Honda EM4000SX, EM6500SX, EM5000SX Owner's Manual

Owner’s Manual

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GENERATOR

EM4000SX/EM5000SX/EM6500SX

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

California Proposition 65

This product contains or emits

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 people may be present.

partly closed area where

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 reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever.

of approval for printing. Honda Motor Co., Ltd.

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 the information on how to do that; please read it carefully.

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

symbol. That information is intended to help you avoid

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

We suggest you read the Distributor’s Limited Warranty (see page 82) to fully understand its coverage and your responsibilities of ownership.

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.

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 judgment.

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 GENERATOR SAFETY.

• Instructions — how to use this generator correctly and safely.

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

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.......................................................................10

COMPONENT & CONTROL LOCATIONS...........................................10

CONTROLS...........................................................................................12

Engine Switch ..................................................................................12

Starter Grip.......................................................................................12

Fuel Valve Lever...............................................................................13

Voltage Selector Switch ..................................................................13

Auto Throttle System ......................................................................14

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

AC Circuit Protectors .......................................................................15

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

DC Terminals....................................................................................17

DC Circuit Protector .........................................................................17

Folding Handle .................................................................................18

FEATURES............................................................................................19

Oil Alert System ...............................................................................19

Automatic Engine Stop Function....................................................19

Oil Alert Function.............................................................................19

Overspeed Detection Function .......................................................19

Abnormal Voltage Detection Function...........................................19

Auto Choke and Throttle Control System......................................20

iAVR (Intelligent Auto Voltage Regulator) .....................................20

Fuel Gauge .......................................................................................21

Ground Terminal..............................................................................21

BEFORE OPERATION ..............................................................................22

ARE YOU READY TO GET STARTED?................................................22

Knowledge........................................................................................22

IS YOUR GENERATOR READY TO GO?.............................................22

Check the Engine .............................................................................23

Check the GFCI .................................................................................23

CONTENTS

OPERATION .............................................................................................24

SAFE OPERATING PRECAUTIONS.....................................................24

STARTING THE ENGINE .....................................................................25

STOPPING THE ENGINE .....................................................................28

GFCI OPERATION CHECK ...................................................................29

AC OPERATION....................................................................................32

AC Applications................................................................................34

AC Receptacle Selection..................................................................35

Power Producing Circuits................................................................35

Voltage Selector Switch ..................................................................36

DC OPERATION....................................................................................38

AUTO THROTTLE SYSTEM.................................................................40

STANDBY POWER...............................................................................41

Connections to a Building’s Electrical System ..............................41

System Ground ................................................................................41

Special Requirements......................................................................42

SERVICING YOUR GENERATOR............................................................43

THE IMPORTANCE OF MAINTENANCE.............................................43

MAINTENANCE SAFETY.....................................................................44

Safety Precautions ...........................................................................44

MAINTENANCE SCHEDULE ...............................................................45

REFUELING ..........................................................................................46

FUEL RECOMMENDATIONS...............................................................47

ENGINE OIL LEVEL CHECK .................................................................48

ENGINE OIL CHANGE..........................................................................49

ENGINE OIL RECOMMENDATIONS ...................................................50

AIR CLEANER SERVICE .......................................................................51

AIR CLEANER ELEMENT CLEANING .................................................53

SPARK PLUG SERVICE........................................................................54

SPARK ARRESTER SERVICE...............................................................56

SEDIMENT CUP CLEANING................................................................57

BATTERY SERVICE ..............................................................................58

FUSE .....................................................................................................62

STORAGE.................................................................................................63

STORAGE PREPARATION...................................................................63

Cleaning............................................................................................63

Fuel....................................................................................................63

Engine Oil .........................................................................................66

Engine Cylinder................................................................................66

STORAGE PRECAUTIONS ..................................................................67

REMOVAL FROM STORAGE...............................................................67

CONTENTS

TRANSPORTING......................................................................................68

TAKING CARE OF UNEXPECTED PROBLEMS ......................................69

ENGINE WILL NOT START..................................................................69

ENGINE LACKS POWER......................................................................70

NO POWER AT THE AC RECEPTACLES.............................................71

NO POWER AT THE DC TERMINALS.................................................71

TECHNICAL INFORMATION ...................................................................72

Serial Number Location ......................................................................72

Carburetor Modification for High Altitude Operation.......................73

Emission Control System Information...............................................74

Air Index ...............................................................................................76

Specifications.......................................................................................77

Wiring Diagram....................................................................................78

CONSUMER INFORMATION ..................................................................80

Dealer Locator Information.................................................................80

Honda Publications..............................................................................80

Customer Service Information ...........................................................81

Distributor’s Limited Warranty ...........................................................82

Emission Control System Warranty...................................................87

ASSEMBLY ..............................................................................................92

SAFETY.................................................................................................92

The Importance of Proper Assembly .............................................92

Important Safety Precautions .........................................................93

ASSEMBLY...........................................................................................94

Unpacking.........................................................................................94

Loose Parts .......................................................................................94

Handle Installation ...........................................................................95

Wheel Kit Installation.......................................................................96

INITIAL USE INSTRUCTIONS .................................................................97

ENGINE OIL..........................................................................................97

FUEL......................................................................................................98

BATTERY ..............................................................................................99

BEFORE OPERATION.........................................................................100

REGISTRATION..................................................................................100

OPTIONAL PARTS .................................................................................101

Remote Control Kit ............................................................................101

Remote Control Box ..........................................................................102

Hanger Kit...........................................................................................103

INDEX .....................................................................................................104

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

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 of the 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

A generator's exhaust contains toxic carbon monoxide, which you cannot see or smell. Breathing carbon monoxide can KILL YOU IN MINUTES. To avoid carbon monoxide poisoning, follow these instructions when operating a generator:

• Only run a generator OUTSIDE, far away from windows, doors, and vents.

• Never operate a generator inside a house, garage, basement, crawl space, or any enclosed or partially enclosed space.

• Never operate a generator near open doors or windows.

• Get fresh air and seek medical attention immediately if you suspect you have inhaled carbon monoxide.

Early symptoms of carbon monoxide exposure include headache, fatigue, shortness of breath, nausea, and dizziness. Continued exposure to carbon monoxide can cause loss of muscular coordination, loss of consciousness, and then death.

To alert you to potentially dangerous levels of carbon monoxide coming from a generator operating outside, or from other sources, install battery operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up on every level of the home and outside sleeping areas in accordance with the manufacturer's instructions.

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 the Ground Fault Circuit Interrupter (GFCI) receptacle and all other electrical components on the control panel before each use. Moisture or ice can cause a malfunction or short circuit in electrical components that could result in electrocution.

• Do not connect to a building’s electrical system unless an isolation switch has been installed by a qualified electrician.

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.

GENERATOR SAFETY

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode. Do not refuel during operation. Allow the engine to cool if it has been in operation. Refuel only outdoors in a well-ventilated area and on a level surface. Never smoke near gasoline, and keep other flames and sparks away. Do not overfill the fuel tank. Make sure that any spilled fuel has been wiped up and cleaned before starting the engine. Always store gasoline in an approved container.

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.

