Honda EM6500is User Manual

8GENERATOR SAFETYRefuel With CareGasoline is extremely flammable, and gasoline vapor can explode.Allow the engine to cool if the generator has been in

9GENERATOR SAFETYSAFETY LABEL LOCATIONSThese labels warn you of potential hazards that can cause seriousinjury. Read them carefully. If a label comes

10CONTROLS & FEATURESCOMPONENT & CONTROL LOCATIONSENGINE SWITCHOUTPUTINDICATORi-MONITORBUTTONi-MONITORFUEL VALVEVOLTAGE SELECTOR SWITCHCIRCUIT

11CONTROL & FEATURESHANDLEAIR CLEANERFUEL TANK CAPSTARTER GRIPGROUND TERMINALSTANDOIL DRAIN PLUGOIL FILLERCAP/DIPSTICKWHEELMUFFLER TIPSPARK PLUGIN

−−−−12CONTROL & FEATURESCONTROLSFuel Valve LeverEngine SwitchFUEL VALVE LEVEROOFFFFOONNOOFFFFOONNOOFFFFSSTTAARRTTENGINE SWITCHENGINE SWITCHRREEMMO

−−13CONTROL & FEATURESEco-Throttle SwitchStarter GripSTARTER GRIPONOFFECO-THROTTLE SWITCHPulling the starter grip operatesthe recoil starter to cr

14CONTROL & FEATURESVoltage Selector SwitchSwitch PositionAC Circuit Protectors120/240V:120V ONLY:AC CIRCUIT PROTECTORPUSHONVOLTAGE SELECTOR SWITC

15CONTROL & FEATURESFolding HandleTo Extend The HandleTo Fold The HandleHANDLEHANDLE LOCK LEVERHandletransportpositionGeneratorstationarypositionT

16CONTROL & FEATURESFEATURESGround TerminalGROUND TERMINALThe ground terminal is connected to the frame of the generator, themetal non-current-car

17CONTROL & FEATURESOutput IndicatorOverload IndicatorOUTPUTINDICATOR(GREEN)OVERLOADINDICATOR (RED)The output indicator (green) is illuminated whe

Exhaust contains poisonous carbonmonoxide gas that can build up todangerous levels in closed areas.Breathing carbon monoxide cancause unconsciousness

18CONTROL & FEATURESOil Alert IndicatorIt blinks.OIL ALERT(RED)The Oil Alert system is designed to prevent engine damage causedby an insufficient

−19CONTROL & FEATURESi-Monitori-Monitor Display Mode 1 Total Operating Hoursi-Monitor DisplayDisplay Backlight Flashesi-Monitor at StartupSINGLE-D

−−−20CONTROL & FEATURESi-Monitor Display Mode 2 Power Outputi-Monitor Display Mode 3 Engine RPMi-Monitor Display Mode 4 Battery VoltageThis mode d

21CONTROL & FEATURESi-Monitor Low Battery Messagei-Monitor System Error MessagesOVERLOAD INDICATOR LIGHTERROR MESSAGE(Example: E-01)If the generat

22CONTROL & FEATURESFuel GaugeFUEL TANK CAPFULLEMPTYFUEL GAUGEThe fuel gauge is a mechanical device that measures the fuel level inthe tank. The r

23BEFORE OPERATIONARE YOU READY TO GET STARTED?KnowledgeIS YOUR GENERATOR READY TO GO?Your safety is your responsibility. A little time spent in prepa

24BEFORE OPERATIONCheck the EngineMaintenance CoverMAINTENANCE COVERCheck the oil level (see page ). A low oil level will cause the Oil Alertsystem to

25SAFE OPERATING PRECAUTIONSOPERATIONBefore operating the generator for the first time, please review theGENERATOR SAFETYsection and the chapter title

26OPERATIONSTARTING THE ENGINEVOLTAGE SELECTOR SWITCH120VONLY120V/240VFUEL VALVE LEVERECO-THROTTLE SWITCHOONNOOFFFFOONNOOFFFFRefer to Safe Operating P

27OPERATIONOONNOOFFFFSSTTAARRTTENGINE SWITCHStart the engine.Using the electric starter:Turn the engine switch to theSTART position, and hold itthere

1INTRODUCTIONCongratulations on your selection of a Honda generator. We arecertain you will be pleased with your purchase of one of the finestgenerato

28OPERATIONOONNENGINE SWITCHONOOFFFFOOFFFFSTARTER GRIPECO-THROTTLE SWITCHUsing the recoil starter:Turn the engine switch tothe ON position.Pull the st

