, check the engine oil level (see page 30 ) before troubleshooting in other areas.
Auto Throttle
System
The Auto Throttle
system automatically reduces engine speed when all loads are turned off or disconnected. When appliances are turned on or reconnected, the engine returns to the rated speed.
Switch Position
AUTO: Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator.
OFF: The Auto Throttle system does not operate.
Recommended to minimize warm-up time when the generator is started and when starting a load with large startup power equipments.
AUTO THROTTLE SWITCH
OFF
ON
OFF
ON
14
AC Circuit Breaker
The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the 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 circuit before switching the AC circuit breaker ON again.
The AC circuit breaker may be used to switch the generator power ON or OFF.
ON
OFF
AC CIRCUIT BREAKER
15
AC Circuit Protector
The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at the 20A 120V, 30A 120V locking plug, or 120/240V locking plug receptacle. If 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 PROTECTORS
ON
1
OFF
1:Except EM3800SX
16
GENERATOR USE
Connections to a Building’s Electrical System
Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers.
Improper connections to a building’s electrical system can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored. Consult the utility company or a qualified electrician.
Ground System
Honda portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire. If the generator is tested by a receptacle tester, it will show the same ground circuit condition as for a home receptacle.
Special Requirements
There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.
In some areas, generators are required to be registered with local utility companies.
17
AC Applications
Before connecting an appliance or power cord to the generator:
Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock.
If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance or the rated load capacity of the generator has been exceeded.
Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.
Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF, but will shorten the service life of the generator.
Limit operation requiring maximum power to 30 minutes. Maximum power is:
EM3800SX: 3.8 kVA EM5000SX: 5.0 kVA EM6500SX: 6.5 kVA
For continuous operation (longer than 30 minutes), do not exceed the rated power.
Rated power is: EM3800SX: 3.3 kVA EM5000SX: 4.5 kVA EM6500SX: 5.5 kVA
The total power requirements (VA) of all appliances connected must be considered. Appliance and power tool manufacturers usually list rating information near the model number or serial number.
18
AC Operation
1.Start the engine (see page 33 ).
2.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.
3.Switch the AC circuit breaker ON.
4.Plug in the appliance.
Be sure that all appliances are in good working order before connecting them to the generator. If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn off the ignition switch lever immediately. Then disconnect the appliance and examine it for signs of malfunction.
Most motorized appliances require more than their rated power for startup.
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.
VOLTAGE SELECTOR SWITCH
AC CIRCUIT PROTECTORS
1
AC CIRCUIT BREAKER
1:Except EM3800SX
19
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.
EM3800SX:
4B |
○ |
○ |
4A |
|
120V 30A
120V 20A (in total) 
120V 20A (in total)
○4A &○4B 120/240V 20A
Power Producing Circuits
This generator is equipped with two power generating circuits. When the voltage selector switch is in the 120V/240V position, each of the two power producing circuits supplies power to specific receptacles.
When the voltage selector switch is in the 120V ONLY position, the power producing circuits operate in parallel, sharing the total load connected to terminal 4A and receptacles 1, 2, and 3.
120V/240V |
120V ONLY |
POWER |
|
CIRCUIT 1 |
|
POWER |
POWER CIRCUIT 2 |
CIRCUIT 2 |
POWER CIRCUIT 1 |
|
20
Voltage Selector Switch
The power available to each receptacle depends on the position of the voltage selector switch.
Switch Position |
Receptacle |
Available Power |
120V ONLY |
1 |
27.5A at 120V |
|
2 |
20A at 120V |
|
3 |
20A at 120V |
|
4A |
20A at 120V |
|
4B |
None |
120V/240V |
1 |
13.8A at 120V |
|
2 |
13.8A at 120V |
|
3 |
13.8A at 120V |
|
4A-4B |
13.8A at 240V |
120V ONLY Position
When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles. You must, however, make sure the load on any receptacle does not exceed its available power shown in the preceding table and the total load does not exceed 27.5 amps.
120V/240V Position
When the voltage selector switch is in the 120V/240V position, you must balance the load. Divide the load between the two sets of receptacles shown below. Balancing is necessary because each set of receptacles is powered by only one power producing circuit that can produce a maximum of 13.8 amps.
|
Set of |
Total Current |
Power Producing |
|
Receptacles |
Available |
Circuit |
1 |
3 4B |
13.8A |
1 |
2 |
4A |
13.8A |
2 |
21
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