CONTROLS & FEATURES

VOLTAGE SELECTOR SWITCH

AC CIRCUIT BREAKER

DC CIRCUIT PROTECTOR

ENGINE SWITCH

DC TERMINALS

AUTO THROTTLE SWITCH

GROUND TERMINAL

RECEPTACLES

GFCI RECEPTACLES

AC CIRCUIT PROTECTORS

AC CIRCUIT PROTECTOR (EM5000SX ∙ EM6500SX)

COMPONENT & CONTROL LOCATIONS

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

CONTROLS & FEATURES

AIR CLEANER

FUEL VALVE LEVER

SEDIMENT CUP

STARTER GRIP

OIL DRAIN PLUG

OIL FILLER CAP/DIPSTICK

BATTERY COVER

CONTROL PANEL

HANDLE

SPARK PLUG

FUEL TANK CAP

FUEL GAUGE

WHEEL

MUFFLER

STAND

MANUAL CHOKE LEVER

CONTROLS & FEATURES

ENGINE SWITCH

OFF

STARTER GRIP

START

Direction to pull

CONTROLS

Engine Switch

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

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

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

START – Operates the electric starter.

Starter Grip

Used when the battery voltage is too low to turn the starter motor. Pulling the starter grip operates the recoil starter to crank the engine.

• Do not allow the starter grip to

snap back against the generator. Return it gently to prevent damage to the starter.

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

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

CONTROLS & FEATURES

OFF

FUEL VALVE LEVER

VOLTAGE SELECTOR SWITCH

120 V/240 V

120 V ONLY

Fuel Valve Lever

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

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

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

Voltage Selector Switch

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

Switch Position

120V/240V: The 120V and 120V/240V receptacles can be used

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

CONTROLS & FEATURES

AUTO THROTTLE SWITCH

OFF

AC CIRCUIT BREAKER

OFF

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 start-up power requirements.

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.

CONTROLS & FEATURES

AC CIRCUIT PROTECTOR for Receptacle ④

AC CIRCUIT PROTECTOR for Receptacle ③

AC CIRCUIT PROTECTOR for Receptacle ②

AC CIRCUIT PROTECTOR for Receptacle ①

(EM5000SX ∙ EM6500SX)

① 120 V 30 A

④ 120/240 V 30 A

② GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE)

③ GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE)

OFF

PUSH

AC CIRCUIT PROTECTOR

④ 120/240 V 20 A

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.

CONTROLS & FEATURES

GFCI RECEPTACLES (120 V 20 A DUPLEX RECEPTACLES)

Ground Fault Circuit Interrupter (GFCI) Receptacle

Each 120 V 20 A duplex receptacle is protected by a Ground Fault Circuit Interrupter (GFCI) for protection against the shock hazard of ground-fault currents.

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

The GFCI will not protect against short circuit or overloads.

GFCIs can be expected to interrupt power supply if there are ground faults or stray current imposed on the wiring by other electrical devices, wiring, or equipment. Due to the risk of a power interruption, this generator is not recommended for powering medical or life support equipment.

CONTROLS & FEATURES

DC CIRCUIT PROTECTOR

POSITIVE DC TERMINAL (RED)

NEGATIVE DC TERMINAL (BLACK)

OFF

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

CONTROLS & FEATURES

HANDLE LOCK LEVER

HANDLE

Handle transport position

Generator stationary position

Folding Handle

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

To Extend The Handle

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

To Fold The Handle

1. Press handle lock lever downward.

2. Lower the handle.

CONTROLS & FEATURES

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 48) 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.

System

Abnormal Voltage Detection Function

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

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

CONTROLS & FEATURES

MANUAL CHOKE LEVER

ECM

Auto Choke and Throttle Control System

The ECM (Engine Control Module) controls the choke valve and throttle automatically.

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

iAVR (Intelligent Auto Voltage Regulator)

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

The total amount of power available for each generator model is: EM4000SX 5,000 watts for up to 10 seconds EM5000SX 7,000 watts for up to 10 seconds EM6500SX 7,000 watts for up to 10 seconds

CONTROLS & FEATURES

FUEL GAUGE FUEL TANK CAP

EMPTYFULL

GROUND TERMINAL

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.

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.

NEUTRAL FLOATING:

• The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin.

• Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional.

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 34).

IS YOUR GENERATOR READY TO GO?

For your safety, to ensure compliance with environmental regulations, 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.

Failure to properly maintain this generator, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can seriously hurt or kill you.

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

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

• Before each use, look around and underneath the engine for signs of oil or gasoline leaks.

• Check the oil level (see page 48). 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 51). A dirty air cleaner element will restrict air flow to the carburetor, reducing engine and generator performance.

• Check the fuel level (see page 46). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

Check the GFCI

Check the GFCI operation (see page 29) after starting the engine.

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, review chapters GENERATOR SAFETY (see page 6) and BEFORE OPERATION (see page 22).

For your safety, do not operate the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas.

Breathing carbon monoxide can cause unconsciousness or death.

Never run this product's engine in a closed, or even partly closed area where people may be present.

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

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

• Inspect cords and plugs, and replace if damaged.

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

• 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 the rated power of the generator or the receptacle being used.

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

• Do not operate the generator in an enclosed structure.

• Do not place flammable objects close to the engine or locate the generator near flammable materials.

OPERATION

OFF

AC CIRCUIT BREAKER

FUEL VALVE LEVER

STARTING THE ENGINE

To prevent a possible fire, keep the generator at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects close to the engine.

Operating this generator less than 3 feet (1 meter) from a building or other obstruction can cause overheating and damage the generator. For proper cooling, allow at least 3 feet (1 meter) of empty space above and around the generator.

Refer to SAFE OPERATING PRECAUTIONS on page 24 and perform the IS YOUR GENERATOR RE ADY TO GO checks (see page 22). Refer to AC OPERATION (see page 32) or DC OPERATION (see page 38) for connecting loads to the generator.

1. Make sure that all appliances are disconnected from the AC receptacle.

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

3. Turn the fuel valve lever to the ON position.

OPERATION

AUTO THROTTLE SWITCH

OFF

START

OFF

ENGINE SWITCH

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

5. Start the engine.

• Using the electric starter:

Turn the engine switch to the START position, and hold it there until the engine starts. When the engine starts, release the key, allowing the switch to return to the ON position.

If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again.

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

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

• Using the recoil starter:

ENGINE SWITCH

STARTER GRIP

Direction to pull

AUTO THROTTLE SWITCH

a. Turn the engine switch to the

ON position.

OPERATION

b. Pull the starter grip lightly

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

• Do not allow the starter

grip to snap back against the engine. Return it gently to prevent damage to the starter.

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

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

6. If you wish to use the Auto Throttle system, turn the Auto Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes.

OPERATION

AC CIRCUIT BREAKER

OFF

ENGINE SWITCH

OFF

FUEL VALVE LEVER

STOPPING THE ENGINE

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

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

2. Move the AC circuit breaker to the OFF position.

3. Turn the engine switch to the OFF position.

4. Turn the fuel valve lever to the OFF position.

OPERATION

GFCI RECEPTACLES (120 V 20 A DUPLEX RECEPTACLES)

GFCI OPERATION CHECK

Always check GFCI operation before using the generator.

A faulty GFCI system will not provide proper protection against electric shock as designed.

An electric shock can result in serious injury or death.

Always perform the GFCI system inspection before using the generator. If the GFCI system fails the test, the generator must be repaired by an authorized Honda servicing dealer before use.

OPERATION

INDICATOR

RESET BUTTON

AC CIRCUIT BREAKER

AUTO THROTTLE SWITCH

TEST BUTTON

1. Unplug all tools and appliances from the generator.

2. Start the engine (see page 25).

3. Turn OFF the auto throttle switch (see page 26).

4. Turn the AC circuit breaker to the ON position. When the GFCI is operating normally, the indicator will continuously light green.

