EM3800SX•EM5000SX•EM6500SXcdn.powerequipment.honda.com/pe/pdf/manuals/31Z21600.pdf · EM3800SX•EM5000SX•EM6500SX K2:EM5000SX See page 54 for instructions on assembling your

EM3800SX•EM5000SX•EM6500SX

K2:EM5000SXSee page 54 for instructionson assembling your generator.

31Z2160000X31-Z21-6000

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

Keep this owner’s manual handy, so you can refer to it at any time.This owner’s manual is considered a permanent part of the generatorand should remain with the generator if resold.

The information and specifications included in this publication were ineffect at the time of approval for printing. Honda Motor Co., Ltd.reserves the right, however, to discontinue or change specifications ordesign at any time without notice and without incurring any obligationwhatever. No part of this publication may be reproduced withoutwritten permission.

The engine exhaust from this productcontains chemicals known to the Stateof California to cause cancer, birthdefects or other reproductive harm.

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Congratulations on your selection of a Honda generator. We arecertain you will be pleased with your purchase of one of the finestgenerators on the market.

We want to help you get the best results from your new generator andto operate it safely. This manual contains the information on how todo that; please read it carefully.

As you read this manual, you will find information preceded by asymbol. That information is intended to help you avoid

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

We suggest you read the warranty policy to fully understand itscoverage and your responsibilities of ownership. The warranty policyis a separate document that should have been given to you by yourdealer.

When your generator needs scheduled maintenance, keep in mindthat your Honda servicing dealer is specially trained in servicingHonda generators. Your authorized Honda servicing dealer isdedicated to your satisfaction and will be pleased to answer yourquestions and concerns.

Best Wishes,Honda Motor Co., Ltd.

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A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

To help you make informed decisions about safety, we have providedoperating procedures and other information on labels and in thismanual. This information alerts you to potential hazards that couldhurt you or others.

Of course, it is not practical or possible to warn you about all thehazards associated with operating or maintaining a generator. Youmust use your own good judgement.

You will find important safety information in a variety of forms,including:

on the generator.

These signal words mean:

be or ifyou don’t follow instructions.

be or ifyou don’t follow instructions.

be if you don’t follow instruc-tions.

Your safety and the safety of others are very important. And usingthis generator safely is an important responsibility.

preceded by a safety alert symbol and oneof three signal words, DANGER, WARNING, or CAUTION.

such as IMPORTANT SAFETY INFORMATION.

such as

how to use this generator correctly and safely.

This entire book is filled with important safety information pleaseread it carefully.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERATOR SAFETY .

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CONTENTS

......................................................................................................SAFETY . 5.......................................................................Safety Label Locations . 5

..............................................................................Safety Information . 6..............................................................COMPONENT IDENTIFICATION . 8

..............................................................................................CONTROLS . 10....................................................................................Engine Switch . 10.....................................................................................Recoil Starter . 10

................................................................................Fuel Valve Lever . 11..........................................................................................Choke Rod . 11

............................Voltage Selector Switch (Dual Voltage System) . 12...............................................................................Ground Terminal . 12

.......................................................................................DC Terminal . 13..........................................................................DC Circuit Protector . 13

..............................................................................Oil Alert System . 14......................................................................Auto Throttle System . 14

.............................................................................AC Circuit Breaker . 15..........................................................................AC Circuit Protector . 16

...................................................................................GENERATOR USE . 17...............................Connections to a Building’s Electrical System . 17

..................................................................................Ground System .17.......................................................................Special Requirements . 17

.................................................................................AC Applications . 18.....................................................................................AC Operation . 19

...................................................................AC Receptacle Selection . 20.....................................................................................DC Operation . 23

......................................................................Auto Throttle System . 25....................................................................High Altitude Operation . 26

.......................................................................PRE-OPERATION CHECK . 27..........................................................................................Engine Oil . 27

.....................................................................................................Fuel . 28..............................STARTING THE ENGINE/STOPPING THE ENGINE . 30

......................................................................................MAINTENANCE . 31......................................................The Importance of Maintenance . 31

..........................................................................Maintenance Safety . 32............................................Emission Control System Information . 33

.............................................................................................Air Index . 36.....................................................................Maintenance Schedule . 37

............................................................................Engine Oil Change . 38...........................................................................Air Cleaner Service . 39

...........................................................Fuel Sediment Cup Cleaning . 40............................................................................Spark Plug Service . 41

............................................................Spark Arrester Maintenance . 42.............................................................................Fuse Replacement . 43

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..................................................................TRANSPORTING/STORAGE . 44.............................................................................TROUBLESHOOTING . 47

.................................................................................WIRING DIAGRAM . 49....................................................................................SPECIFICATIONS . 51

..............................................................................................ASSEMBLY . 54.................................................WARRANTY SERVICE INFORMATION . 66

......................................................................................................INDEX . 67

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SAFETY

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause seriousinjury. Read them carefully.

If a label comes off or becomes hard to read, contact your Hondagenerator dealer for a replacement.

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SAFETY INFORMATION

Operator Responsibility

Carbon Monoxide Hazards

Honda generators are designed to give safe and dependable service ifoperated according to instructions. Read and understand this owner’smanual before operating your generator. You can help preventaccidents by being familiar with your generator’s controls, and byobserving safe operating procedures.

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 properinstruction. Do not let children operate the generator withoutparental supervision.

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

If you run the generator in an area that is confined, or even partiallyenclosed, the air you breathe could contain a dangerous amount ofexhaust gas. To keep exhaust gas from accumulating, provideadequate ventilation.

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Electric Shock Hazards

Fire and Burn Hazards

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

Using a generator or electrical appliance in wet conditions, such asrain or snow, or near a pool or sprinkler system, or when your handsare wet, could result in electrocution. Keep the generator dry.

If the generator is stored outdoors, unprotected from the weather,check all of the electrical components on the control panel, beforeeach use. Moisture or ice can cause a malfunction or short circuit inelectrical components which could result in electrocution.

Do not connect to a building electrical system unless an isolationswitch has been installed by a qualified electrician.

The exhaust system gets hot enough to ignite some materials.Keep the generator at least 3 feet (1 meter) away from buildingsand 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 fora while after stopping the engine. Be careful not to touch the mufflerwhile it is hot. Let the engine cool before storing the generatorindoors.