29OPERATIONStarting the engine with remote control (optional part)ONOOFFFFOFFENGINE SWITCHREMOTEPILOT LAMPFUEL VALVESTART BUTTONDetermine the voltage

30OPERATIONSTOPPING THE ENGINEOONNENGINE SWITCHOONNFUEL VALVE LEVEROOFFFFOOFFFFTo stop the engine in an emergency, simply turn the engine switch tothe

31OPERATIONStopping the engine with remote control (optional part)ONOOFFFFFUEL VALVEENGINE SWITCHREMOTESTOP BUTTONPILOT LAMPOOFFFFTurn the engine swit

−32OPERATIONAC OPERATION120V/240V120V ONLYVOLTAGE SELECTOR SWITCHOUTPUTINDICATOR(GREEN)OVERLOADINDICATOR(RED)If an appliance begins to operate abnorma

33OPERATIONPLUGMost motorized appliancesrequire more than their ratedwattage for startup.Plug in the appliance.Determine if the cause is a short circu

34OPERATIONAC ApplicationsBefore connecting an appliance or power cord to the generator:Make sure that it is in good working order. Faulty appliances

＋＋＋＋＋＋35OPERATIONAC Receptacle SelectionThe generator has separate main power producing circuits. These twocircuits supply power to different receptac

36OPERATION120V 20A120/240V 30A120/240V 30A120V 30A 120V 20AExample: EM5000isReceptacle 1 has a 15A load connected to it. Receptacle 3 has a 10Aload c

37OPERATIONECO-THROTTLE SYSTEMOOFFFFONECO-THROTTLE SWITCHAppliances with large start-up power demands may not allow theengine to reach normal operatin

−−−−−−2A FEW WORDS ABOUT SAFETYSafety LabelsSafety MessagesSafety HeadingsSafety SectionInstructionsYour safety and the safety of others are very impo

38OPERATIONSTANDBY POWERSystem GroundConnections to a Building’s Electrical SystemHonda portable generators have a system ground that connects thegene

39OPERATIONSpecial RequirementsThere may be Federal or State Occupational Safety and HealthAdministration (OSHA) regulations, local codes, or ordinanc

40SERVICING YOUR GENERATORTHE IMPORTANCE OF MAINTENANCEMaintenance, replacement, or repair of the emission control devicesand systems may be performed

−−−41SERVICING YOUR GENERATORMAINTENANCE SAFETYSafety PrecautionsCarbon monoxide poisoning from engine exhaust.Burns from hot parts.Injury from moving

42SERVICING YOUR GENERATORMAINTENANCE SCHEDULEREGULAR SERVICE PERIOD (3)ITEM EachusePerform at every indicated month oroperating hour interval, whiche

43SERVICING YOUR GENERATORREFUELINGGasoline is highly flammable andexplosive.You can be burned or seriouslyinjured when handling fuel.Stop the engine

44SERVICING YOUR GENERATORFUEL RECOMMENDATIONSFULLEMPTYFUEL TANK CAPFUEL GAUGEMAXIMUM FUEL LEVEL(FUEL STRAINER SHOULDER)After refueling, reinstall the

45SERVICING YOUR GENERATORENGINE OIL LEVEL CHECKUPPER LIMITOIL FILLER CAPDIPSTICKCheck the engine oil level with the generator on a level surface and

46SERVICING YOUR GENERATORENGINE OIL CHANGEUPPER LIMITOIL DRAIN PLUGOIL FILLER CAP/DIPSTICKSEALINGWASHEROIL FILLER CAP/DIPSTICKDrain the oil while the

−47SERVICING YOUR GENERATORENGINE OIL RECOMMENDATIONSSAE Viscosity GradesAMBIENT TEMPERATUREOil is a major factor affecting performance and service li

3CONTENTS...GENERATOR SAFETY .6...