Light order: (red) Blink once  (green) Light once  (red) Blink once  (green) Lights continuously

• If the green indicator does not light on, press the RESET button.

• If the red indicator starts to blink continuously, contact an

authorized Honda generator dealer.

5. Press the TEST button:

• The RESET button will pop out and the green indicator will go off.

• If the GFCI does not function as described, contact an authorized

Honda generator dealer.

OPERATION

RESET BUTTON

INDICATOR

6. Press the RESET button:

• The green indicator will light continuously.

• If the red indicator starts to blink continuously, contact an

authorized Honda generator dealer.

When the RESET button pops out or the green indicator does not lit during operation:

• Unplug all appliances from the GFCI protected receptacle.

• Press the RESET button.

– If the GFCI cannot be reset, the GFCI is faulty. Contact an authorized

Honda generator dealer.

– If the RESET button extends, this usually indicates a faulty

power tool, appliance, or cord. If that occurs, perform operation check steps 1 through 6 to verify that the GFCI is in proper working order. If the GFCI tests correctly, then the fault is likely to be in the power tool, appliance, or cord. Repair or replace the faulty power tool, appliance, or cord before further use.

OPERATION

VOLTAGE SELECTOR SWITCH

120 V/240 V

120 V ONLY

AC OPERATION

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

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

1. Turn the voltage selector switch to either position. With the voltage selector switch in the ‘‘120V/240V’’ position, you can use the 120V and 120V/240V receptacles simultaneously. If you

are NOT using 240 volts, then select the ‘‘120V ONLY’’ position.

Disconnect or turn OFF all appliances or tools connected to the generator before changing the voltage selector switch position. The generator may be damaged if the switch position is changed with loads connected and operating.

2. Start the engine (see page 25).

OPERATION

AC CIRCUIT BREAKER

PLUG

AC CIRCUIT PROTECTORS

AC CIRCUIT PROTECTOR (EM5000SX ∙ EM6500SX)

3. Switch ON the AC circuit breaker.

4. Plug in the appliance. Most motorized appliances require more than their rated wattage for startup.

5. Turn on the appliance.

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

If the generator is overloaded and the internal circuit is overheated, current to the connected appliance(s) may shut off, even though the AC circuit breaker stays ON and the engine keeps running. Stop the engine and correct the problem. Allow the generator to cool for a few minutes, and then restart the engine (see page 25).

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.

Most appliance motors require more than their rated wattage for startup. Make sure the electrical rating of the tool or appliance does not exceed the maximum power rating of the generator.

Maximum power is:

EM4000SX: 4.0 kVA EM5000SX: 5.0 kVA EM6500SX: 6.5 kVA

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

EM4000SX: 3.6 kVA EM5000SX: 4.5 kVA EM6500SX: 5.5 kVA

In either case, 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.

Substantial overloading will open the AC circuit breaker. Slightly overloading the generator may not switch the AC circuit breaker OFF, but will shorten the service life of the generator.

OPERATION

TERMINAL

VOLTAGE SE LE CTOR SWITCH

RECEPTACLE ④

TERMINAL

RECEPTACLE ①

TERMINAL

RECEPTACLE ④

RECEPTACLE ② GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE)

RECEPTACLE ③ GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE)

POWER CIRCUIT B

POWER CIRCUIT A

120 V/240 V 120 V ONLY

POWER CIRCUIT B

POWER CIRCUIT A

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.

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.

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

120V ONLY Position

When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles. You must, however, make sure the load on any receptacle does not exceed its available power shown in the table above and the total load does not exceed the total current available.

Total Current Available:

30.0 A (EM4000SX)

37.5 A (EM5000SX)

45.8 A (EM6500SX)

Receptacle

① ② ③

EM4000SX EM5000SX EM6500SX

30A at 120V 30A at 120V 30A at 120V 20A at 120V 20A at 120V 20A at 120V 20A at 120V 20A at 120V 20A at 120V

20A at 120V 30A at 120V 30A at 120V

None None None

15.0A at 120V

15.0A at 240V

Available Power

18.8A at 120V

18.8A at 240V

22.9A at 120V 20A at 120V 20A at 120V

22.9A at 240V

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 (EM4000SX)

18.8 A (EM5000SX)

22.9 A (EM6500SX)

Set of

Receptacles

① + ③ + ② +

Total Current Available

EM4000SX EM5000SX EM6500SX

15.0A 18.8A 22.9A B

15.0A 18.8A 22.9A A

Power Producing

Circuit

OPERATION

POSITIVE DC TERMINAL (RED)

NEGATIVE DC TERMINAL (BLACK)

BATTERY NEGATIVE (–) TERMINAL

BATTERY POSITIVE (+) TERMINAL

DC OPERATION

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

Connecting the battery charging cable (optional equipment):

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

The battery gives off explosive hydrogen gas during normal operation.

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

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

WARNING: Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling.

2. Connect the red lead of battery charging cable into the positive (+) DC terminal of the generator.

OPERATION

DC CIRCUIT PROTECTOR

OFF

3. Connect the black lead of battery charging cable into the negative

(–) DC terminal of the generator.

4. Connect the red lead of the battery charging cable to the positive (+)

battery terminal and the black lead to the negative (–) battery terminal.

5. Start the generator.

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

An overloaded DC circuit, excessive current drawn by the battery, or a wiring problem will trip the DC circuit protector (the yellow indicator inside the clear circuit protector button will pop out). If this happens, wait a few minutes before pushing in the circuit protector button to resume operation. If the circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer. The DC circuit protector does not prevent overcharging the battery.

Disconnecting the battery charging cable:

1. Stop the engine.

2. Disconnect the black lead of the battery charging cable from the

negative (–) battery terminal.

3. Disconnect the red lead of the battery charging cable from the

positive (+) battery terminal.

4. Disconnect the battery charging cables from the DC terminals of the

generator.

5. Connect the vehicle battery ground cable to the negative (–) battery

terminal.

OPERATION

AUTO THROTTLE SWITCH

OFF

AUTO THROTTLE® SYSTEM

With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the Auto Throttle system does not operate. The Auto Throttle system will not respond to electrical loads of less than 1 ampere or intermittent loads such as a staple gun. Turn the Auto Throttle switch to the OFF position to operate loads of less than 1 amp.

Appliances with large start-up power demands may not allow the engine to reach normal operating rpm when they are connected to the generator. Push the Auto Throttle switch to the OFF position and connect the appliance to the generator. If the engine still will not reach normal operating speed, check that the appliance does not exceed the rated load capacity of the generator.

To avoid extended warm-up periods, keep the switch OFF until the engine reaches operating temperature.

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

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

This generator has a system ground that connects generator frame components to ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire.

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.

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.

Failure to properly maintain this generator, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can seriously hurt or kill you.

Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

Remember that an authorized Honda 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.

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.

Improper maintenance can cause an unsafe condition.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in this 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.

MAINTENANCE SCHEDULE

ITEM

SERVICING YOUR GENERATOR

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

Engine oil Check level o 48

Change o o 49

Air cleaner Check o 51

Clean o (1) 53 GFCI operation Check o 29 Sediment cup Clean o 57 Spark plug Check-adjust o

Replace o Spark arrester Clean o 56 Valve clearance Check-adjust o (2) — Combustion chamber Clean After every 1,000 Hrs. (2) — Fuel tank and filter Clean o (2) — Fuel tube Check Every 2 years (Replace if necessary) (2) — Canister Check Every 2 years (2) — Purge tube Check Every 2 years (2) — Charge tube Check Every 2 years (2) —

(1) Service more frequently when used in dusty areas. (2) These items should be serviced by your servicing dealer, unless you have the proper tools

and are mechanically proficient. Refer to the Honda shop manual for service procedures. See ‘‘Honda Publications’’ on page 80 for ordering information.