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

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

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COMPONENT IDENTIFICATION

CONTROL PANEL

CHOKE ROD

ENGINE SWITCHCONTROL PANEL

AIR CLEANER

FUEL VALVE LEVER

RECOIL STARTER GRIP

ENGINE SERIAL NUMBER

OIL FILTER CAP/DIP STICK

AC CIRCUIT PROTECTORS

120/240 ACRECEPTACLE

GROUND TERMINALAUTO THROTTLESWITCH

120 ONLY 120/240VOLTAGE SELECTOR SWITCH

AC RECEPTACLES

DC CIRCUITPROTECTOR

DC OUTPUTTERMINAL

OIL DRAIN BOLT

AC CIRCUIT BREAKER

1

FUSE

1:Except EM3800SX

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CONTROLS

Engine Switch

Recoil Starter

Key position:OFF:ON:START:

STARTER GRIP

ENGINE SWITCH

ONOOFFFF SSTTAARRTT

RECOIL STARTER

To start and stop the engine.

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

Do not allow the starter grip to snap back against the engine. Return itgently to prevent damage to the starter.

To stop the engine. Key can be removed/inserted.To run the engine after starting.To start the engine by operating the starter motor.

The recoil starter is used to start the engine if the generator is notequipped with a 12 volt battery to operate the starter motor, or if thebattery does not contain adequate charge to operate the starter motor.

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Fuel Valve Lever

Choke Rod

OPEN

CHOKE ROD

OFF

ON

FUEL VALVE LEVER

CCLLOOSSEEDD

The choke is used to provide an enriched fuel mixture when starting acold engine. It can be opened and closed by operating the choke rodmanually. Pull the rod out toward CLOSED to enrich the mixture forcold starting.

The fuel valve is located between the fuel tank and carburetor. Whenthe valve lever is in the ON position, fuel is allowed to flow from thefuel tank to the carburetor. Be sure to return the fuel valve lever to theOFF position after stopping the engine.

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Voltage Selector Switch (Dual Voltage System)

Ground Terminal

Switch Position120/240V:

120V ONLY:

GROUND TERMINAL

VOLTAGE SELECTOR SWITCH

120V ONLY

120/240V

112200//224400VV

112200VV OONNLLYY

The voltage selector switch switches the main power carryingwindings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a240V appliance is connected to the 4-prong receptacle, the switchmust be in the ‘‘120/240V’’ position. If only a 120V appliance is beingconnected to any of the 120V 3-prong receptacles, select the ‘‘120VONLY’’ position.

ONLY the 120V receptacles can be used. Do not use the120/240V receptacle in this position. The most powerwill be available at the 30A 120V locking plugreceptacle.

The 120V and 120/240V receptacles can be usedsimultaneously.

Before using the ground terminal, consult a qualified electrician,electrical inspector or local agency having jurisdiction for local codesor ordinances that apply to the intended use of the generator.

The generator ground terminal is connected to the frame of thegenerator, the metal non-current-carrying parts of the generator, andthe ground terminals of each receptacle.

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DC Terminals

DC Circuit Protector

DC CIRCUITPROTECTOR

NEGATIVE TERMINAL(BLACK)

POSITIVE TERMINAL(RED)

The DC terminals may ONLY be used for charging 12 volt automotivetype batteries.The terminals are colored red to identify the positive ( ) terminal andblack to identify the negative ( ) terminal. The battery must beconnected to the generator DC terminals with the proper polarity(battery positive to generator red terminal and battery negative to thegenerator black terminal).

The DC circuit protector automatically shuts off the DC batterycharging circuit when the DC charging circuit is overloaded, whenthere is a problem with the battery, or when the connections betweenthe battery and the generator are improper.

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Oil Alert System

Auto Throttle System

Switch PositionAUTO:

OFF:

OFF

ON

OFF

ON

AUTO THROTTLE SWITCH

If the engine stops and will not restart, check the engine oil level (seepage ) before troubleshooting in other areas.

The auto throttle system automatically reduces engine speed when allloads are turned off or disconnected. When appliances are turned onor reconnected, the engine returns to the rated speed.

Recommended to minimize fuel consumption and furtherreduce noise levels when no load is applied to the generator.

The Oil Alert system is designed to prevent engine damage causedby an insufficient amount of oil in the crankcase. Before the oil level inthe crankcase can fall below a safe limit, the Oil Alert system willautomatically stop the engine (the engine switch will remain in the ONposition). The Oil Alert system should not take the place of checkingthe oil level before each use.

The auto throttle system does not operate.Recommended to minimize warm-up time when thegenerator is started and starting load with large start-uppower equipments.

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AC Circuit Breaker

OFF

ON

AC CIRCUIT BREAKER

The AC circuit breaker will automatically switch OFF if there is a shortcircuit or a significant overload of the generator at the receptacle. If theAC circuit breaker is switched OFF automatically, check that theappliance is working properly and does not exceed the rated loadcapacity of the circuit before switching the AC circuit breaker ON again.

The AC circuit breaker may be used to switch the generator power ONor OFF.

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AC Circuit Protector

ON

OFF


1

1:Except EM3800SX

The AC circuit protectors will automatically switch OFF if there is ashort circuit or a significant overload of the generator at the 20A 120V,30A 120V locking plug, or 120/240V locking plug receptacle. If a ACcircuit protector switches OFF automatically, check that the applianceis working properly and does not exceed the rated load capacity of thecircuit before resetting the AC circuit protector ON.

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GENERATOR USE

Improper connections to a building electrical system can allowelectrical current from the generator to backfeed into the utility lines.Such backfeed may electrocute utility company workers or otherswho contact the lines during a power outage, and the generator mayexplode, burn, or cause fires when utility power is restored. Consultthe utility company or a qualified electrician.

Connections to a Building Electrical System

Ground System

Special Requirements

There may be Federal or State Occupational Safety and HealthAdministration (OSHA) regulations, local codes, or ordinances thatapply to the intended use of the generator. Please consult a qualifiedelectrician, electrical inspector, or the local agency having jurisdiction.

Connections for standby power to a building electrical system must bemade by a qualified electrician. The connection must isolate thegenerator power from utility power, and must comply with allapplicable laws and electrical codes. A transfer switch, which isolatesgenerator power from utility power, is available through authorizedHonda generator dealers.

In some areas, generators are required to be registered with localutility companies.

Honda portable generators have a system ground that connectsgenerator frame components to the ground terminals in the AC outputreceptacles. The system ground is not connected to the AC neutralwire. If the generator is tested by a receptacle tester, it will show thesame ground circuit condition as for a home receptacle.

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

Make sure that it is in good working order. Faulty appliances orpower cords can create a potential for electrical shock.

