Honda EM5000SX Owner's Manual
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Honda EM5000SX Owner's Manual

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Owner's Manual
GENERATOR
EM5000SX/EM6500SX
See page 12 for instructions on assembling your generator.
See page 17 for Initial Use Instructions.
2020 Honda Motor Co., Ltd. -All Rights Reserved
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Summary of Contents for Honda EM5000SX

  • Page 1 Owner’s Manual GENERATOR EM5000SX/EM6500SX See page 12 for instructions on assembling your generator. See page 17 for Initial Use Instructions. 2020 Honda Motor Co., Ltd. -All Rights Reserved...
  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever.

  • Page 3: Introduction

    When your generator needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the generator. This information alerts you to potential hazards that could hurt you or others.

  • Page 5: Table Of Contents

    CONTENTS INTRODUCTION ....................1 GENERATOR SAFETY ..................7 IMPORTANT SAFETY INFORMATION................7 Operator Responsibility....................7 Carbon Monoxide Hazards..................... 8 Electric Shock Hazards ..................... 9 Fire and Burn Hazards ...................... 9 Refuel With Care.......................10 Vehicles and Transportation Hazards...............10 SAFETY LABEL LOCATIONS....................11 ASSEMBLY .......................
  • Page 6 CONTENTS FEATURES ..........................34 Oil Alert® System ......................34 Automatic Engine Stop Function................34 Auto Choke and Throttle Control System...............35 iAVR (Intelligent Auto Voltage Regulator) ..............35 Fuel Gauge .........................36 Ground Terminal......................36 Bluetooth® Function ......................37 Smartphone application ....................37 BEFORE OPERATION..................38 ARE YOU READY TO GET STARTED? ................38 Knowledge .........................38 IS YOUR GENERATOR READY TO GO?................38 Check the Engine ......................39...
  • Page 7 CONTENTS SERVICING YOUR GENERATOR ..............63 THE IMPORTANCE OF MAINTENANCE................63 MAINTENANCE SAFETY ......................64 Safety Precautions......................64 MAINTENANCE SCHEDULE....................65 ENGINE OIL CHANGE ......................66 AIR CLEANER SERVICE ......................67 Foam Air Filter Cleaning....................67 SPARK PLUG SERVICE ......................68 SPARK ARRESTER SERVICE ....................70 SEDIMENT CUP CLEANING ....................71 BATTERY SERVICE........................72 Emergency Procedures....................72 Battery Removal .......................73...
  • Page 8 EMISSION CONTROL SYSTEM INFORMATION.............89 AIR INDEX..........................91 SPECIFICATION ........................92 WIRING DIAGRAM.........................94 CONSUMER INFORMATION................96 DEALER LOCATOR INFORMATION ..................96 Honda PUBLICATIONS......................96 CUSTOMER SERVICE INFORMATION ................97 Distributor’s Limited Warranty ..................98 Emission Control System Warranty ................103 REGISTRATION ........................108 OPTIONAL PARTS ..................109 REMOTE CONTROL KIT.....................

  • Page 9: Generator Safety

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

  • Page 10: Carbon Monoxide Hazards

    GENERATOR SAFETY Carbon Monoxide Hazards A generator's exhaust contains toxic carbon monoxide, which you cannot see or smell. Breathing carbon monoxide can KILL YOU IN MINUTES. To avoid carbon monoxide poisoning, follow these instructions when operating a generator: • Only run a generator OUTSIDE, far away from windows, doors, and vents with engine exhaust directed away from occupied structures.

  • Page 11: Electric Shock Hazards

    GENERATOR SAFETY Electric Shock Hazards The generator produces enough electric power to cause a serious shock or electrocution if misused. • Do not use in wet conditions. Keep the generator dry. – Do not use in the rain or snow. –...