48SERVICING YOUR GENERATORAIR CLEANER SERVICEAIR CLEANERCOVERCOVER SCREWFOAM AIR FILTERRemove the foam air filter from the air cleaner cover.Loosen th

49SERVICING YOUR GENERATORFOAM AIR FILTER CLEANINGFOAM AIR FILTERA dirty foam air filter will restrict air flow to the carburetor, reducingengine perf

50SERVICING YOUR GENERATORSEDIMENT CUP CLEANINGFUEL VALVE LEVERONOFFKEYSEDIMENT CUPO-RING(replace)Wash the sediment cup in nonflammable solvent, and d

51SERVICING YOUR GENERATORRecommended spark plugs:SPARK PLUG SERVICESPARK PLUGINSPECTION COVERCOVER SCREWSPARK PLUG WRENCHBPR5ES (NGK)W16EPR-U (DENSO)

−−−−−52SERVICING YOUR GENERATORSEALING WASHER0.028 0.031 in(0.70 0.80 mm)Inspect the spark plug. Replaceit if the electrodes are worn or ifthe insulat

53SERVICING YOUR GENERATORSPARK ARRESTER SERVICEMUFFLER PROTECTOR8 mm FLANGE BOLT (2)REAR BAR6 mm FLANGE NUT (6)The spark arrester must be serviced ev

54SERVICING YOUR GENERATOREXHAUST TAIL PIPESPARK ARRESTER6 mm FLANGE BOLT6 mm FLANGE BOLTSTORQUE:TORQUE:Remove the three 6 mm flange bolts, and remove

−−−55SERVICING YOUR GENERATORBATTERY SERVICEEmergency ProceduresEyesSkinSwallowingYour generator’s engine charging system charges the battery whilethe

−＋＋−56SERVICING YOUR GENERATORBattery RemovalWARNING:Wash hands after handling.POSITIVE ( ) CABLENEGATIVE ( ) CABLEMAINTENANCE COVERCOVER SCREWBATTERY

−−＋＋＋−57SERVICING YOUR GENERATORBattery ChargingBattery InstallationThe battery gives off explosivehydrogen gas during normaloperation.A spark or flam

4CONTENTS...OPERATION .25...

58SERVICING YOUR GENERATORFUSESpecified fuse:FUSE HOLDERFUSE (15A)FUSE HOLDER COVERFUSE (1A)MAINTENANCECOVERCOVERSCREWIn the event of fuse failure, lo

59STORAGE PREPARATIONCleaningFuelSTORAGEProper storage preparation is essential for keeping your generatortrouble-free and looking good. The following

60STORAGEAdding a Gasoline Stabilizer to Extend Fuel Storage LifeWhen adding a gasoline stabilizer, fill the fuel tank with fresh gasoline.If only par

61STORAGEDraining the Fuel Tank and CarburetorDRAIN SCREWGasoline is highly flammable andexplosive.You can be burned or seriouslyinjured when handling

−62STORAGEEngine OilChange the engine oil (see page ).Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder.Remove the spark plug (see pag

63STORAGESTORAGE PRECAUTIONSREMOVAL FROM STORAGEIf your generator will be stored with gasoline in the fuel tank andcarburetor, it is important to redu

64TRANSPORTINGIf the generator has been running, allow the engine to cool for at least15 minutes before loading the generator on the transport vehicle

65ENGINE PROBLEMSEngine Will NotStartPossible Cause CorrectionTAKING CARE OF UNEXPECTED PROBLEMSCheck controlpositions.Check fuel.Check engine oilleve

66TAKING CARE OF UNEXPECTED PROBLEMSEngine LacksPowerPossible cause CorrectionCheck air filter.Check fuel.Take generator toan authorizedHonda servicin

67TAKING CARE OF UNEXPECTED PROBLEMSGENERATOR PROBLEMSNo Power at theAC ReceptaclesPossible Cause CorrectionCheck AC load.Stop and restartthe engine.C

5CONTENTS...TRANSPORTING .64...

68TECHNICAL INFORMATIONSerial Number LocationTECHNICAL & CONSUMER INFORMATIONFRAME SERIAL NUMBERFrame serial number:Date purchased:Record the fram

69TECHNICAL & CONSUMER INFORMATIONCarburetor Modification for High Altitude OperationAt high altitude, the standard carburetor air-fuel mixture wi

70TECHNICAL & CONSUMER INFORMATIONEmission Control System InformationSource of EmissionsThe U.S. and California Clean Air ActsThe combustion proce

71TECHNICAL & CONSUMER INFORMATIONTampering and AlteringTampering with or altering the emission control system may increaseemissions beyond the le

72TECHNICAL & CONSUMER INFORMATIONProblems That May Affect EmissionsReplacement PartsMaintenanceIf you are aware of any of the following symptoms,

−−−73TECHNICAL & CONSUMER INFORMATIONAir Index(Models certified for sale in California)The Air Index Information hang tag must remain on the gener