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

Make sure that the electrical rating of the tool or appliance does notexceed that of the generator. Never exceed the maximum powerrating of the generator. Power levels between rated and maximummay be used for no more than 30 minutes.

Limit operation requiring maximum power to 30 minutes.Maximum power is:

Substantial overloading will open the circuit breaker. Exceeding thetime limit for maximum power operation or slightly overloading thegenerator may not switch the circuit breaker or circuit protector OFF,but will shorten the service life of the generator.

For continuous operation (longer than 30 minutes), do not exceed therated power.Rated power is:

The total power requirements (VA) of all appliances connected mustbe considered. Appliance and power tool manufacturers usually listrating information near the model number or serial number.

3,300 VA

3,800 VA5,000 VA6,500 VA

4,500 VA5,500 VA

EM3800SX:EM5000SX:EM6500SX:

EM3800SX:EM5000SX:EM6500SX:

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AC Operation

VOLTAGE SELECTOR SWITCH

1


AC CIRCUIT BREAKER

1:Except EM3800SX

Start the engine (see page ).

Turn the voltage selector switch to either position.

With the voltage selector switch in the ‘‘120/240V’’ position, you canuse the 120V and 120/240V receptacles simultaneously. If you areNOT using the 120/240V receptacle, but require more power fromthe 120V locking plug receptacle, then select the ‘‘120V ONLY’’position.

Plug in the appliance.

Most motorized appliances require more than their rated power forstartup.

Do not exceed the current limit specified for any one receptacle. If anoverloaded circuit causes the AC circuit breaker or AC circuit protectorto switch OFF, reduce the electrical load on the circuit, wait a fewminutes and then reset the AC circuit breaker or AC circuit protector.

Switch the AC circuit breaker ON.

1.

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4.

3.

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AC Receptacle Selection

Main power circuit

Main Circuit I

Main Circuit II

Receptacles poweredby each main circuit

Power distribution

EM3800SX:

120V 30A120V 20A120/240V 20A

The generator has two separate main power producing circuits.These two circuits supply equal power to different receptaclesshown when the voltage selector switch is in the 120/240Vposition.

Example:

Receptacle 1 has a 10A load connected to it. Receptacle 3 has a 10A load connected to it. Both receptacles are powered by mainpower circuit II. The equation tells us that the total power draw oncircuit II is 20A. This is a substantial overload of this circuit. Toeliminate the excess power draw on circuit II, the load fromreceptacle 3 should be switched to receptacle 2. Now circuit I ispowering the 10A load (less than 13.8A) and circuit II is poweringa 10A load (less than 13.8A).

The table shows the specifications when the 120/240V lockingplug receptacle is used for 120V.

2 and 4

1, 3 and 5

2 4=13.8A rated.

1 3 5=13.8A rated.

When two or more receptacles are used; prevent overloading bydividing the load between the two power circuits.The chart below shows the rated load in amperes that can beconnected to each receptacle to balance the generator.The total rated ampere draw is 27.5A.

&&

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Main power circuit

Main Circuit I

Main Circuit II


Power distribution

EM5000SXK2:

120V 30A120V 20A120/240V 30A



2 and 4

1, 3 and 5

2 4=18.8A rated.

1 3 5=18.8A rated.

Example:


The generator has separate main power producing circuits. Thesetwo circuits supply equal power to different receptacles shownwhen the voltage selector switch is in the 120/240V position.

&&

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Main power circuit

Main Circuit I

Main Circuit II


Power distribution

EM6500SX:

120V 30A120V 20A120/240V 30A



The generator has separate main power producing circuits. Thesetwo circuits supply equal power to different receptacles shownwhen the voltage selector switch is in the 120/240V position.

Example:


2 and 4

1, 3 and 5

2 4=22.9A rated.

1 3 5=22.9A rated.

&&

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The battery gives off explosive gases; keep sparks, flames andcigarettes away. Provide adequate ventilation when charging orusing batteries.

Battery posts, terminals and related accessories contain lead andlead compounds. Wash hands after handling.

DC Operation

Connecting the battery cables:



DC CIRCUITPROTECTOR

The DC terminals may ONLY be used for charging 12 volt automotivetype batteries.

Start the generator.

Do not start the vehicle while the battery charging cable is connectedand the generator is running. The vehicle or the generator may bedamaged.

Connect the positive ( ) battery cable to the battery positive ( )terminal.Connect the other end of the positive ( ) battery cable to thegenerator positive ( ) terminal.

Connect the negative ( ) battery cable to the battery negative ( )terminal.Connect the other end of the negative ( ) battery cable to thegenerator negative ( ) terminal.

Before connecting the battery charging cables to a battery that isinstalled in a vehicle, disconnect the vehicle ground battery cablefrom the battery negative ( ) terminal.

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Disconnecting the battery cables:



DC CIRCUITPROTECTOR

Stop the engine.

An overloaded DC circuit, excessive current draw by the battery, or awiring problem will trip the DC circuit protector (PUSH button extendsout). If this happens, wait a few minutes before pushing in the circuitprotector to resume operation. If the DC circuit protector continues togo OFF, discontinue charging and see your authorized Hondagenerator dealer.

Disconnect the negative ( ) battery cable from the generatornegative ( ) terminal.Disconnect the other end of the negative ( ) battery cable from thebattery negative ( ) terminal.Disconnect the positive ( ) battery cable from the generatorpositive ( ) terminal.Disconnect the other end of the positive ( ) battery cable from thebattery positive ( ) terminal.Reconnect the vehicle ground battery cable to the battery negative( ) terminal.

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6.

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Auto Throttle System

OFF

ON

OFF

ON

AUTO THROTTLE SWITCH

With the switch in the AUTO position, engine speed is automaticallyreduced when ALL loads are turned OFF or disconnected. Whenappliances are turned ON or reconnected, the engine returns to ratedspeed. In the OFF position, the auto throttle system does not operate.

The auto throttle system will not respond to electrical loads of lessthan 1 ampere or intermittent loads such as a staple gun. Turn theauto throttle switch to the OFF position to operate loads of less than 1.

Appliances with large start-up power demands may not allow theengine to reach normal operating rpm when they are connected to thegenerator. Push the auto throttle switch to the OFF position andconnect the appliance to the generator. If the engine still will not reachnormal operating speed, check that the appliance does not exceed therated load capacity of the generator.

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

The auto throttle system is not effective for use with appliances thatrequire only momentary power. If the tool or appliance will be turnedON and OFF quickly, the auto throttle switch should be in the OFFposition.

