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Honda EX1000 Owner's Manual

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  • Page 3 Thank you for purchasing a Honda generator. We want to help you get the best results from your new generator and to operate it safely. This manual contains the information on how to do that; please read it carefully. EX1000 This owner’s manual describes the operation and maintenance of the EX650...

  • Page 4: Table Of Contents

    CONTENTS SAFETY ..................... Safety Label Locations ................Safety Information .................. COMPONENT IDENTIFICATION ............. . . 8 CONTROLS ....................
  • Page 5 MAINTENANCE ..................Maintenance Schedule ................. Tool Kit ....................Engine Oil Change ................Air Cleaner Service ................Spark Plug Service ................Spark Arrester Maintenance ..............30 TRANSPORTING/STORAGE ..............32 TROUBLESHOOTING .

  • Page 6: Safety

    SAFETY LABEL LOCATION These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda Generator dealer for a replacement. E BEFORE FllllNC FUEL TANK. W NOT FILL OVER ICONTR~LER QU’IL N’Y ANI FIJITE NESSENCE REPANDUE SUR L’APPAREIL...
  • Page 7 EXIOOO HONDA HONDA MOTOR CO., LTD. MADE IN JAPAN&I CONTAINS POISONOUS CAREON MONOXIDE. lLUBRlCANT : 0.431 <SAE 1OW 30> HOUSE WIRING. THIS DAMAGE GENERATOR OR ELECTORICAL APPLIANCES. lCLEAN ELEMENT EVERY 50 HOURS (EVERY HOURS UNDER DUSTY CONDITIONS) WASH IN HIGH FLASH-POINT...

  • Page 8: Safety Information

    SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating...
  • Page 9 Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials. Keep the generator at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not enclose the generator in any structure. Keep flammable materials away from the generator. The muffler becomes very hot during operation and remains hot for a while after stopping the engine.

  • Page 10: Component Identification

    COMPONENT ODENTUFICATION FRAME SERIAL NUMBER CIRCUITBREAKERS TOP COVER TOOL KIT SPARK PLUG CAP PILOT LAMP ENGINE FREQUENCY SWITCH METER LEFT SIDE COVER AC RECEPTACLES GROUND TERMINAL ENGINE SERIAL NUMBER RECOIL OIL FILLER STARTER GRIP Record the engine and frame serial numbers for your future reference. Refer to these serial numbers when ordering parts, and when making technical or warranty inquiries (see page 39) Frame serial number:...
  • Page 11 CARRYING HANDLE FUEL GAUGE FUEL TANK RIGHT SIDE, COVER CHOKE LEVER AIR CLEANER EXHdUST OUTLET CASE MUFFLER COVER...

  • Page 12: Controls

    CONTROLS Engine Switch To start and stop the engine. Switch position: To stop the engine. OFF: ON: To run the engine. ENGINE SWITCH Recoil Starter To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly.

  • Page 13: Choke Lever

    Choke Lever The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke lever manually. Move the lever to the CLOSED position to enrich the mixture. ‘CLOSED Pilot Lamp The pilot lamp is illuminated when the generator is operating normally.

  • Page 14: Ground Terminal

    Ground Terminal The gernerator ground terminal is connected to the frame of the generater, the metal non-current carrying parts of the generator, and the ground terminals of each receptacle. Before using the ground terminal, consult a qualified electrician, electrical inspector or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator,...

  • Page 15: Oil Alert System

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

  • Page 16: Dc Terminals

    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 17: Generator Use

    Ground System Honda portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire. If the generator is tested by a receptacle tester, it will not show the same ground circuit condition as for a home receptacle.

  • Page 18: Ac Operation

    AC Operation 1. Start the engine (refer to page 24) and make sure the pilot lamp comes on. If not, the filament may be burnt out. 2. Plug in the appliance. CAUTION: Substantial overloading will switch off the circuit breaker. Marginal overloading may not switch off the circuit breaker, but it will shorten the service life off the generator.

  • Page 19: Dc Operation

    DC circuit breaker (PUSH button extends out). If this happens, wait a few minutes before pushing in the circuit breaker to resume operation. If the circuit breaker continues to go OFF, discontinue charging and see your authorized Honda generator dealer.

  • Page 20: Disconnecting The Battery Cables

    Disconnecting the battery cables: 1. Stop the engine, 2. Disconnect the negative (-) battery cable from the generator negative (-) terminal. 3. Disconnect the other end of the negative (-) battery cable from the battery negative (-) terminal. 4. Disconnect the positive (+) battery cable from the generator positive (+) terminal.

  • Page 21: High Altitude Operation

    If you always operate the engine at altitudes higher than 6,000 feet above sea level, have an authorized Honda generator dealer perform this carburetor modification. Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 1,000 foot increase in altitude.

  • Page 22: Pre-Operation Check

    PRE-OPERAT0ON CHIECK Engine Oil 1 NOTICE Engine oil is a major factor affecting engine performance and service life. Non-detergent and P-stroke engine oils will damage the engine and are not recommended. Check the oil level BEFORE EACH with the generator on a level surface with the engine stopped.