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

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

Each

use

First

month

20 Hrs.

Every

months

50 Hrs.

Every

months

100 Hrs.

Every

year

page

300 Hrs.

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 when refueling.

• 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 the Distributor’s Limited 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 (see page 47) or fuel may flow into the charcoal canister causing fuel spillage. This overflow may also prevent the fuel tank from venting properly.

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.

SERVICING YOUR GENERATOR

UPPER LEVEL MARK (RED)

FUEL FILTER

UPPER LEVEL MARK (RED)

EMPTYFULL

FUEL GAUGE

FUEL TANK CAP

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 gasoline that is stale, contaminated, or mixed with oil. 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 (see page 63) for additional information regarding fuel deterioration.

SERVICING YOUR GENERATOR

OIL FILLER CAP/DIPSTICK

OIL FILLER NECK

UPPER LIMIT

ENGINE OIL LEVEL CHECK

Check the engine oil level with the engine stopped and in a level position.

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

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

3. If the oil level is low, fill with the recommended oil (see page 50) to the upper limit on the oil filler cap/dipstick.

4. Reinstall the oil filler cap/dipstick securely.

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.

SERVICING YOUR GENERATOR

UPPER LIMIT

SEALING WAS HER (Replace)

12×15 mm OIL DRAIN PLUG

OIL FILLER CAP/DIPSTICK

ENGINE OIL CHANGE

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

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

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

TORQUE: 16.6 lbf·t (22.5 N·m, 2.25 kgf·m)

3. With the generator in a level position, fill with the recommended oil to the upper limit on the oil filler cap/dipstick (see page 48).

Maximum oil capacity: 1.2 US qt (1.1 L)

4. Reinstall the oil filler cap/dipstick securely.

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.

SERVICING YOUR GENERATOR

AMBIENT TEMPERATURE

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.

SERVICING YOUR GENERATOR

HOOK

SETTING PIN

AIR CLEANER CASE

FRAME PIPE

AIR CLEANER ELEMENT

AIR CLEANER COVER

CLIP

AIR CLEANER SERVICE

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

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

3. Remove the air cleaner element from the air cleaner case.

4. Check the air cleaner element to be sure it is clean and in good condition. If the air cleaner element is dirty, clean it as described on page 53. Replace the air cleaner element if it is damaged.

SERVICING YOUR GENERATOR

GOOD NO GOOD

HOOK

AIR CLEANER CASE

AIR CLEANER ELEMENT

CLIP

AIR CLEANER COVER

SETTING PIN

5. Reinstall the air cleaner element in the air cleaner case.

6. Set the hooks of the air cleaner cover to the setting pins securely, and then push the air cleaner cover to lock the clips. Be sure that the cover is set securely. There must be no clearance between the air cleaner cover and air cleaner case.

Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty.

SERVICING YOUR GENERATOR

Clean

Squeeze and Dry Do not twist.

Dip in Oil Squeeze

Do not twist.

AIR CLEANER ELEMENT CLEANING

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

1. Clean the foam air filter in warm soapy water, rinse, and allow to dry thoroughly, or clean in non-flammable solvent and allow to dry.

2. Dip the foam air filter in clean engine oil, and then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the filter.

3. Wipe dirt from the air cleaner housing and cover using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor.

SERVICING YOUR GENERATOR

SPARK PLUG WRENCH

SPARK PLUG CAP

SPARK PLUG SERVICE

In order to service the spark plug, you will need a spark plug wrench (commercially available).

Recommended spark plug: BPR5ES (NGK)

W16EPR-U (DENSO)

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

An incorrect spark plug can cause engine damage.

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

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

2. Remove the spark plug with a spark plug wrench.

SERVICING YOUR GENERATOR

SIDE ELECTRODE

0.028–0.031 in (0.7–0.8 mm)

SEALING WASHER

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

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

0.028–0.031 in (0.7–0.8 mm)

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

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

If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten 1/8–1/4 turn after the spark plug seats to compress the washer.

TORQUE: 13.3 lbf·ft (18 N·m, 1.8 kgf·m)

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

7. Attach the spark plug cap.

SERVICING YOUR GENERATOR

5 mm SCREWS SPARK ARRESTER

SPARK ARRESTER SCREEN

SPARK ARRESTER SERVICE

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

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

Clean the spark arrester as follows:

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

2. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and tears. Replace the spark arrester if it is damaged.

3. Install the spark arrester in the reverse order of removal.

SERVICING YOUR GENERATOR

KEY

FUEL VALVE LEVER

O-RING (Replace)

SEDIMENT CUP

OFF

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.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Wipe up spills immediately.

1. Turn the engine switch to the OFF position and remove the key.

2. Turn the fuel valve lever to the 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.

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

5. Turn the fuel valve lever to the ON position and check for leaks.

SERVICING YOUR GENERATOR

BATTERY SERVICE

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

The battery contains sulfuric acid (electrolyte), which is highly corrosive and poisonous.

Getting electrolyte in your eyes or on your skin can cause serious burns.

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

KEEP CHILDREN AWAY FROM THE BATTERY.

Emergency Procedures

Eyes – Flush with water from a cup or other container for at least

fifteen minutes. (Water under pressure can damage the eye.) Immediately call 911 (USA only) or a physician.

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

Swallowing – Drink water or milk. Call your local Poison Control Center (USA only) or a physician immediately.

SERVICING YOUR GENERATOR

COVER SCREW

BATTERY COVER

BATTERY HOLDER BAND

POSITIVE (+) CABLE

NEGATIVE (–) CABLE

BATTERY

Battery Removal

WARNING: Battery posts, terminals, and related accessories contain

lead and lead components. Wash hands after handling.

1. Loosen the cover screw and remove the battery cover.

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

3. Remove the battery holder band.

4. Remove the battery from the battery tray.

This symbol on the battery means that this product must not be treated as household waste.

An improperly disposed of battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal.

SERVICING YOUR GENERATOR

Battery Charging

The battery will expel explosive hydrogen gas when overcharged.

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

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

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

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

1. Connect the battery charger following the manufacturer’s instructions.

2. Charge the battery 5–10 hours.

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

SERVICING YOUR GENERATOR

BATTERY HOLDER BAND

POSITIVE (+) CABLE

NEGATIVE (–) CABLE

Battery Installation

1. Install the battery in the generator.

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

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

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

5. Install the battery holder band.

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

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

SERVICING YOUR GENERATOR

FUSE (20 A)

FUSE HOLDER COVER

FUSE

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

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

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

2. Remove the fuse holder cover and pull the fuse out.

3. Replace the fuse with a fuse of the same type and rating. Specified fuse: 20 A

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

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

STORAGE

STORAGE PREPARATION

Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your generator’s function and appearance, and will make the engine easier to start when you use the generator again.

Cleaning

Wipe the generator with a moist cloth. After the generator has dried, touch up any damaged paint, and coat other areas that may rust with a light film of oil.

Fuel

Depending on the region where you operate your equipment, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and/or fuel system. Please check with your servicing dealer for local storage recommendations.

Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your generator deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced. The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.

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

STORAGE

Service according to the table below:

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasoline

stabilizer Fill with fresh gasoline and add gasoline

2 months to 1 year

stabilizer Drain the carburetor float bowl (see page 65). Drain the fuel sediment cup (see page 57). Fill with fresh gasoline and add gasoline stabilizer Drain the carburetor float bowl (see page 65). Drain the fuel sediment cup (see page 57). Remove the spark plug. Put a teaspoon of

1 year or more

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 (see page 49). After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting.

