Honda EM6500SX Owner's Manual
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Honda EM6500SX Owner's Manual

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Owner's Manual
GENERATOR
EM4000SX/EM5000SX/EM6500SX
Click to Save As
See page 81 for instructions
on assembling your generator.
2015 Honda Motor Co., Ltd. -All Rights Reserved
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  • Page 1 Owner’s Manual GENERATOR EM4000SX/EM5000SX/EM6500SX Click to Save As See page 81 for instructions on assembling your generator. 2015 Honda Motor Co., Ltd. -All Rights Reserved...
  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever.
  • Page 3 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.
  • Page 4 A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS 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...
  • Page 6 CONTENTS OPERATION .....................24 SAFE OPERATING PRECAUTIONS.............24 STARTING THE ENGINE ..............25 STOPPING THE ENGINE ..............28 GFCI OPERATION CHECK ..............29 AC OPERATION..................31 AC Applications................33 AC Receptacle Selection..............34 Power Producing Circuits..............34 Voltage Selector Switch ..............35 DC OPERATION..................37 AUTO THROTTLE SYSTEM..............39 STANDBY POWER ................40 Connections to a Building’s Electrical System ......40 System Ground ................40 Special Requirements..............41...
  • Page 7 Carburetor Modification for High Altitude Operation.......72 Emission Control System Information..........73 Air Index ....................75 Specifications..................76 Wiring Diagram..................77 CONSUMER INFORMATION ..............79 Dealer Locator Information..............79 Honda Publications................79 Customer Service Information ............80 ASSEMBLY ....................81 SAFETY....................81 The Importance of Proper Assembly ..........81 Important Safety Precautions ............82 ASSEMBLY...................83 Unpacking..................83...

  • Page 8: Generator Safety

    GENERATOR SAFETY IMPORTANT SAFETY INFORMATION Honda generators are designed for use with electrical equipment that has suitable power requirements. Other uses can result in injury to the operator or damage to the generator and other property. Most injuries or property damage can be prevented if you follow all instructions in this manual and on the generator.

  • Page 9: Electric Shock Hazards

    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.

  • Page 10: Refuel With Care

    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.

  • Page 11: Safety Label Locations

    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.

  • Page 12: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the illustrations on these pages to locate and identify the most frequently used controls. AC CIRCUIT PROTECTORS RECEPTACLES VOLTAGE SELECTOR SWITCH AC CIRCUIT BREAKER DC CIRCUIT PROTECTOR <EM4000SX> GFCI RECEPTACLES GROUND TERMINAL AUTO THROTTLE SWITCH DC TERMINALS ENGINE SWITCH...
  • Page 13 CONTROLS & FEATURES CONTROL PANEL AIR CLEANER BATTERY COVER FUEL VALVE LEVER SEDIMENT CUP OIL FILLER CAP/DIPSTICK STARTER GRIP OIL DRAIN PLUG HANDLE FUEL TANK CAP FUEL GAUGE SPARK PLUG STAND MUFFLER MANUAL CHOKE LEVER WHEEL...

  • Page 14: Controls

    CONTROLS & FEATURES CONTROLS Engine Switch The engine switch controls the START 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 –...

  • Page 15: Fuel Valve Lever

    CONTROLS & FEATURES 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. FUEL VALVE LEVER Voltage Selector Switch The voltage selector switch switches generator output to produce...

  • Page 16: Auto Throttle System

    CONTROLS & FEATURES ® 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.

  • Page 17: Ac Circuit Protectors

    CONTROLS & FEATURES AC Circuit Protectors The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at each receptacle. If an AC circuit protector switches OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before resetting the AC circuit protector ON.

  • Page 18: Ground Fault Circuit Interrupter (Gfci) Receptacle

    CONTROLS & FEATURES 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.

  • Page 19: Dc Terminals

    CONTROLS & FEATURES 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).

  • Page 20: Folding Handle

    CONTROL & FEATURES 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.

  • Page 21: Features

    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.

  • Page 22: Auto Choke And Throttle Control System

    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...