  • Page 23: Fuel Recommendation

    Fuel Recommendation 1. Check the fuel level gauge. 2. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped.
  • Page 24 If you notice any undesirable operating symptoms, switch to a conventional unleaded gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel are not the responsibility of Honda and are not covered under warranty. Oxygenated fuels can damage paint and plastic.

  • Page 25: Starting/Stopping The Engine

    STARTING/STOPPING THE ENGINE Starting the engine 1. The generator may be hard to start if a load is connected. 2. Turn the choke lever to the CLOSE position. 3. Turn the engine switch to the ON position. 4. Pull the starter grip until compression is felt, then pull briskly. Do not allow the starter grip to snap back.

  • Page 26: Maintenance

    Every 2 years (2) necessary) (1) Service more frequently when used in dusty areas. (2) These items should be serviced by an authorized Honda generator dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop Manual.

  • Page 27: Tool Kit

    Tool Kit The tools supplied with the generator will help you to perform the owner maintenance procedures listed on the following pages. Always keep this tool kit with the generator. COMBINATION SCREWDRIVER e-34 c--’ PLUG WRENCH/l2 mm WRENCH/ SCREWDRIVER HANDLE...

  • Page 28: Engine Oil Change

    Engine Oit Change Drain the oil while the engine is warm to assure complete and rapid draining. 1. Remove the oil filler cap. 2. Turn the engine switch OFF and tilt the generator to drain the oil. 3. Refill with the recommended oil (see page 18 and check the oil level. Oil capacity: 0.43 Q (0.46 US qt, 0.38 imp qt) Oli FILLER...

  • Page 29: Air Cleaner Service

    Air Cleaner Service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly (page 25). Service more frequently when operating the generator in extremely dusty areas. Usinggasolineorflammablesolventtocleanthefilterelement can cause a fire or explosion. Use only soapy water or nonflammable solvent.

  • Page 30: Spark Plug Service

    Spark Plug Service Recommended spark plugs: BW4HS (NGK) or Wi$FR-U (NIPPON DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
  • Page 31 6. Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent cross-threading. 7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. If installing a new spark plus, tighten l/2 turn after the spark plug seats to compress the washer.

  • Page 32: Spark Arrester Maintenance

    Spark Arrester Maintenance If the generator has been running, the muffler will be very hot. Allow to cool before proceeding. ps7EE-j The spark arrester must be serviced every 100 hours to maintain its efficiency. Remove the two 6 mm bolts and the two 6 mm cap nuts. Remove the cover.
  • Page 33 3. Use a brush to remove carbon deposits from the spark arrester screen. Inspect the screen for holes, and replace it if necessary. NOTE: Take care not to damage the wire mesh. 4. Check the exhaust pipe gaskets; replace if damaged. Reinstall the muffler and the cover.

  • Page 34: Transporting/Storage

    Change the engine oil (page 27). After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting. *Use gasoline conditioners that are formulated to extend storage life. Contact your authorized Honda generator dealer for conditioner recommendations.
  • Page 35 1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.

  • Page 36: Troubleshooting

    Take the generator Replace the to an authorized to an authorized spark plug spark plug ’ ‘^“?A HONDA dealer. dealer. To check: mlml 1) Remove the rear cover and Be sure there is no Be sure the- spark plug cap, and clean any spiller’...
  • Page 37 No electricity at the AC receptacles: Push the AC circuit breaker button in. Take the generator to Check the electrical NO DEFECTS an authorized HONDA appliance or equipment for any dealer. defects Replace the electrical appliance or equipment. DEFECTS Take the electrical...

  • Page 39: Specifications

    SPECIFICATIONS Dimensions 430 x 285 x 390 mm Length x Width x Height (16.9x11.2~15.4in) 26 kg (57.3 lb) Dry Weight Engine 4-stroke, side valve, 1 cylinder Engine Type 97 cc (5.93 cu in) Displacement [52 x 46 mm (2.05 x 1.81 in)] [Bore x Stroke] Compression Ratio...

  • Page 40: Customer Service Information

    CUSTOMER SERVBCE DNFORMATOON Honda power equipment dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help.
  • Page 41 When you write or call, please provide the following information: • Model and serial numbers • Name of the dealer who sold the Honda power equipment to you • Name and address of the dealer who services your equipment •...

  • Page 42: Index

    INDEX COMPONENT IDENTIFICATION ............... 8 CONTROLS ....................AC Circuit Breaker................Choke Lever ..................DC Circuit Breaker ................DC Terminals ..................Engine Switch ..................Ground Terminal .................. Oil Alert System ..................Pilot Lamp .................... Recoil Starter ..................CUSTOMER SERVICE INFORMATION...........38 GENERATOR USE ..................
  • Page 43 INQEX PRE-OPERATION CHECK ..............Engine Oil .................... Fuel Recommendation ................ SAFETY ..................... Safety Information ................. Safety Label Locations ................SPECIFICATIONS ................... STARTING/STOPPING THE ENGINE ............ .23 TRANSPORTING/STORAGE ..............TROUBLESHOOTING ................WIRING DIAGRAM ..................

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