Use gasoline stabilizers that are formulated to extend storage life.

Follow the manufacturer’s instructions for use. Contact your authorized Honda generator dealer for stabilizer recommendations.

STORAGE

DRAIN SCREW

Draining the Fuel Tank and Carburetor

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Wipe up spills immediately.

1. Turn the fuel valve lever to the OFF position.

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

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

STORAGE

FUEL VALVE LEVER

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

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

6. Remove the sediment cup (see page 57), and then turn the fuel valve lever to the ON position.

7. Allow the gasoline to drain completely, and then install the sediment cup and a new O-ring (see page 57).

Engine Oil

Change the engine oil (see page 49).

Engine Cylinder

1. Remove the spark plug, and pour a teaspoon (5 cc) of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug.

2. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke, and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion.

Battery

Charge the battery before storing the generator (see page 60).

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 28) to reduce the possibility of leakage.

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

With the engine and exhaust system cool, cover the generator to keep out dust. A hot engine and exhaust system can ignite or melt some materials.

Do not use a plastic sheet 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 BEFORE OPERATION chapter of this manual (see page 22).

If the generator was stored for 1 year or longer, drain the fuel tank (see page 65) 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.

TRANSPORTING

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

If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

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

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

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause Correction

Fuel valve lever OFF. Turn lever ON (see page 25).

Engine switch OFF. Turn engine switch to ON

(see page 26).

Out of fuel. Refuel (see page 46).

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.

Drain fuel tank and carburetor (see page 65). Refuel with fresh gasoline (see page 46).

Add oil (see page 48). Turn engine switch to OFF and then restart the engine.

Gap or replace spark plug (see page 54).

Dry and reinstall spark plug.

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

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE LACKS POWER

Possible cause Correction

Air filter restricted. Clean or replace air filter

(see pages 51, 53).

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

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

Drain fuel tank and carburetor (see page 65). Refuel with fresh gasoline (see page 46).

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

TAKING CARE OF UNEXPECTED PROBLEMS

NO POWER AT THE AC RECEPTACLES

Possible Cause Correction

AC circuit breaker left in the OFF position after starting.

GFCI system activated. • GFCI receptacle

AC circuit protector tripped. Check AC load and reset AC

Faulty power tool or appliance.

Internal circuit overheated. Stop the engine. Reduce the

Faulty generator. Take the generator to an

Switch AC circuit breaker ON (see page 32).

(120 V 20 A duplex receptacle): Test GFCI and press the RESET button (see page 29).

• Replace or repair power tool or appliance.

circuit protector (see page 15).

Replace or repair power tool or appliance. Stop and restart the engine.

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

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

NO POWER AT THE DC TERMINALS

Possible Cause Correction

DC circuit protector OFF. Turn DC circuit protector ON

(see page 17).

Faulty generator. Take the generator to an

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

TECHNICAL INFORMATION

ENGINE SERIAL NUMBER

FRAME SERIAL NUMBER

Serial Number Location

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

Engine serial number:

Frame serial number:

Date purchased:

TECHNICAL INFORMATION

Carburetor Modification for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 5,000 feet (1,500 meters), have your authorized Honda servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetor has been modified for high altitude operation, the air/fuel mixture will be too lean for low altitude use. Operation at altitudes below 5,000 feet (1,500 meters) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.

TECHNICAL INFORMATION

Emission Control System Information

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

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

The U.S. and California Clean Air Acts

EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards.

Tampering and Altering

Tampering is a violation of Federal and California law.

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.

TECHNICAL INFORMATION

Problems That May Affect Emissions

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

• Hard starting or stalling after starting.

• Rough idle.

• Misfiring or backfiring under load.

• Afterburning (backfiring).

• Black exhaust smoke or high fuel consumption.

Replacement Parts

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

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

Maintenance

Follow the MAINTENANCE SCHEDULE on page 45. 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 dusty conditions, will require more frequent service.

TECHNICAL INFORMATION

Air Index (Models sold in California)

An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.

The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your Emission Control System Warranty (see page 87) for additional information.

Descriptive Term Applicable to Emission Durability Period Moderate 50 hours (0–80 cc, inclusive)

125 hours (greater than 80 cc)

Intermediate 125 hours (0–80 cc, inclusive)

250 hours (greater than 80 cc)

Extended 300 hours (0–80 cc, inclusive)

500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

TECHNICAL INFORMATION

Specifications

Dimensions

Model EM4000SX EM5000SX EM6500SX Type AT1 type Description code EBRC EBMC EBJC Length 41.1 in (1,043 mm) Width 27.8 in (706 mm) Height 28.3 in (719 mm) Dry mass [weight]

Engine

Model iGX270 iGX390 Engine type 4-stroke, overhead valve, single cylinder Displacement [Bore×Stroke]

Compression ratio 8.5:1 8.2:1 Engine speed 3,600 rpm Cooling system Forced air Ignition system CDI magneto Oil capacity 1.2 US qt (1.1 L) Fuel tank capacity 6.21 US gal (23.5 L) Spark plug BPR5ES (NGK) · W16EPR-U (DENSO)

203.9 lbs (92.5 kg) 228.2 lbs (103.5 kg) 233.7 lbs (106.0 kg)

16.5 cu-in (270 cm3) [3.03×2.28 in

(77.0×58.0 mm)]

23.7 cu-in (389 cm3) [3.46×2.52 in

(88.0×64.0 mm)]

41.4 in (1,051 mm)

Generator

Model EM4000SX EM5000SX EM6500SX

Type AT1 type

Rated voltage 120 V/240 V

AC output

DC output Only for charging 12V automotive batteries.

Tuneup

Spark plug gap Valve clearance (cold) IN: 0.15±0.02 mm

Other specifications No other adjustments needed.

Rated frequency 60 Hz Rated current 30.0 A/15.0 A 37.5 A/18.8 A 45.8 A/22.9 A Rated output 3.6 kVA 4.5 kVA 5.5 kVA Maximum output 4.0 kVA 5.0 kVA 6.5 kVA

Maximum charging output = 8.3 A

ITEM SPECIFICATION MAINTENANCE

0.028–0.031 in (0.7–0.8 mm)

EX: 0.20±0.02 mm

Refer to page 54 See your authorized Honda dealer.