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High Altitude OperationAt high altitude, the standard carburetor air/fuel mixture will be toorich. Performance will decrease, and fuel consumption will increase. Avery rich mixture will also foul the spark plug and cause hard starting.Operation at an altitude that differs from that at which this engine wascertified, for extended periods of time, may increase emissions.

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

High altitude performance can be improved by specific modificationsto the carburetor. If you always operate your generator at altitudesabove 5,000 feet (1,500 meters), have your dealer perform thiscarburetor modification. This engine, when operated at high altitudewith the carburetor modifications for high altitude use, will meet eachemission standard throughout its useful life.

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

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PRE-OPERATION CHECK

Engine Oil

UPPER LEVEL

OIL FILLER CAPOIL FILLER HOLE

SAE Viscosity Grades

AMBIENT TEMPERATURE

Engine oil is a major factor affecting engine performance and servicelife. Non detergent and 2-stroke engine oils will damage the engineand are not recommended.

SAE 10W-30 is recommended for general, all-temperature use. Otherviscosities shown in the chart may be used when the averagetemperature in your area is within the indicated range.

Remove the oil filler cap and wipe the dipstick clean.Check the oil level by inserting the dipstick into the filler neckwithout screwing it in.If the level is low, fill to the top of the oil filler neck with therecommended oil.

Use 4-stroke motor oil thatmeets or exceeds the require-ments for API service classifi-cation SJ. Always check the APISERVICE label on the oil contain-er to be sure it includes the letterSJ.

Check the oil level BEFOREEACH USE with the generator ona level surface and the enginestopped.

1.2.

3.

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Fuel

Gasoline is highly flammable and explosive, and you can be burned orseriously injured when refueling.

Stop engine and keep heat, sparks, and flame away.Refuel only outdoors.Wipe up spills immediately.

Fuel tank capacity:

FUEL FILLER CAP

FUEL GAUGEFUEL STRAINER SHOULDER

Check the fuel gauge, and refill the tank if the fuel level is low.

Refuel carefully to avoid spilling fuel. Do not fill above the shoulder ofthe fuel strainer.

Use unleaded gasoline with a pump octane rating of 86 or higher.

This engine is certified to operate on unleaded gasoline.Unleaded gasoline produces fewer engine and spark plug depositsand extends exhaust system life.Never use stale or contaminated gasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fuel tank.

6.6 US gal (25 )

Fuel can damage paint and plastic. Be careful not to spill fuel whenfilling your fuel tank. Damage caused by spilling fuel is not coveredunder warranty.

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Oxygenated Fuels

ETHANOL

MTBE

METHANOL

Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’(metallic rapping noise) while operating under heavy loads. This is nocause for concern.If spark knock or pinging occurs at a steady engine speed, undernormal load, change brands of gasoline. If spark knock or pingingpersists, see an authorized Honda generator dealer.

Running the engine with persistent spark knock or pinging can causeengine damage.

Running the engine with persistent spark knock or pinging is misuse,and the Distributor’s Limited Warranty does not cover parts damagedby misuse.

If you use an oxygenated fuel, be sure it is unleaded and meets theminimum octane rating requirement.Before using an oxygenated fuel, try to confirm the fuel’s contents.Some states/provinces require this information to be posted on thepump.The following are the EPA approved percentages of oxygenates:

(methyl or wood alcohol) 5% by volumeYou may use gasoline containing up to 5% methanolby volume as long as it also contains cosolvents andcorrosion inhibitors to protect the fuel system.Gasoline containing more than 5% methanol byvolume may cause starting and/or performanceproblems. It may also damage metal, rubber, andplastic parts of your fuel system.

If you notice any undesirable operating symptoms, try another servicestation or switch to another brand of gasoline.

(ethyl or grain alcohol) 10% by volumeYou may use gasoline containing up to 10% ethanolby volume. Gasoline containing ethanol may bemarketed under the name ‘‘Gasohol’’.(methyl tertiary butyl ether) 15% by volumeYou may use gasoline containing up to 15% MTBE byvolume.

Some conventional gasolines are being blended with alcohol or anether compound. These gasolines are collectively referred to asoxygenated fuels. To meet clean air standards, some areas of theUnited States and Canada use oxygenated fuels to help reduceemissions.

Fuel system damage or performance problems resulting from the useof an oxygenated fuel containing more than the percentages ofoxygenates mentioned above are not covered under the Distributor’sLimited Warranty.

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STARTING THE ENGINE/STOPPING THE ENGINE

Starting the Engine

Stopping the Engine

In normal use:

In an emergency:

Make sure that the AC circuit breaker is in the OFF position. Thegenerator may be hard to start if a load is connected.Turn the fuel valve lever to the ON position.The automatic choke will be closed if the engine is cold. If you wantto operate the choke manually, pull the choke rod out to the CLOSEDposition.Make sure the auto throttle switch is in the OFF position, or moretime will be required for warm up.

Pull the starter grip lightly until resistance is felt, then pull briskly.Turn the engine switch to the ON position.

Do not allow the starter grip to snap back against the engine. Return itgently to prevent damage to the starter.

If you wish to use the auto throttle system, turn the auto throttleswitch to the AUTO position after the engine has warmed up for 2 or3 minutes.

With electric starter:Connect the battery cables to the generator. (page )Turn the engine switch to the START position and hold it there for 5seconds or until the engine starts.

Operating the starter motor for more than 5 seconds can damagethe motor. If the engine fails to start, release the switch and wait 10seconds before operating the starter again.If the speed of the starter motor drops after a period of time, it is anindication that the battery should be recharged.

Turn the fuel valve lever to the OFF position.

To stop the engine in an emergency, move the engine switch to theOFF position.

When the engine starts, allow the engine switch to return to the ONposition.

If you have manually closed the choke, push it to the OPEN positionas the engine warms up.

Turn the AC circuit breaker to the OFF position.Disconnect DC battery charging cables.Turn the engine switch to the OFF position.

1.

2.3.

4.

5.6.

7.

8.

1.

2.3.

1.2.

62

03/11/17 18:42:57 31Z21600_031

31

MAINTENANCE

Improper maintenance, or failure to correct a problem beforeoperation, can cause a malfunction in which you can be seriously hurtor killed.

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

Maintenance, replacement, or repair of the emission control devicesand systems may be performed by any engine repair establishment orindividual, using parts that are ‘‘certified’’ to EPA standards.

The Importance of Maintenance

Good maintenance is essential for safe, economical, and trouble-freeoperation. It will also help reduce air pollution.