  • Page 12: Refuel With Care

    GENERATOR SAFETY Refuel With Care Gasoline is highly flammable, and gasoline vapor can explode. • Do not refuel during operation. • Allow the engine to cool if it has been in operation. • Refuel only outdoors in a well-ventilated area and on a level surface. •...

  • Page 13: Safety Label Locations

    GENERATOR SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda generator dealer for a replacement.

  • Page 14: Assembly

    ASSEMBLY SAFETY The Importance of Proper Assembly Proper assembly is essential to operator safety and the reliability of the machine. Improper assembly can cause an unsafe condition. Failure to properly follow assembly procedures can lead to serious injury or death. Follow the procedures and precautions in this owner’s manual carefully.

  • Page 15: Assembly

    ASSEMBLY ASSEMBLY Unpacking 1. Remove the generator and loose parts box from the carton. 2. Compare the loose parts with the inventory list below. Tools Required: 12 mm wrench (2), pliers Loose Parts (Wheel kit and handle) Do not add fuel or oil before tipping the generator. Oil or fuel may damage the engine or your property.

  • Page 16: Handle Installation

    ASSEMBLY Handle Installation 1. Install the handle holder assembly on the generator upper frame using the 8×18 mm flange bolts. 2. Install the handle assembly on the generator upper frame pipe using the 8×16 mm flange bolts, handle bush A, handle bush B, and handle lower bracket.

  • Page 17: Wheel Kit Installation

    ASSEMBLY Wheel Kit Installation 1. Install the two stands on the under frame using four 8×16 mm flange bolts. 2. Install the two wheels on the axle shaft using the plain washers and split pins. After installing the split pins, bend the pins to ensure that the wheels are secured to the axle.

  • Page 18: Battery

    ASSEMBLY Battery WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. The battery is disconnected for shipment. 1. Remove the cover (see page 73). 2. Connect the battery positive (+) cable to the battery positive (+) terminal first, and tighten the bolt securely.

  • Page 19: Initial Use Instructions

    INITIAL USE INSTRUCTIONS ENGINE OIL The generator is shipped WITHOUT OIL in the engine. 1. Place the generator on a level surface. 2. Remove the oil filler cap/dipstick by turning it counterclockwise. 3. Add enough oil to bring the oil level to the upper limit mark on the oil dipstick.

  • Page 20: Engine Oil Recommendations

    AMBIENT TEMPERATURE Read the instructions on the oil container before use. The SAE oil viscosity and service category are in the API label on the oil container. Honda recommends that you use API service category SJ or later (or equivalent) oil.

  • Page 21: Fuel

    INITIAL USE INSTRUCTIONS FUEL Add fuel to the generator in a well-ventilated area. Fuel only outdoors. Keep gasoline away from appliance, such as pilot lights, barbecues, electric appliances, power tools, etc. Spilled fuel is not only a fire hazard, it causes environmental damage.
  • Page 22 INITIAL USE INSTRUCTIONS 1. Remove the fuel tank cap. 2. Fuel carefully to avoid spilling fuel. Do not fill the fuel tank above the upper level mark (red) on the fuel strainer. 3. After refueling, reinstall the fuel tank cap securely. UPPER LEVEL MARK (RED) FUEL TANK CAP FUEL GAUGE...

  • Page 23: Fuel Recommendations

    INITIAL USE INSTRUCTIONS FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher. Never use gasoline that is stale, contaminated, or mixed with oil. Avoid getting dirt or water in the fuel tank. You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume.

  • Page 24: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the illustrations on these pages to locate and identify the most frequently used controls. AC CIRCUIT PROTECTORS VOLTAGE SELECTOR SWITCH AC CIRCUIT BREAKER DC CIRCUIT PROTECTOR CO-MINDER RECEPTACLE GFCI RECEPTACLES RECEPTACLE GROUND TERMINAL DC TERMINALS ENGINE SWITCH AUTO THROTTLE SWITCH...
  • Page 25 CONTROLS & FEATURES CONTROL PANEL AIR CLEANER BATTERY COVER FUEL VALVE LEVER SEDIMENT CUP OIL FILLER CAP/DIPSTICK STARTER GRIP OIL DRAIN PLUG HANDLE FUEL TANK CAP FUEL GAUGE SPARK PLUG STAND MUFFLER MANUAL CHOKE LEVER WHEEL...