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

TECHNICAL INFORMATION

Abbreviations

Symbol Part name

AC O AC CB AC CP Au Sw BAT CBB ChC CT D1 D2 D-AVR

D-CDI DC D DC CP DC T DC W ECU ESw EgB EX W FrB Fu FW GeB GFCI

GND GT J/B MW OLSw OP PoC RCBB

RCBX RCCa SP SSw St Stp Sw VSSw

AC Outlet AC Circuit Breaker AC Circuit Protector Auto Throttle Switch Battery Control Box Block Charge Coil Current Transformer Diode (MMB) Diode (196) Digital-Automatic Voltage Regulator Digital-CDI DC Diode DC Circuit Protector DC Terminal DC Winding Engine Control Unit Engine Switch Engine Block Exciter Winding Frame Block Fuse Field Winding Generator Block Ground Fault Circuit Interrupter Ground Ground Terminal Junction Box Main Winding Oil Level Switch Option Power Coil Remote Control Box Block Remote Control Box Remote Control Cable Spark Plug Start Switch Starter Stop Switch Voltage Selector Switch

Wire color code

Engine Switch

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

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

EXT

(+)

EXT

(–)

LO BAT ST

OFF

ON o o o o

ST o o o o o

Wiring Diagram

TECHNICAL INFORMATION

AC CP

(20A)

AC CP

(30A)

AC CP

(20A)

AC CP

(30A)

AC CP

(20A)

AC CP

(30A)

AC CP

(20A)

12V

MODE

GND

TX1

RX1

OIL

(FW)

LED

D26

D12

D25

D13

20A

GND GND

BlW

Bu/R

Bl/W

Bu/Y

Bl/R

OLSw ECU D-CDI StBATSP ChC

SET_NE

COM_RX

COM_TX

COM_12V

S_GND

PWR1

PWR2

LED

OIL ALT

EXT(+)

EXT(-)

PoC

EX W

DC W

DC D

CBB

RCBB

RCBX

D-AVR

J/B

GeB

EgB

FrB

ESw

EXT(-)

EXT(+)

BATSTLO

Bl/Y

Bl/W

BlRW

Bl/W

316

VSSw

120V/240V 120V

2122232435

362526272829303132

46474139384042

454843

97521

611101213849

50555153656667

6970717273

WRW

RGGGY

AC CB

AuSw

DC T

StpSw

LED

RCCa

ECU

DC CP

W/R

RECT

Bl/R

(-)

(+)

CHG

BAT

EARTH

LED

START

SSw

W/Bu

Bl/W Bl/Y

W/Bu

W/R

Br Br

Bl/R

D15

D16

D17

D18

D19

D24

D21

D14

D23

D20

D11

D10

D27

TX0

RX0

12V

GND

Power CT

(V)

EARTH

(N)

(U)

Reset

(L14-30R)

(L5-30R)

(5-20R) (5-20R)

AC O *2

LOAD

LNE

GFCI

LOAD

LNE

GFCI

(Bu)

(W)

(G)

(R)

(W)

(L14-30R)

(L5-30R)

(5-20R) (5-20R)

AC O *1

LOAD

LNE

GFCI

LOAD

LNE

GFCI

(Bu)

(W)

(G)

(R)

(W)

EM4000SX: *1 · EM5000SX, EM6500SX: *2

CONSUMER INFORMATION

Dealer Locator Information

To find an authorized Honda Servicing Dealer anywhere in the United States, visit our website: http://powerequipment.honda.com/dealer-locator

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 visit http://powerequipment.honda.com/support/shop-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 http://powerequipment.honda.com/generators/accessories and click on Generators and Welders to see the entire catalog of accessories.

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 to:

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

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

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

• Model and serial numbers (see page 72)

• 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

CONSUMER INFORMATION

Distributor’s Limited Warranty

This warranty is limited to the following Honda Power Equipment products when distributed by American Honda Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847. The following warranty applies to products purchased at retail or placed in rental service on or after January 1, 2010.

PRODUCTS COVERED

BY THIS WARRANTY

EM4000SX/EM5000SX/

EM6500SX generator

(1) Private residential: Used in maintaining owner’s primary and/or

secondary residence. Any other use, including but not limited to informal ‘‘for hire’’ use, is considered commercial/rental/ institutional use.

To Qualify for this Warranty:

The product must be purchased in the United States, Puerto Rico, or the U.S. Virgin Islands from American Honda or a dealer authorized by American Honda to sell those products. This warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period.

What American Honda will Repair or Replace Under Warranty:

American Honda will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period. Warranty repairs and replacements will be made without charge for parts or labor. Anything replaced under warranty becomes the property of American Honda Motor Co., Inc. All parts replaced under warranty will be considered as part of the original product, and any warranty on those parts will expire coincident with the original product warranty.

(from date of original retail purchase)

RESIDENTIAL (1)

24 months 12 months

LENGTH OF WARRANTY

PRIVATE

RENTAL/INSTITUTIONAL

COMMERCIAL/

CONSUMER INFORMATION

To Obtain Warranty Service:

You must, at your expense, take the Honda Power Equipment product, accessory, replacement part, apparel, or the power equipment on which the accessory or replacement part is installed, and proof of purchase to any Honda Power Equipment dealer in the United States, Puerto Rico, or the U.S. Virgin Islands who is authorized to sell that product, during the dealer’s normal business hours. To locate a dealer near you, visit our web site at http://powerequipment.honda.com/ dealer-locator/. If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive, contact the owner of the dealership involved; normally this will resolve the problem. However, if you should require further assistance, write or call the Power Equipment Customer Relations Dept. of American Honda Motor Co., Inc. at the following address:

American Honda Motor Co., Inc.

Power Equipment Customer Relations Dept.

4900 Marconi Drive

Alpharetta, GA 30005-8847 Telephone: (770) 497-6400

CONSUMER INFORMATION

Exclusions:

1. Any damage or deterioration resulting from the following: – Neglect of the periodic maintenance as specified in this manual – Improper repair or maintenance – Operating methods other than those indicated in this manual – The use of non-genuine Honda parts and accessories other than

those approved by Honda (other than recommended lubricants and fluids)

– Exposure of the product to soot and smoke, chemical agents, bird

droppings, sea water, salt or other corrosive environments

– Collision, fuel contamination or deterioration, neglect, unauthorized

alteration, misuse, incorporation or use of unsuitable attachments or parts

– Natural wear and tear (natural fading of painted or plated surfaces,

sheet peeling and other natural deterioration)

2. Consumable parts: Honda does not warrant parts deterioration due

to natural wear and tear. The parts listed below are not covered by warranty (unless they are needed as a part of another warranted repair):

– Spark plug, fuel filter, air cleaner element, clutch disc, tire, wheel

bearing, recoil starter rope, cable, belt, cutter blade.

– Lubricant: oil and grease.

3. Cleaning, adjustment, and normal periodic maintenance work

(carburetor cleaning, engine oil draining, blade sharpening, belt and cable adjustments).

4. Any product that has ever been declared a total loss or sold for

salvage by a financial institution or insurer.

5. Auger and paddle assemblies of snowthrowers, tiller tines of

rototillers, mower blades and mower deck housings, are specifically not warranted against impact damage, including but not limited to, abrasive damage.

Disclaimer of Consequential Damage and Limitation of Implied Warranties:

American Honda disclaims any responsibility for loss of time or use of the product, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written limited warranty. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

CONSUMER INFORMATION

Honda Accessories, Replacement Parts, And Apparel

This warranty is limited to Honda Power Equipment parts, accessories, and apparel when distributed by American Honda Motor Co., Inc., 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.

PRODUCTS COVERED

BY THIS WARRANTY

Accessories 12 months 3 months Replacement parts 6 months 3 months Apparel 6 months 3 months

To Qualify for This Warranty:

1. The accessories, replacement parts, or apparel must be purchased

from American Honda, or a dealer, distributor, or distributor’s dealer authorized by American Honda to sell those products in the United States, Puerto Rico, and the U.S. Virgin Islands. Parts and Accessories must be purchased for installation on original Honda equipment or engines to be eligible for warranty coverage. Installing parts and accessories on non-Honda products or engines voids this warranty.

2. You must be the first retail purchaser. This warranty is not

transferable to subsequent owners.