To help you properly care for your generator, the following pagesinclude a maintenance schedule, routine inspection procedures, andsimple maintenance procedures using basic hand tools. Other servicetasks that are more difficult, or require special tools, are best handledby professionals and are normally performed by a Honda technician orother qualified mechanic.

The maintenance schedule applies to normal operating conditions. Ifyou operate your generator under severe conditions, such assustained high-load or high-temperature operation, or use it inunusually wet or dusty conditions, consult your servicing dealer forrecommendations applicable to your individual needs and use.

03/11/17 18:43:04 31Z21600_032

－

－

－

32

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

Always follow the procedures and precautions in the owner’s manual.

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Injury from moving parts.

Burns from hot parts.

Maintenance Safety

Some of the most important safety precautions follow. However, wecannot warn you of every conceivable hazard that can arise inperforming maintenance. Only you can decide whether or not youshould perform a given task.

Make sure the engine is off before you begin any maintenance orrepairs. This will eliminate several potential hazards:

Be sure there is adequate ventilation whenever you operate theengine.

Do not run the engine unless instructed to do so.

To ensure the best quality and reliability, use only new, genuineHonda parts or their equivalents for repair or replacement.

Let the engine and exhaust system cool before touching.

Read the instructions before you begin, and make sure you have thetools and skills required.

To reduce the possibility of fire or explosion, be careful whenworking around gasoline. Use only a nonflammable solvent, notgasoline, to clean parts. Keep cigarettes, sparks, and flames awayfrom all fuel-related parts.

Remember that your servicing dealer knows your generator best andis fully equipped to maintain and repair it.

03/11/17 18:43:15 31Z21600_033

33

Source of Emissions

Tampering and Altering

The U.S. and California Clean Air Acts

Emission Control System Information

EPA and California regulations require all manufacturers to furnishwritten instructions describing the operation and maintenance of emis-sion control systems.

The following instructions and procedures must be followed in orderto keep the emissions from your Honda engine within the emissionstandards.

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

Honda utilizes lean carburetor settings and other systems to reducethe emissions of carbon monoxide, oxides of nitrogen, andhydrocarbons.

Tampering with or altering the emission control system may increaseemissions beyond the legal limit. Among those acts that constitutetampering are:

Removal or alteration of any part of the intake, fuel, or exhaustsystems.

Altering or defeating the governor linkage or speed-adjustingmechanism to cause the engine to operate outside its designparameters.

03/11/17 18:43:24 31Z21600_034

34

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engineinspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

03/11/17 18:43:28 31Z21600_035

35

Maintenance

Replacement Parts

The emission control systems on your Honda engine were designed,built, and certified to conform with EPA and California emissionregulations. We recommend the use of genuine Honda partswhenever you have maintenance done. These original-designreplacement parts are manufactured to the same standards as theoriginal parts, so you can be confident of their performance. The useof replacement parts that are not of the original design and qualitymay impair the effectiveness of your emission control system.

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

Follow the maintenance schedule on page . Remember that thisschedule is based on the assumption that your machine will be usedfor its designed purpose. Sustained high-load or high-temperatureoperation, or use in unusually wet or dusty conditions, will requiremore frequent service.

37

03/11/17 18:43:33 31Z21600_036

－

－

－

36

Air Index

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

The durability description is intended to provide you with informationrelating to the engine’s emission durability period. The descriptiveterm indicates the useful-life period for the engine’s emission controlsystem. See your Emission Control Warranty for additionalinformation.

The Air Index Information hang tag must remain on the generator untilit is sold. Remove the hang tag before operating the generator.

300 hours (0 65 cc)500 hours (greater than 65 cc)



Extended

Intermediate

Moderate

Applicable to Emissions Durability PeriodDescriptive Term

An Air Index Information hang tag/label is applied to engines certifiedto an emission durability time period in accordance with therequirements of the California Air Resources Board.

03/11/17 18:43:44 31Z21600_037

37

Maintenance Schedule

Performed at every indicatedmonth or operating hour interval,whichever comes first.

ITEMFirst

monthor

20 Hrs.

Every3 months

or50 Hrs.

(1)

Engine oil

Air cleaner

Sediment cupSpark plug

Spark arresterIdle speedValve clearanceCombustionchamberFuel tank and filterFuel tube

CheckChangeCheckCleanCleanClean-AdujstReplaceCleanCheck-AdujstCheck-AdujstClean

CleanCheck

Beforeeachuse

Every6 months

or100 Hrs.

(2)

Everyyearor

300 Hrs.

(2)(2)

After every 500 Hrs.(2)

Every 2 years (Replace if necessary)(2)

Emission related items.

These items should be serviced by an authorized Honda generator dealer, unless the ownerhas the proper tools and is mechanically proficient. See the Honda Shop Manual.

Service more frequently when used in dusty areas.

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

(1)(2)

(3)

REGULAR SERVICE PERIOD (3)

03/11/17 18:43:58 31Z21600_038

38

Oil capacity:

Engine Oil Change

UPPER LEVEL

OIL DRAIN PLUG

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

Remove the drain plug and sealing washer, remove the oil filler cap,and drain the oil.Reinstall the drain plug and sealing washer. Tighten the plugsecurely.Refill with the recommended oil (see page ) and check the oillevel.

Wash your hands with soap and water after handling used oil.

Please dispose of used motor oil in a manner that is compatible withthe environment. We suggest you take it in a sealed container to yourlocal service station or recycling center for reclamation. Do not throw itin the trash, pour it on the ground, or down a drain.

1.2 US qt (1.1 )

1.

2.

3. 27

03/11/17 18:44:08 31Z21600_039

39

Air Cleaner Service

AIR CLEANER COVER

CLIP

CLIP

ELEMENT

ELEMENT

A dirty air cleaner will restrict air flow to the carburetor. To preventcarburetor malfunction, service the air cleaner regularly. Service morefrequently when operating the generator in extremely dusty areas.

Never run the generator without the air filter. Rapid engine wear willresult.

Unsnap the air cleaner cover clips, remove the air cleaner cover, andremove the element.

Wash the air cleaner element in a solution of household detergentand warm water, then rinse thoroughly, or wash in nonflammable orhigh flashpoint solvent. Allow the air cleaner element to drythoroughly.

Soak the air cleaner element in clean engine oil and squeeze out theexcess oil. The engine will smoke during initial startup if too muchoil is left in the air cleaner element.

Reinstall the air cleaner element and the cover.

1.

2.

3.

4.