  • Page 26: Controls

    CONTROLS & FEATURES CONTROLS Engine Switch The engine switch controls the ignition system, and it operates the START electric starter. OFF – Stops the engine. The engine switch key can be removed/inserted. ON – Running position, and for starting with the recoil starter. START –...

  • Page 27: Fuel Valve Lever

    CONTROLS & FEATURES Fuel Valve Lever The fuel valve lever is located between the fuel tank and carburetor. The fuel valve must be in the ON position for the engine to run. After stopping the engine, turn the fuel valve to the OFF position. FUEL VALVE LEVER...

  • Page 28: Co-Minder (Co Shut-Off System)

    CONTROLS & FEATURES CO-MINDER (CO Shut-off System) CO-MINDER is a system that automatically stops the engine before the surrounding carbon monoxide concentration exceeds a certain level. If the CO-MINDER detects a high carbon monoxide concentration, the engine will stop and the CO ALARM indicator will flash for about five minutes. Continuously using the generator in areas with high concentrations of carbon monoxide can cause serious health hazards due to carbon monoxide poisoning (see page 8).
  • Page 29 • The FAULT/CO SENSOR LIFE indicator indicates the estimated life left in the CO- MINDER. • The generator stopping period and storage period are also included in the useful lifespan of the CO-MINDER. • Contact an authorized Honda Power Equipment dealer for CO-MINDER replacement.

  • Page 30: Voltage Selector Switch

    CONTROLS & FEATURES Voltage Selector Switch The voltage selector switch switches generator output to produce “120V ONLY” or “120V/240V.” If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the “120V/240V” position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the “120V ONLY”...

  • Page 31: Auto Throttle® System

    CONTROLS & FEATURES Auto Throttle® System The Auto Throttle® system automatically reduces engine speed when all loads are turned off or disconnected. When appliances are turned on or reconnected, the engine returns to the rated speed. SWITCH POSITION ON - Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator.

  • Page 32: Ac Circuit Protectors

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

  • Page 33: Ground Fault Circuit Interrupter (Gfci) Receptacle

    CONTROLS & FEATURES Ground Fault Circuit Interrupter (GFCI) Receptacle Each 120 V 20 A duplex receptacle is protected by a Ground Fault Circuit Interrupter (GFCI) for protection against the shock hazard of ground-fault currents. An example of ground-fault current is the current that would flow through a person who is using an appliance with faulty insulation and, at the same time, is in contact with an electrical ground such as a plumbing fixture, wet floor, or earth.

  • Page 34: Dc Terminals

    CONTROLS & FEATURES DC Terminals The DC terminals may ONLY be used for charging 12-volt automotive type batteries. The terminals are colored red to identify the positive (+) terminal and black to identify the negative (–) terminal. The battery must be connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal).

  • Page 35: Folding Handle

    CONTROLS & FEATURES Folding Handle The foldable handle is intended for ease of transportation and should be folded when the generator is stationary. Do not rest objects on the extended handle. To extend the handle, lift handle upward. Lock lever will lock and secure the handle into place.

  • Page 36: Features

    If the engine stops, make sure the oil level is correct. Wait a few minutes, and then try to restart the engine. If the engine still won’t start, take the generator to your authorized servicing Honda Power Equipment dealer.

  • Page 37: Auto Choke And Throttle Control System

    The total amount of power available for each generator model is: EM5000SX 7,000 watts for up to 10 seconds EM6500SX 7,000 watts for up to 10 seconds...

  • Page 38: Fuel Gauge

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

  • Page 39: Bluetooth® Function

    You may create your own personal password. Please record this password (see page 87). It is very important that you do not forget or lose it. If a password is lost, you must, at your expense, take your generator to an authorized Honda Power Equipment dealer so it can be reset.