  • Page 23: Fuel Gauge

    CONTROLS & FEATURES Fuel Gauge The fuel gauge is a mechanical device that measures the fuel level in the tank. The red indicator in the window will reference the level in relation to full or empty. To provide increased operating time, start with a full tank before beginning operation.

  • Page 24: Before Operation

    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.

  • Page 25: Check The Engine

    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.

  • Page 26: Operation

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

  • Page 27: Starting The Engine

    OPERATION STARTING THE ENGINE To prevent a possible fire, keep the generator at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects close to the engine. Operating this generator less than 3 feet (1 meter) from a building or other obstruction can cause overheating and damage the generator.
  • Page 28 OPERATION 4. Make sure the Auto Throttle AUTO THROTTLE SWITCH switch is in the OFF position, or more time will be required for warm up. 5. Start the engine. • Using the electric starter: START Turn the engine switch to the START position, and hold it there until the engine starts.
  • Page 29 OPERATION • Using the recoil starter: a. Turn the engine switch to the ON position. ENGINE SWITCH 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 •...

  • Page 30: Stopping The Engine

    OPERATION STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. 1. Turn off or disconnect all appliances that are connected to the generator. 2.

  • Page 31: Gfci Operation Check

    If the GFCI system fails the test, the generator must be repaired by an authorized Honda servicing dealer before use. 1. Unplug all tools and appliances from the generator. 2. Start the engine (see page 25).
  • Page 32 • The RESET button should be flush with the base. • If the RESET button is not flush with the TEST button, contact an authorized Honda generator dealer. 7. Check the GFCI LED to see if it is correctly functioning.

  • Page 33: Ac Operation

    OPERATION AC OPERATION If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is in the appliance or the rated load capacity of the generator has been exceeded. Substantial overloading may damage the generator.
  • Page 34 OPERATION 3. Switch ON the AC circuit breaker. 4. Plug in the appliance. Most motorized appliances require more than their rated wattage for startup. AC CIRCUIT PROTECTORS AC CIRCUIT BREAKER PLUG *: Except EM4000SX 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...

  • Page 35: Ac Applications

    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...

  • Page 36: Ac Receptacle Selection

    OPERATION AC Receptacle Selection The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. TERMINAL TERMINAL TERMINAL TERMINAL VOLTAGE SELECTOR SWITCH RECEPTACLE ④ <EM4000SX> RECEPTACLE ④ RECEPTACLE ③...

  • Page 37: Voltage Selector Switch

    Total Current Available: 30.0 A (EM4000SX) 37.5 A (EM5000SX) 45.8 A (EM6500SX)
  • Page 38 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 Total Current Available Power Producing Receptacles...

  • Page 39: Dc Operation

    OPERATION 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.
  • Page 40 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.

  • Page 41: Auto Throttle System

    OPERATION ® 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.

  • Page 42: Standby Power

    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.

  • Page 43: Special Requirements

    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. •...

  • Page 44: Servicing Your Generator

    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.

  • Page 45: Maintenance Safety

    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.

  • Page 46: Maintenance Schedule

    (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 79 for ordering information.

  • Page 47: Refueling

    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.

  • Page 48: Fuel Recommendations

    SERVICING YOUR GENERATOR UPPER LEVEL MARK (RED) FUEL TANK CAP FUEL GAUGE FUEL FILTER FULL EMPTY UPPER LEVEL MARK (RED) After refueling, reinstall the fuel tank cap securely. FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher.

  • Page 49: Engine Oil Level Check

    SERVICING YOUR GENERATOR 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.

  • Page 50: Engine Oil Change

    SERVICING YOUR GENERATOR 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.

  • Page 51: Engine Oil Recommendations

    AMBIENT TEMPERATURE 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.

  • Page 52: Air Cleaner Service

    SERVICING YOUR GENERATOR 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.
  • Page 53 SERVICING YOUR GENERATOR 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.