03/11/17 18:44:19 31Z21600_040

40

Fuel Sediment Cup Cleaning

SEDIMENT CUP

O-RING

FUEL FILTER

OFF

FUEL VALVE LEVER

The sediment cup prevents dirt or water which may be in the fuel tankfrom entering the carburetor. If the engine has not been run for a longtime, the sediment cup should be cleaned.

Clean the sediment cup, O-ring, and filter in nonflammable or highflash point solvent.

Turn the fuel valve lever to the OFF position. Remove the sedimentcup, O-ring, and filter.

Reinstall the filter, O-ring, and sediment cup.Turn the fuel valve lever ON and check for leaks.

1.

2.

3.4.

03/11/17 18:44:26 31Z21600_041

－－

－－

41

Recommended spark plugs:

Spark Plug Service

The gap should be:

PLUG CAP

SPARK PLUG WRENCH

0.028 0.031 in(0.70 0.80 mm)

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

Use a spark plug wrench to remove the spark plug.

Remove the spark plug cap.Clean any dirt from around the spark plug base.

If the engine has been running, the muffler will be very hot. Be carefulnot to touch the muffler.

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

BPR5ES (NGK)

Measure the plug gap with afeeler gauge.Correct as necessary by carefullybending the side electrode.

0.028 0.031 in (0.70 0.80 mm)

Visually inspect the spark plug.Discard it if the insulator iscracked, chipped or fouled.

W16EPR-U (DENSO)

1.2.3.

4.

5.

,

03/11/17 18:44:37 31Z21600_042

－

－

42

Spark Arrester Maintenance

SPARK ARRESTER

SPARK ARRESTER SCREENSCREW

Check that the spark plug washer is in good condition, and threadthe spark plug in by hand to prevent cross-threading.After the spark plug is seated, tighten with a spark plug wrench tocompress the washer.

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

If the generator has been running, the muffler will be very hot. Allow itto cool before proceeding.

The spark plug must be securely tightened. An improperly tightenedspark plug can become very hot and could damage the engine.Never use spark plugs which have an improper heat range. Use onlythe recommended spark plugs or equivalent.

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

Clean the spark arrester as follows:Loosen the screw by the exhaust port of the muffler and remove thespark arrester.Use a brush to remove carbon deposits from the spark arresterscreen.Inspect the screen for breaks or tears and replace it if necessary.Install the spark arrester in the reverse order of removal.

6.

7.

1.

2.

3.

03/11/17 18:44:51 31Z21600_043

43

Fuse Replacement

FUSE HOLDER

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

Turn the engine switch to the OFF position.Remove the fuse holder cover and replace the fuse.The specified fuse is 10A.

If frequent fuse failure occurs, determine the cause and correct theproblem before attempting to operate the generator further.

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

1.2.

03/11/17 18:44:57 31Z21600_044

44

TRANSPORTING/STORAGE

Contact with a hot engine or exhaust system can cause serious burnsor fires. Let the engine cool before transporting or storing thegenerator.

When transporting the generator, turn the engine switch and the fuelvalve OFF. Keep the generator level to prevent fuel spillage. Fuel vaporor spilled fuel may ignite.

Take care not to drop or strike the generator when transporting. Do notplace heavy objects on the generator.

When transporting the generator by loading it on to a vehicle, secureto the generator frame as shown.

03/11/17 18:45:03 31Z21600_045

45

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TOPREVENT HARD STARTING

Before storing the unit for an extended period:

1. Be sure the storage area is free of excessive humidity and dust.2. Service according to the table below:

Less than 1 month1 to 2 months

2 months to 1 year

1 year or more

Use gasoline conditioners that are formulated to extend storagelife.Contact your authorized Honda generator dealer for conditionerrecommendations.

No preparation requiredFill with fresh gasoline and add gasolineconditioner *.Fill with fresh gasoline and add gasolineconditioner *.Drain the carburetor float bowl. (page 46 ).Drain the fuel sediment cup. (page 40 ).Fill with fresh gasoline and add gasolineconditioner *.Drain the carburetor float bowl. (page 46 ).Drain the fuel sediment cup. (page 40 ).Remove the spark plug. Put a tablespoon ofengine oil into the cylinder. Turn the engineslowly with the recoil starter to distribute theoil. Reinstall the spark plug.Change the engine oil. (page 38 ).After removal from storage, drain the storedgasoline into a suitable container, and fillwith fresh gasoline before starting.

*

03/11/17 18:45:08 31Z21600_046

46

Gasoline is extremely flammable and is explosive under certainconditions. Perform this task in a well-ventilated area with the enginestopped. Do not smoke or allow flames or sparks in the area duringthis procedure.

Storage

DRAIN SCREW

Align the notch on the starter pulleywith the hole at the top of recoil starter.

Drain the carburetor by loosening the drain screw. Drain thegasoline into a suitable container.

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

Remove the spark plug, and pour about a tablespoon of cleanengine oil into the cylinder. Turn the engine several revolutionsslowly with the recoil starter to distribute the oil, then reinstall thespark plug.

Change the engine oil (page 38 ).

1.

2.3.

4.

03/11/17 18:45:17 31Z21600_047

47

TROUBLESHOOTING

When the engine will not start:

Is there fuel in thetank?

Is there enough oilin the engine?

Is the spark plug ingood condition?

Is the fuel reachingthe carburetor?

If the engine stilldoes not start, takethe generator to anauthorized Hondagenerator dealer.

Clean the fuelsediment cup.

Refill the fuel tank.

Add the recom-mended oil.

Readjust gap anddry the spark plug.R e p l a c e i t i fnecessary.

Turn off the engine switch and loosenthe drain screw (see page 46).Turn the fuel valve to ON. Fuel shouldflow from the drain when the fuel valveis turned ON.

To check:

YES

YES

YES

NO

NO

NO

YES

NO

1)

2)

03/11/17 18:45:26 31Z21600_048

48

Is the AC circuit breakerON.

Check the electrical ap-pliance or equipment forany defects.

Turn the AC circuit breakerON.

Take the generator to anauthorized Honda generatordealer.

Replace the electrical ap-pliance or equipment.Take the electrical ap-pliance or equipment to anelectrical shop for repair.

