Honda EX650 Owner's Manual

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

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

Thank you for purchasing a Hondagenerator. 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.
This owner’s manual describes the operation and maintenance of the EX650

Honda Generator. All information in this publication is based on the latest

product information available at the time of printing. Honda Motor Co,. Ltd.

reserves the right to make changes at any time without notice and without

incurring any obligation. No part of this publication may be reproduced without

written permission.

This manual should be considered a permanent part of the generator and

should remain with it if it is resold.

Honda generators normally have spark arresters as standard equipment.
Check whether this EX650 has a spark arrester as standard equipment. If it
does, then the owner will not have to buy one, and you can delete this

paragraph.
Safety Messages

Your safety and the safety of others is very important. We have provided

important safety messages in this manual and on the generator. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others.

Each safety message is preceded by asafety alertsymbol8and one of three
words: DANGER, WARNING, or CAUTION.

These mean

m You WILL be KILLED or SERIOUSLY HURT if you don’t follow

instructions.
m You CAN be KILLED or SERIOUSLY HURT if you don’t follow

instructions.
m You CAN be HURT if you don’t follow instructions.

Each message tells you what the hazard is, what can happen, and what you

can do to avoid or reduce injury.

Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.

This word means:

riiEiq

Your generator or other property could be damaged if you

don’t follow instructions.
The purpose of these messages is to help prevent damage to your generator,

other property, or the environment.

1

CONTENS

SAFETY

Safety Label Locations

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...................................................................

Safety Information ..........................................................................

COMPONENT
CONTROLS

........................................................................................

Engine Switch

IDENTIFICATION

.................................................................................

.......................................................

Recoil Starter.. ................................................................................

Choke .............................................................................................

Pilot Lamp
Ground Terminal

.....................................................................................

...........................................................................

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

AC Circuit Protector.. ....................................................................

DC Terminals ...............................................................................

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

GENERATOR

USE ...........................................................................

AC Operation ................................................................................

DC Operation ...............................................................................

Connecting the battery cables
Disconnecting the battery cables
High Altitude Operation

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.4
.4
.5
.7
.9

.9
.9
.9

10

10
.1 1
.l 1

.12
.12
.13
.14
.15
.15
.16

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2

PRE-OPERATION CHECK

Engine Oil

Fuel Recommendation
STARTING/STOPPING THE ENGINE
MAINTENANCE

Maintenance

Tool Kit ..........................................................................................

Engine Oil Change

Air Cleaner Service

Spark Plug Service

Spark Arrester Maintenance
TRANSPORTING/STORAGE..
TROUBLESHOOTING
WIRING DIAGRAM
SPECIFICATIONS
CUSTOMER

INDEX

......................................................................................

................................................................................ .22

Schedule

...........................................................................

............................................................................

SERVICE INFORMATION

................................................................................................ 37

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..................................................................

.............................................. 21

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.18

18
19

.22

23
.24
.25
.26

28

30
.32
.34
.35

.36

3

SAFETY

SAFETY LABEL LOCATION

These labels warn you of potential hazards that can cause serious injury.

Read them carefully.
If a label comes off or becomes hard to read, contact your Honda Generator

dealer for a replacement.

EXHAUST OUTLET CAUTION

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

l

Know how to stop the generator quickly in case of emergency.

l

Understand the use of all generator controls, output receptacles, and
connections.

l

Be sure that anyone who operates the generator receives proper instruc-

tion. Do not let children operate the generator without parental supervision.

Carbon Monoxide Hazards

l

Exhaust contains poisonous carbon monoxide, a colorless and odorless
gas. Breathing exhaust can cause loss of consciousness and may lead to
death.

l

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

Electric Shock Hazards

The generator produces enough electric power to cause a serious shock
or electrocution if misused.

Using a generator or electrical appliance in wet conditions, such as rain or
snow, or near a pool or sprinkler system, or when your hands are wet, could

result in electrocution. Keep the generator dry.

If the generator is stored outdoors, unprotected from the weather, check all
electrical components on the control panel, before each use. Moisture or

ice can cause a malfunction or short circuit in electrical components which
could result in electrocution.

Do not connect to a building’s electrical system unless an isolation switch

has been installed by a qualified electrician.

5

Fire and Burn Hazards

l

The exhaust system gets hot enough to ignite some materials.

- Keep the generator at least 1 meter (3 feet) away from buildings and
other equipment during operation.

- Do not enclose the generator in any structure.

- Keep flammable materials away from the generator.

l

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.

l

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

l

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

6

FREQUENCY
METER

AC CIRCUIT
PROTECTOR \

DC CIRCUIT ’
PROTECTOR

COMPONENT IDENTIFICATION

CARRYING
HANDLE

I

PILOT LAMP

STARTER
GRIP

ENGINE
SERIAL NUMBER

OIL FILLER
CAP COVER

l

Record the engine serial number for your future reference. Refer to this

/

\

ENGINE

SWITCH

serial number when ordering parts, and when making technical or warranty
inquiries (see page 37)

Engine serial number:

7

FUEL TANK CAP

EXHAUST
OUTLET

\

/

FUEL GAUGE

CEPTACLE

DC TERMINALS

‘GROUND

TERMINAL

8

CONTROLS

Engine Switch
To start and stop the engine.
Switch position:
OFF: To stop the engine.
ON:
CHOKE: To start the engine. (“Cold” engine)

ENGINE SWITCH

To run the engine. (Restart “HOT” engine)

HOKE

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

piEiEq

Do not allow the starter to snap back against the engine.

Return it gently to prevent damage to the starter.

STARTER GRIP

9

Pilot Lamp
The pilot lamp is illuminated when the generator is operating normally. It
indicates that the generator is producing electrical power. If the pilot light is
illuminated, the frequency meter should be displaying 60 Hz.

FREQUENCY METER

\

PILOT

LAMP

Ground Terminal
The gernerator ground terminal is connected to the frame of the generater, 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.

10

GROUND TERMINAL

Oil Alert System
The Oil Alert system is designed to prevent engine damage caused by an
insufficient amount of oil in the crankcase. Before the oil level in the crankcase
can fall below a safe limit, the Oil Alert system will automatically stop the
engine (the engine switch will remain in the ON position). If the engine stops

and will not restart, check the engine oil level (p.18) before troubleshooting in
other areas.

OIL KILLER
CAP COVER

AC Circuit Protector
The AC circuit protector automatically shuts off the AC receptacle circuit when
the generator is overloaded, when there is a problem with the electrical load;
or the connections between the electrical load and the generator are improper.

L

-A

-am

ON OFF

\

AC CIRCUIT PROTECTOR

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

The terminals are colored red to identify the positive (+) terminal and black to
identify the negative (-) terminal. The battery must be connected to the
generator DC terminals with the proper polarity (battery positive to generator
red terminal and battery negative to the generator black terminal).

NEGATIVE
TERMINAL

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

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