  • Page 54: Air Cleaner Element Cleaning

    SERVICING YOUR GENERATOR AIR CLEANER ELEMENT CLEANING A dirty air cleaner element will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in very dusty areas, clean the air cleaner element more frequently than specified in the Maintenance Schedule. 1.

  • Page 55: Spark Plug Service

    SERVICING YOUR GENERATOR SPARK PLUG SERVICE In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.
  • Page 56 SERVICING YOUR GENERATOR 3. Visually inspect the spark plug. Replace it if the electrodes are 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.

  • Page 57: Spark Arrester Service

    SERVICING YOUR GENERATOR SPARK ARRESTER SERVICE The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester. Clean the spark arrester as follows: 1.

  • Page 58: Sediment Cup Cleaning

    SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING The sediment cup prevents dirt or water that may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1.

  • Page 59: Battery Service

    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.
  • Page 60 SERVICING YOUR GENERATOR 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. COVER SCREW BATTERY COVER 2. Remove the negative (–) BATTERY HOLDER BAND cable from the battery negative (–) terminal, and...
  • Page 61 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.
  • Page 62 SERVICING YOUR GENERATOR 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.

  • Page 63: Fuse

    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.

  • Page 64: Storage

    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.
  • Page 65 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.
  • Page 66 STORAGE Draining the Fuel Tank and Carburetor Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks, and flame away when refueling. • Handle fuel only outdoors. •...

  • Page 67: Engine Oil

    STORAGE 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 56), and then turn the fuel valve lever to the ON position.

  • Page 68: Storage Precautions

    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.

  • Page 69: Transporting

    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.

  • Page 70: Taking Care Of Unexpected Problems

    (see page 53). Spark plug wet with fuel Dry and reinstall spark plug. (flooded engine). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.

  • Page 71: Engine Lacks Power

    (see page 64). gasoline, or refueled with bad Refuel with fresh gasoline gasoline. (see page 45). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.

  • Page 72: No Power At The Ac Receptacles

    Wait a few minutes for the internal circuit to cool down. Restart the engine. Faulty generator. Take the generator to an authorized Honda servicing dealer, or refer to the shop manual. NO POWER AT THE DC TERMINALS Possible Cause Correction DC circuit protector OFF .

  • Page 73: Technical Information

    TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER FRAME SERIAL NUMBER 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:...

  • Page 74: Carburetor Modification For High Altitude Operation

    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.

  • Page 75: Emission Control System Information

    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.
  • Page 76 • 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.

  • Page 77: Air Index

    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.

  • Page 78: Specifications

    TECHNICAL INFORMATION Specifications Dimensions Model EM4000SX EM5000SX EM6500SX Type AT1 type Description code EBRC EBMC EBJC Length 41.1 in (1,043 mm) 41.4 in (1,051 mm) Width 27.8 in (706 mm) Height 28.3 in (719 mm) Dry mass [weight] 203.9 lbs (92.5 kg) 228.2 lbs (103.5 kg)

  • Page 79: Wiring Diagram

    TECHNICAL INFORMATION Wiring Diagram Abbreviations Wire color code Symbol Part name BLACK AC O AC Outlet YELLOW AC CB AC Circuit Breaker BLUE AC CP AC Circuit Protector GREEN Au Sw Auto Throttle Switch Battery WHITE Control Box Block BROWN Charge Coil LIGHT GREEN Current Transformer...
  • Page 80 TECHNICAL INFORMATION EM4000SX: *1 · EM5000SX, EM6500SX: *2...

  • Page 81: Consumer Information

    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.

  • Page 82: Customer Service Information

    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.

  • Page 83: Assembly

    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.

  • Page 84: Important Safety Precautions

    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.

  • Page 85: Assembly

    ASSEMBLY 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) 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.

  • Page 86: Wheel Kit Installation

    ASSEMBLY Wheel Kit Installation 1. Install the two wheels on the axle shaft using the plain washers and split pins. 2. Install the axle assembly on the generator using four 8×16 mm flange bolts and 8 mm flange nuts. 3. Install the two stands on the under frame using four 8×16 mm flange bolts.