No electricity at the AC receptacles:

YES

DEFECTS

NO DEFECTS

NO

03/11/17 18:45:30 31Z21600_049

49

WIRING DIAGRAM

EM3800SX

03/11/17 18:45:59 31Z21600_050

50

EM5000SX, EM6500SX

03/11/17 18:46:27 31Z21600_051

× ××

±±

－－

51

SPECIFICATIONS

Dimensions

Engine

Generator

ITEM MAINTENANCESPECIFICATION

Tune-up Specifications

EAMC

GX240

2.9 2.3 in (73 58 mm)

27.2 in (690 mm)28.3 in (720 mm)192 lbs (87 kg)

14.8 cu-in (243 cm )

6.6 US gal (25 )1.2 US qt (1.1 )Transistorized magnetoForced air cooling3,600 rpm8.2 : 1

3,800 VA

60 Hz120/240 V

3,300 VA27.5/13.8 A

40.9 in (1,040 mm)

ModelPower product description codeLengthWidthHeightDry weight

ModelEngine TypeDisplacementBore StrokeCompression RatioEngine SpeedCooling SystemIgnition SystemOil CapacityFuel Tank CapacitySpark Plug

ModelType

Rated voltageRated frequency

AC output Rated currentRated outputMaximum output

DC output

Spark plug gapValve clearance

Other specifications No other adjustments needed.

IN: 0.15 0.02 mm (cold)EX: 0.20 0.02 mm (cold)

Refer to page: 41See your authorizedHonda dealer

Only for charging 12V automotivebatteries.Maximum charging output 8.3A

BPR5ES (NGK) W16EPR-U (DENSO)

AEM3800SX

EM3800SX

,

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

0.028 0.031 in (0.70 0.80 mm)

4-stroke, overhead valve, single cylinder

03/11/17 18:46:43 31Z21600_052

× × ×

±±

－－

52

Dimensions

Engine

Generator

ITEM MAINTENANCESPECIFICATION




ModelType



DC output

EANC41.3 in (1,050 mm)27.2 in (690 mm)28.3 in (720 mm)223 lbs (101 kg)

GX340

20.6 cu-in (338 cm )3.2 2.5 in (82 64 mm)8.0 : 13,600 rpmForced air coolingTransistorized magneto1.2 US qt (1.1 )6.6 US gal (25 )

120/240 V60 Hz37.5/18.8 A4,500 VA5,000 VA







A

EM5000SXK2

EM5000SXK2

,


0.028 0.031 in (0.70 0.80 mm)


03/11/17 18:46:58 31Z21600_053

× × ×

±±

－－

53

Dimensions

Engine

Generator

ITEM SPECIFICATION MAINTENANCE




ModelType



DC output

EAPC41.9 in (1,065 mm)27.2 in (690 mm)28.3 in (720 mm)227 lbs (103 kg)

GX390

23.7 cu-in (389 cm )3.5 2.5 in (88 64 mm)8.0 : 13,600 rpmForced air coolingTransistorized magneto1.2 US qt (1.1 )6.6 US gal (25 )

120/240 V60 Hz45.8/22.9 A5,500 VA6,500 VA







A

EM6500SX

EM6500SX

,


0.028 0.031 in (0.70 0.80 mm)


03/11/17 18:47:17 31Z21600_054

54

ASSEMBLY

The Importance of Proper Assembly

Improper assembly can cause an unsafe condition that can lead toserious injury or death.Follow the procedures and precautions in the assembly instructionscarefully.

Failure to properly follow instructions and precautions can cause youto be seriously hurt or killed.Follow the procedures and precautions in this manual carefully.

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

Some of the most important safety precautions are given below.However, we cannot warn you of every conceivable hazard that canarise in performing this assembly. Only you can decide whether or notyou should perform a given task.

03/11/17 18:47:23 31Z21600_055

□

□

□

□

55

Important Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Injury from moving parts.

Burns from hot parts.

Make sure you have a clear understanding of all basic shop safetypractices and that you are wearing appropriate clothing and safetyequipment. When performing this assembly, be especially careful ofthe following:

Make sure the engine is off before you begin any maintenance orrepairs. This will help eliminate several potential hazards:

Read the instructions before you begin and be sure you havethe tools and skills required to perform the tasks safely.

Be sure there is adequate ventilation whenever you run theengine.

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

Let the engine and exhaust system cool before touching.

To reduce the possibility of a fire or explosion, be careful whenworking around gasoline or batteries. Use only a nonflammablesolvent, not gasoline, to clean parts. Keep all cigarettes, sparks, andflames away from all fuel-related parts.

03/11/17 18:47:31 31Z21600_056

×

×

56

Loose Parts (Wheel kit and handle)

Unpacking

Remove the generator and loose parts box from the carton.

Compare the loose parts with the inventory list below.

Tools Required:

Check all loose parts against the following list. Contact your dealer ifany of the loose parts shown below are not included with yourgenerator.

1.

2.

14 mm wrench (2), pliers

Ref. No.1234567891011

DescriptionWheelAxleLeft upper handle assyRight upper handle assyLeft handle bracketRight handle bracketStand8 16 mm Flange bolt20 mm Washer4.0 30 mm Cotter pin8 mm Flange nut

Qty.211111212224

03/11/17 18:47:43 31Z21600_057

－－－

×

57

Handle Installation

TORQUE:

RIGHT HANDLEBRACKET

LEFT HANDLE BRACKET

8 16 mm FLANGE BOLT (4)

LEFT UPPER HANDLE ASSY

RIGHT UPPER HANDLE ASSY

Install the right and left handles on the generator upper frame usingthe brackets and 4 flange bolts.

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

03/11/17 18:47:48 31Z21600_058

×

×

－－－

×

×

×

58

Wheel Kit Installation

TORQUE:

AXLE

WHEEL (2)


GENERATORSIDE


4.0 30 mm COTTER PIN (2)STAND (2)

20 mm WASHER (2)

LONGER

8 mm FLANGE NUT (4)

Install the two wheels on the axle shaft using the washers and cotterpins.

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

Install the two stands on the under frame using four 8 16 mmflange bolts.

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

1.

2.

3.

03/11/17 18:47:57 31Z21600_059

－－－

×

59

Hanger Kit Installation (optional)

TORQUE:

HANGER

HANGER

GENERATORSIDE

HANGER BRACKET (2)


280 mm (11 in)

Position the hanger at the generator’s balance point as shown below.

Fit the end tabs of the hanger through the bracket slots, and bolt thebrackets to the hanger and tighten securely.

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

1.

2.

03/11/17 18:48:03 31Z21600_060

60

Remote Control Kit (optional)

REMOTE CONTROLCABLE

REMOTE CONTROLBOX

REMOTE CONTROLCABLE

CABLE TIES

Remove the blind 6-P connector from the back of the control panel.Connect the remote control cable to the back of the control paneland remote control box.