What American Honda Will Repair or Replace Under Warranty:

American Honda will repair or replace, at its option, any Honda Power Equipment accessories, replacement parts, or apparel that are proven to be defective in material or workmanship under normal use during the applicable warranty time period. Anything replaced under warranty becomes the property of American Honda Motor Co., Inc. All parts replaced under warranty will be considered as part of the original product, and any warranty on those parts will expire coincident with the original product warranty. Accessories and replacement parts installed by a dealer, distributor, or distributor’s dealer who is authorized by American Honda to sell them will be repaired or replaced under warranty without charge for parts or labor. If installed by anyone else, accessories and replacement parts will be repaired or replaced under warranty without charge for parts, but any labor charges will be the responsibility of the purchaser. Apparel will be repaired or replaced under warranty without any charge.

(from date of original retail purchase)

RESIDENTIAL

LENGTH OF WARRANTY

PRIVATE

RENTAL/INSTITUTIONAL

COMMERCIAL/

CONSUMER INFORMATION

To Obtain Warranty Service:

You must, at your expense, take the Honda Power Equipment accessory, replacement part, apparel, or the Honda Power Equipment on which the accessory or replacement part is installed, and proof of purchase to any Honda Power Equipment dealer, distributor, or distributor’s dealer in the United States, Puerto Rico, or the U.S. Virgin Islands who is authorized to sell that product, during the dealer’s or distributor’s normal business hours. To locate a dealer near you, go to our web site at http://powerequipment.honda.com/dealer-locator/. If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive, contact the owner of the dealership or distributorship involved; normally this will resolve the problem. However, if you should require further assistance, write or call the Power Equipment Customer Relations Department of America Honda Motor Co., Inc. Refer to page 83 for contact information.

Exclusions:

This warranty does not extend to accessories, parts, or apparel affected or damaged by collision, normal wear, use in an application for which the product was not designed or any other misuse, neglect, incorporation or use of unsuitable attachments or parts, unauthorized alteration, improper installation, or any causes other than defects in material or workmanship of the product. Installing Parts and Accessories on non-Honda products or engines voids this warranty.

Disclaimer of Consequential Damage and Limitation of Implied Warranties:

American Honda disclaims any responsibility for loss of time or use of the product, or the power equipment on which the product is installed, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written warranty. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

CONSUMER INFORMATION

Emission Control System Warranty

Your new Honda Power Equipment engine complies with the U.S. EPA, Environment Canada, and State of California (models certified for sale in California only) emission regulations. American Honda Motor Co., Inc. provides the emission warranty coverage for engines in the United States and its territories. Honda Canada Inc. provides the emission warranty for engines in the 13 provinces and territories of Canada. In the remainder of this Emission Control System Warranty, American Honda Motor Co., Inc. and Honda Canada Inc. will be referred to as Honda.

Your Warranty Rights And Obligations

California

The California Air Resources Board and Honda are pleased to explain the emission control system warranty on your 2016 and later Honda Power Equipment engine. In California, new spark-ignited small off-road equipment engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. Specific Honda products that do not meet the California emissions regulations can be identified by a ‘‘Not for sale in California’’ decal.

Other States, U.S. territories, and Canada

In other areas of the United States and in Canada, your engine must be designed, built, and equipped to meet the U.S. EPA and Environment Canada emission standards for spark-ignited engines at or below 19 kilowatts.

All of the United States and Canada

Honda must warrant the emission control system on your power equipment engine for the period of time listed below, provided there has been no abuse, neglect, or improper maintenance of your power equipment engine. Where a warrantable condition exists, Honda will repair your power equipment engine at no cost to you including diagnosis, parts, and labor.

Your emission control system may include such parts as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, connectors, and other emission-related assemblies (see page 91 for additional covered parts).

CONSUMER INFORMATION

Owner’s Warranty Responsibility

As the power equipment engine owner, you are responsible for completing all required maintenance listed in your owner’s manual. Honda recommends that you retain all receipts covering maintenance on your power equipment engine, but Honda cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure that all scheduled maintenance has been completed.

As the power equipment engine owner, you should however be aware Honda may deny you warranty coverage if your power equipment engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your power equipment engine to a Honda Power Equipment dealer as soon as a problem exists. The emission related warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your emission warranty rights and responsibilities, you should contact the Honda office in your region:

American Honda Motor Co., Inc. Honda Canada Inc. Power Equipment Customer Power Equipment Relations Customer Relations 4900 Marconi Drive or 180 Honda Blvd, Alpharetta, Georgia 30005-8847 Markham, ON L6C 0H9 Telephone: (888) 888-3139 Telephone: (888) 946-6329 Email: powerequipmentemissions

@ahm.honda.com

CONSUMER INFORMATION

Warranty Coverage

Honda power equipment engines sold in the United States and Canada are covered by this warranty for a period of two years from the date of delivery to the original retail purchaser or the length of the Honda Distributor’s Limited Warranty, whichever is longer. This warranty is transferable to each subsequent purchaser for the duration of the warranty period.

If any emission-related part on your engine is defective, the part will be repaired or replaced by Honda without charge for diagnosis, parts, or labor. All defective parts replaced under this warranty become the property of Honda. Only Honda-approved replacement parts may be used in the performance of any warranty repairs and must be provided without charge to the owner. A list of warranted parts is on page 91. Normal maintenance items, such as spark plugs and filters, that are on the warranted parts list are warranted up to their required replacement interval only.

Honda will also replace other engine components damaged by a failure of any warranted part during the warranty period.

The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system. If such a replacement part is used in the repair or maintenance of your engine, and an authorized Honda dealer determines it is defective or causes a failure of a warranted part, your claim for repair of your engine may be denied. If the part in question is not related to the reason your engine requires repair, your claim will not be denied.

CONSUMER INFORMATION

To Obtain Warranty Service

You must, at your own expense, take your Honda Power Equipment engine or the product on which it is installed, along with your sales registration card or other proof of original purchase date, to any Honda Power Equipment dealer who is authorized by Honda to sell and service that Honda product during their normal business hours. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used. If you are unable to obtain emission warranty service or are dissatisfied with the warranty service you received, contact the owner of the dealership involved. Normally this should resolve your problem. However, if you require further assistance, contact the Honda office in your region:

@ahm.honda.com

Exclusions

Failures other than those resulting from defects in material or workmanship are not covered by this warranty. This warranty does not extend to emission control systems or parts that are affected or damaged by owner abuse, neglect, improper maintenance, misuse, misfueling, improper storage, collision, the incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part. This warranty does not cover replacement of expendable maintenance items made in connection with required maintenance service after the item’s first scheduled replacement as listed in the maintenance section of the product owner’s manual, such as: spark plugs and filters.

CONSUMER INFORMATION

Disclaimer of Consequential Damage and Limitation of Implied Warranties

American Honda Motor Co., Inc. and Honda Canada Inc. disclaim any responsibility for incidental or consequential damages such as loss of time or the use of the power equipment, or any commercial loss due to the failure of the equipment; and any implied warranties are limited to the duration of this written warranty. This warranty is applicable only where the California, U.S. EPA, or Environment Canada emission control system warranty regulation is in effect.

Emission Control System Warranty Parts

SYSTEMS COVERED BY THIS WARRANTY:

Fuel Metering Carburetor assembly (includes starting

enrichment system), Oxygen sensor, Throttle body, Engine temperature sensor, Engine control module, Fuel injector, Fuel regulator, Intake manifold

Evaporative Fuel tank, Fuel cap, Fuel hoses,

Vapor hoses, Carbon canister, Canister mounting brackets, Fuel strainer, Fuel valve, Fuel pump,

Fuel hose joint, Canister purge hose joint Exhaust Catalyst, Exhaust pipe, Muffler (with catalyst) Air Induction Air cleaner case, Air cleaner element* Ignition Flywheel comp., Flywheel magneto, Ignition

pulse generator, Crankshaft position sensor,

Power coil, Ignition coil assembly,

Ignition control module, Spark plug cap,

Spark plug* Crankcase Emission

Control Miscellaneous Parts Tubing, fittings, seals, gaskets,

Crankcase breather tube, Breather valve

assembly, Oil filler cap

and clamps associated with these listed

systems.