  • Page 87: Handle Installation

    ASSEMBLY Handle Installation 1. Install the handle folder 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.

  • Page 88: Initial Use Instructions

    INITIAL USE INSTRUCTIONS 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.

  • Page 89: Fuel

    INITIAL USE INSTRUCTIONS FUEL Add fuel to the generator in a well-ventilated area. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Spilled fuel is not only a fire hazard, it causes environmental damage.

  • Page 90: Battery

    INITIAL USE INSTRUCTIONS Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty. Move the generator at least 10 feet (3 meters) away from the fueling source and site before starting the engine.

  • Page 91: Before Operation

    Please Register Your Generator If your dealer did not collect registration information from you, please take a few minutes and register your purchase with Honda. This allows us to contact you with any important updates regarding your generator. Please note registration is not required to obtain warranty service.

  • Page 92: Optional Parts

    OPTIONAL PARTS Remote Control Kit 1. Remove the plug from the 6-pin connector. PLUG 2. Connect the remote control cable to the back of the control panel and remote control box. REMOTE CONTROL CABLE REMOTE CONTROL CABLE REMOTE CONTROL BOX •...

  • Page 93: Remote Control Box

    OPTIONAL PARTS Remote Control Box PILOT LAMP START BUTTON STOP BUTTON Starting the engine with remote control 1. Turn the fuel valve on the generator to the ON position. 2. Turn the Auto Throttle switch on the generator to the OFF position. 3.

  • Page 94: Hanger Kit

    OPTIONAL PARTS Hanger Kit 1. Position the hanger at the generator’s balance point as shown below. 2. Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely. TORQUE: 17–22 lbf·ft (24–29 N·m, 2.4–3.0 kgf·m) HANGER 8×16 mm FLANGE BOLT (4) HANGER BRACKET (2)

  • Page 95: Index

    INDEX Abnormal Voltage Detection Function..........19 AC Applications .................. 33 AC Circuit Protectors ................15 AC Circuit Breaker................14 AC OPERATION................... 31 AC Receptacle Selection ..............34 AIR CLEANER ELEMENT CLEANING ..........52 AIR CLEANER SERVICE ..............50 Air Index ....................75 ARE YOU READY TO GET STARTED?..........
  • Page 96 Ground Fault Circuit Interrupter (GFCI) Receptacle ......16 Ground Terminal ................21 Handle Installation................85 Hanger Kit.................... 92 Honda Publications................79 iAVR (Intelligent Auto Voltage Regulator) ........20 IMPORTANT SAFETY INFORMATION ..........6 Important Safety Precautions ............82 INITIAL USE INSTRUCTIONS ............86...
  • Page 97 INDEX Knowledge ..................22 Loose Parts..................83 MAINTENANCE SAFETY..............43 MAINTENANCE SCHEDULE .............. 44 NO POWER AT THE AC RECEPTACLES..........70 NO POWER AT THE DC TERMINALS ..........70 Oil Alert Function................19 Oil Alert System.................. 19 OPERATION..................24 Operator Responsibility ............... 6 Overspeed Detection Function ............
  • Page 98 INDEX SAFE OPERATING PRECAUTIONS............ 24 SAFETY....................81 SAFETY LABEL LOCATIONS..............9 Safety Precautions................43 SEDIMENT CUP CLEANING............... 56 Serial Number Location ..............71 SERVICING YOUR GENERATOR ............42 SPARK ARRESTER SERVICE.............. 55 SPARK PLUG SERVICE............... 53 Special Requirements ................ 41 Specifications..................

  • Page 99: Quick Reference Information

    QUICK REFERENCE INFORMATION Fuel Type Regular unleaded gasoline with an ethanol content of no more than 10% and a pump octane rating of 86 or higher (page 46) Engine Oil Type SAE 10W-30, API SJ or later (or equivalent), for general use (page 49) Spark Plug Type...
  • Page 100 31Z23610 英 N FM 00X31-Z23-6100 Printed in China...

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