Connect the blind connector when not using the remote control.Engine will not start unless the blind connector is connected.

Install the two cable ties as shown.

1.2.

3.

03/11/17 18:48:10 31Z21600_061

61

Remote Control Box

PILOT LAMP

START SWITCH STOP SWITCH

Turn the auto-throttle switch to the OFF position.Turn the fuel valve to the ON position.

Starting the engine with remote control

Turn the engine switch to the ON position.Press the start switch untill the pilot lamp comes on.

Stopping the engine with remote controlPress the stop switch.Turn the engine switch to the OFF position.Turn the fuel valve lever to the OFF position.

1.2.3.4.

1.2.3.

03/11/17 18:48:21 31Z21600_062

＋－－

62

Battery posts, terminals and related accessories contain lead and leadcompounds. Wash hands after handling.

Battery Tray Kit (optional)

Install the battery guard on the frame.Set the battery tray on the battery guard and tighten the bolts.

Route the starter cable under the tank and connect it to the startersolenoid.

Connect the ground cable to the generator rear housing.

Set the battery on the battery tray and secure with the batterybracket.Connect the starter cable to the battery positive ( ) terminal first,then to the negative ( ) terminal. When disconnecting, disconnectat the battery negative ( ) terminal first.

Install the battery guard plate on the battery guard.

1.

2.

3.

4.

5.

03/11/17 18:48:25 31Z21600_063

○○

○○

＋＋

－－

63

BATTERYTRAY

BATTERYGUARD PLATE

STARTER CABLE(positive)

BATTERYBRACKET

BATTERYGUARD

STARTER SOLENOID

GROUNDCABLE

BATTERYGUARD

BATTERY

Use a battery rated at51R

STARTERCABLE

CABLETIE

CABLE TIE

GROUNDCABLE

03/11/17 19:47:49 31Z21600_064

64

Engine Oil

WITHOUT OIL

Fuel

SAE Viscosity Grades

AMBIENT TEMPERATURE

OIL FILLER HOLE

FILLER CAP/DIPSTICK

UPPER LIMIT

The generator is shippedin the engine.

Place the generator on a levelsurface. Add enough of therecommended oil to bring theoil level to the top of the oilfiller neck.

Use a 4-stroke motor oil thatmeets the requirements forAPI service classification SJ.

Refer to page .

SAE 10W-30 is recommendedfor general, all-temperatureuse. Other viscosities in thechart may be used when thetemperature in your area iswithin the indicated range.

Do not overfill engine oil. Ifthe engine is overfilled, thee x c e s s o i l m a y g e ttransferred to the air cleanerhousing and air filter.

28

03/11/17 18:48:44 31Z21600_065

65

BEFORE OPERATION

SAFETY

CONTROLS

GENERATOR USE

STARTING THE ENGINE

STOPPING THE ENGINE

Before using your generator, you should become familiar withinformation contained in the following chapters and sections:

(page )

(page )

(page )

(page )

(page )

5

10

17

30

30

03/11/17 18:48:51 31Z21600_066

66

WARRANTY SERVICE INFORMATION

Servicing dealership personnel are trained professionals. They shouldbe able to answer any questions you may have. If you encounter aproblem that your dealer does not solve to your satisfaction, pleasediscuss it with the dealership’s management. The Service Manager orGeneral Manager can help. Almost all problems are solved in this way.

If you are dissatisfied with the decision made by the dealership’smanagement, contact the Honda Power Equipment CustomerRelations Office. You can write to:

American Honda Motor Co., Inc.Power Equipment DivisionCustomer Relations Office4900 Marconi DriveAlpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

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

Model and serial number (see pages and )

Name of dealer who sold the generator to you

Name and address of dealer who services your generator

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

98

03/11/17 18:48:59 31Z21600_067

67

INDEX

..............................................................................................ASSEMBLY . 54..............................................................COMPONENT IDENTIFICATION . 8

................................................................................................CONTENTS . 3

..............................................................................................CONTROLS . 10.............................................................................AC Circuit Breaker . 15

..........................................................................AC Circuit Protector . 16......................................................................Auto Throttle System . 14

..........................................................................................Choke Rod . 11..........................................................................DC Circuit Protector . 13

.......................................................................................DC Terminal . 13....................................................................................Engine Switch . 10

................................................................................Fuel Valve Lever . 11...............................................................................Ground Terminal . 12..............................................................................Oil Alert System . 14

.....................................................................................Recoil Starter . 10............................Voltage Selector Switch (Dual Voltage System) . 12

...................................................................................GENERATOR USE . 17.................................................................................AC Applications . 18

.....................................................................................AC Operation . 19...................................................................AC Receptacle Selection . 20

......................................................................Auto Throttle System . 25...............................Connections to a Building’s Electrical System . 17

...................................................................................DC Ooperation . 23.................................................................................Ground System . 17

....................................................................High Altitude Operation . 26.......................................................................Special Requirements . 17

......................................................................................MAINTENANCE . 31...........................................................................Air Cleaner Service . 39

.............................................................................................Air Index . 36............................................Emission Control System Information . 33

............................................................................Engine Oil Change . 38...........................................................Fuel Sediment Cup Cleaning . 40

.............................................................................Fuse Replacement . 43.............................................................Importance of Maintenance . 31

..........................................................................Maintenance Safety . 32.....................................................................Maintenance Schedule . 37

............................................................Spark Arrester Maintenance . 42............................................................................Spark Plug Service . 41

03/11/17 18:49:03 31Z21600_068

68

.......................................................................PRE-OPERATION CHECK . 27..........................................................................................Engine Oil . 27

.....................................................................................................Fuel . 28......................................................................................................SAFETY . 5

..............................................................................Safety Information . 6.......................................................................Safety Label Locations . 5

....................................................................................SPECIFICATIONS . 51..............................STARTING THE ENGINE/STOPPING THE ENGINE . 30

..................................................................TRANSPORTING/STORAGE . 44.............................................................................TROUBLESHOOTING . 47

.................................................WARRANTY SERVICE INFORMATION . 66.................................................................................WIRING DIAGRAM . 49

03/11/17 18:49:06 31Z21600_069

EM3800SX•EM5000SX•EM6500SX

K2:EM5000SXSee page 54 for instructionson assembling your generator.

31Z2160000X31-Z21-6000

Documents

EM3800SX•EM5000SX•EM6500SXcdn.powerequipment.honda.com/pe/pdf/manuals/31Z21600.pdf · EM3800SX•EM5000SX•EM6500SX K2:EM5000SX See page 54 for instructions on assembling your