PARTS

DESCRIPTION:

Note: This list applies to parts supplied by Honda and does not cover parts supplied by the equipment manufacturer. Please see the original equipment manufacturer’s emissions warranty for non-Honda parts. *Covered up to the first required replacement only. See the MAINTENANCE SCHEDULE on page 45.

ASSEMBLY

SAFETY

The Importance of Proper Assembly

Proper assembly is essential to operator safety and the reliability of the machine. Any error or oversight made by the person assembling and servicing a unit can easily result in faulty operation, damage to the machine, or injury to the operator.

Improper assembly can cause an unsafe condition.

Failure to properly follow assembly procedures can lead to serious injury or death.

Follow the procedures and precautions in the assembly instructions carefully.

Some of the most important safety precautions are given in the Important Safety Precautions chapter. However, we cannot warn you of every conceivable hazard that can arise in performing this assembly. Only you can decide whether or not you should perform a given task.

ASSEMBLY

Important Safety Precautions

• Make sure you have a clear understanding of all basic shop safety

practices and that you are wearing appropriate clothing and safety equipment. When performing this assembly, be especially careful of the following:

□ Read the instructions before you begin, and be sure you have

the tools and skills required to perform the tasks safely.

• Make sure the engine is off before you begin any assembly,

maintenance, or repairs. This will help eliminate several potential hazards:

□ Carbon monoxide poisoning from engine exhaust.

Operate outside away from open windows or doors.

□ Burns from hot parts.

Let the engine and exhaust system cool before touching.

□ Injury from moving parts.

Do not run the engine unless the instruction tells you to do so. Even then, keep your hands, fingers, and clothing away. Do not run the engine when any protective guard or shield is removed.

• To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries. Use only a non-flammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel-related parts.

ASSEMBLY

Unpacking

1. Remove the generator and loose parts box from the carton.

2. Compare the loose parts with the inventory list below.

Tools Required: 12 mm wrench (2), pliers

Loose Parts (Wheel kit and handle)

Do not add fuel or oil before tipping the generator. Oil or fuel may damage the engine or your property.

Check all loose parts against the following list. Contact your dealer if any of the loose parts shown below are not included with your generator.

Ref. No. Description Qty.

1 Wheel 2 2 Axle Shaft 1 3 Handle Assembly 1 4 Handle Lower bracket 2 5 Handle Bush B 2 6 Handle Bush A 2 7Stand 2 8 8×16 mm Flange bolt 16 9 20 mm Plain Washer 2

10 4.0×28 mm Split pin 2

11 8 mm Flange nut 4 12 Handle Holder Assembly 1 13 8×18 mm Flange bolt 2

ASSEMBLY

8×18 mm FLANGE BOLT (2)

8×16 mm FLANGE BOLT (8)

HANDLE ASSEMBLY

HANDLE BUSH A (2)

HANDLE BUSH B (2)

HANDLE LOWER BRACKET (2)

FRAME PIPE

HANDLE HOLDER ASSEMBLY

HANDLE

HANDLE LOCK LEVER

Handle Installation

1. Install the handle holder assembly on the generator upper frame using the 8×18 mm flange bolts.

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

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

Operation must be checked after attaching the handle.

• Check that the handle can be folded smoothly.

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

To extend handle:

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

Pressing down on the handles may damage the handle holder assembly. Only pull up on the handles to move the generator.

ASSEMBLY

8×16 mm FLANGE BOLT (8)

SHORTER

UNDER FRAME

GENERATOR SIDE

AXLE SHAFT

20 mm PLAIN WASHER (2)

4.0×28 mm SPLIT PIN (2)

8 mm FLANGE NUT (4)

STAND (2)

WHEEL (2)

Wheel Kit Installation

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

2. Install the two wheels on the axle shaft using the plain washers and split pins. After installing the split pins, bend the pins to ensure that the wheels are secured to the axle.

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

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

INITIAL USE INSTRUCTIONS

UPPER LIMIT

OIL FILLER CAP/DIPSTICK

OIL FILLER NECK

ENGINE OIL

The generator is shipped WITHOUT OIL in the engine.

1. Place the generator on a level surface.

2. Remove the oil filler cap/dipstick.

3. Add enough oil to bring the oil level to the upper limit mark on the oil dipstick. SAE 10W-30 API service category SJ or later (or equivalent) is recommended for general use; for additional recommendations (see page 50).

Maximum oil capacity: 1.2 US qt (1.1 L)

Do not overfill the engine with oil. If the engine is overfilled, the

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

4. Reinstall the oil filler cap/dipstick securely.

INITIAL USE INSTRUCTIONS

FUEL TANK CAP FUEL FILTER

UPPER LEVEL MARK (RED)

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 46 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 when refueling.

• Handle fuel only outdoors.

• Wipe up spills immediately.

1. Remove the fuel tank cap.

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

3. After refueling, reinstall the fuel tank cap securely.

Honda EM4000SX, EM6500SX, EM5000SX Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

A FEW WORDS ABOUT SAFETY

CONTENTS

GENERATOR SAFETY

IMPORTANT SAFETY INFORMATION

SAFETY LABEL LOCATIONS

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

ENGINE SWITCH

STARTER GRIP

CONTROLS

FUEL VALVE LEVER

VOLTAGE SELECTOR SWITCH

Switch Position

AC CIRCUIT BREAKER

Auto Throttle® System

AC Circuit Protectors

Ground Fault Circuit Interrupter (GFCI) Receptacle

DC CIRCUIT PROTECTOR

DC Terminals

Folding Handle

FEATURES

Automatic Engine Stop Function

Auto Choke and Throttle Control System

iAVR (Intelligent Auto Voltage Regulator)

GROUND TERMINAL

Fuel Gauge

BEFORE OPERATION

ARE YOU READY TO GET STARTED?

IS YOUR GENERATOR READY TO GO?

OPERATION

SAFE OPERATING PRECAUTIONS

STARTING THE ENGINE

STOPPING THE ENGINE

GFCI OPERATION CHECK

AC OPERATION

AC Applications

AC Receptacle Selection

Power Producing Circuits

Voltage Selector Switch

DC OPERATION

AUTO THROTTLE® SYSTEM

STANDBY POWER

SERVICING YOUR GENERATOR

THE IMPORTANCE OF MAINTENANCE

MAINTENANCE SAFETY

MAINTENANCE SCHEDULE

REFUELING

FUEL RECOMMENDATIONS

ENGINE OIL LEVEL CHECK

ENGINE OIL CHANGE

ENGINE OIL RECOMMENDATIONS

AIR CLEANER SERVICE

AIR CLEANER ELEMENT CLEANING

SPARK PLUG SERVICE

SPARK ARRESTER SERVICE

SEDIMENT CUP CLEANING

BATTERY SERVICE

FUSE

STORAGE

STORAGE PREPARATION

Cleaning

Fuel

Engine Oil

Engine Cylinder

Battery

STORAGE PRECAUTIONS

REMOVAL FROM STORAGE

TRANSPORTING

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

ENGINE LACKS POWER

NO POWER AT THE AC RECEPTACLES

NO POWER AT THE DC TERMINALS

TECHNICAL INFORMATION

Serial Number Location