××±±−×〈〉−−＊＊74TECHNICAL & CONSUMER INFORMATIONSpecificationsEM5000isSPECIFICATIONTuneup SpecificationsITEM MAINTENANCEDimensionsEngineGeneratorEAJ

±××±−×〈〉−−＊＊75TECHNICAL & CONSUMER INFORMATIONTuneup SpecificationsITEM SPECIFICATION MAINTENANCEDimensionsEngineGeneratorEM6500isEAHJEM6500isSpar

76TECHNICAL & CONSUMER INFORMATIONWiring Diagram07/03/13 16:32:40 31Z11600_077

77TECHNICAL & CONSUMER INFORMATIONCONSUMER INFORMATIONHonda PublicationsShop ManualParts CatalogAccessories CatalogThis manual covers complete mai

6GENERATOR SAFETYOperator ResponsibilityCarbon Monoxide HazardsIMPORTANT SAFETY INFORMATIONHonda generators are designed for use with electrical equip

78TECHNICAL & CONSUMER INFORMATIONCustomer Service InformationHonda Power Equipment dealership personnel are trainedprofessionals. They should be

79SAFETYThe Importance of Proper AssemblyASSEMBLYImproper assembly can cause anunsafe condition that can lead toserious injury or death.Follow the pro

□□□□80ASSEMBLYImportant Safety PrecautionsCarbon monoxide poisoning from engine exhaust.Burns from hot parts.Injury from moving parts.Make sure you ha

×××81ASSEMBLYASSEMBLYUnpackingLoose PartsTools Required:Compare the loose parts with the inventory list below.Remove the generator and loose parts box

−− −×××××82ASSEMBLYWheel Kit InstallationTORQUE:AXLEWHEEL (2)STAND (2)LONGER20 mm WASHER (2)8 16 mm FLANGE BOLT (4)4.0 28 mm COTTER PIN (2)816mmFLANGE

−− −83ASSEMBLYHandle InstallationTo extend handle:TORQUE:SPRING WASHER (2)12 mm WASHER (2)HANDLE HOLDER BOLT (2)HANDLE ASSEMBLYHANDLEHANDLE LOCK LEVER

−− −××84ASSEMBLYRear Bar InstallationTORQUE:8 45mm FLANGE BOLT (2)REAR BAR17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)Install the rear bar on the generato

＋＋−＋−85ASSEMBLYBatteryWARNING:Wash hands after handling.TWIST CLIPBATTERY STRAPRED CABLE(POSITIVE ( ) CABLE)BLACK CABLE(NEGATIVE ( ) CABLE)BOTTOM HOOK

86ASSEMBLYInstall the maintenance cover in the reverse order of removal (seepage ).Never operate the generator without the maintenance cover in place,

87ASSEMBLYEngine OilWITHOUT OILFuelSAE Viscosity GradesAMBIENT TEMPERATUREOIL FILLER HOLEUPPER LIMITFILLER CAP/DIPSTICKThe generator is shippedin the

−−−7GENERATOR SAFETYElectric Shock HazardsFire and Burn HazardsThe generator produces enough electric power to cause a seriousshock or electrocution i

88ASSEMBLYBEFORE OPERATIONSTARTING THE ENGINESTOPPING THE ENGINEGENERATOR SAFETYCONTROLS & FEATURESOPERATIONBefore using your generator, you shoul

89Remote Control KitOPTIONAL PARTSKNOCKOUTMAINTENANCE COVER(backside)PLUGRemove the maintenance cover (see page ).Remove the plug from the 6-pin conne

90OPTIONAL PARTSCABLE TIEREMOTECONTROL CABLEREMOTE CONTROL CABLEREMOTE CONTROL BOXMAINTENANCE COVERGROMMETPLUGPass the remote control cable through th

−− −×91OPTIONAL PARTSHanger KitTORQUE:HANGERGENERATORSIDEHANGER BRACKET (2)8 16 mm FLANGE BOLT (4)HANGERFUEL TANKRIBPosition the hanger at the generat

92INDEXABCE...AC Applications . 34...

93INDEXFGHIKL...FEATURES . 16...

94INDEXMOQR...Maintenance Cover . 24...

95INDEXSTUVW...Unpacking . 81...

96MEMO07/03/13 16:35:36 31Z11600_097

−−QUICK REFERENCE INFORMATIONUnleaded gasoline with a pumpoctane rating of 86 or higher0.028 0.031 in (0.70 0.80 mm)BPR5ESW16EPR-UCheck engine oil lev