  • Page 40: Before Operation

    BEFORE OPERATION ARE YOU READY TO GET STARTED? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Knowledge Read and understand this manual. Know what the controls do and how to operate them.

  • Page 41: Check The Engine

    BEFORE OPERATION Before beginning your pre-operation checks, be sure the generator is on a level surface and the engine switch is in the OFF position. Generators with standard equipment transport wheels must not be operated with the wheels and/or stands removed or else the generator may not operate correctly and can become damaged.

  • Page 42: Engine Oil Level Check

    BEFORE OPERATION ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. 1. Remove the oil filler cap/dipstick and wipe it clean. 2. Insert and remove the dipstick without screwing it into the oil filler neck. Check the oil level shown on the dipstick.

  • Page 43: Air Filter Check

    BEFORE OPERATION AIR FILTER CHECK 1. Unsnap the air cleaner cover clips and open the air cleaner cover. 2. Free the hooks from the setting pins on the air cleaner case and remove the air cleaner cover to the right side of the frame pipe, taking care not to damage the air cleaner cover.
  • Page 44 BEFORE OPERATION 6. Set the hooks of the air cleaner cover to the setting pins securely, and then push the air cleaner cover to lock the clips. Be sure that the cover is set securely. There must be no clearance between the air cleaner cover and air cleaner case.

  • Page 45: Safe Operating Precautions

    BEFORE OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator, review chapters "GENERATOR SAFETY" (see page 7). For your safety, do not operate the generator in an enclosed, or partly enclosed area such as a garage (even if the door is open) or near structures or vehicles. Your generator's exhaust contains poisonous carbon monoxide gas that can collect rapidly in such areas, structures, vehicles, trailers, or boats.

  • Page 46: Operation

    OPERATION STARTING THE ENGINE To prevent a possible fire, keep the generator at least 3 feet (1 meter) away from building or trailer walls, vehicles, trailers, boats, and other equipment during operation. Do not place flammable objects close to the engine. •...
  • Page 47 OPERATION 1. Make sure that all appliances are disconnected from the AC AC CIRCUIT BREAKER receptacle. 2. Make sure that the AC circuit breaker is in the OFF position. FUEL VALVE LEVER 3. Turn the fuel valve lever to the ON position.
  • Page 48 OPERATION 4. Make sure the Auto Throttle switch AUTO THROTTLE SWITCH is in the OFF position, or more time will be required for warm up. 5. Start the engine. • Using the electric starter: Turn the engine switch to the START START position, and hold it there until the engine starts.
  • Page 49 OPERATION • Using the recoil starter: a. Turn the engine switch to the ON position. ENGINE SWITCH b. Pull the starter grip lightly until you feel resistance; then pull briskly in the direction of the arrow as shown. STARTER • Do not allow the starter grip GRIP to snap back against the Direction to pull...

  • Page 50: Stopping The Engine

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

  • Page 51: Starting And Stopping The Engine With Bluetooth® Enabled Smartphone

    OPERATION STARTING AND STOPPING THE ENGINE with Bluetooth® ENABLED SMARTPHONE The engine can be started/stopped via a Bluetooth® enabled smartphone using a Bluetooth® application. Refer to the Bluetooth® application to check the connection, operation, and for help pairing a smartphone. HOW TO RESTART WHEN STOPPED BY CO-MINDER (CO SHUT-OFF SYSTEM) When the engine is automatically stopped by the CO-MINDER, move the generator to an area with fresh air and away from any device that may be...

  • Page 52: Gfci Operation Check

    Always perform the GFCI system inspection before using the generator. If the GFCI system fails the test, the generator must be repaired by an authorized Honda servicing dealer before use. GFCI RECEPTACLES (120 V 20 A DUPLEX RECEPTACLES)
  • Page 53 5. Press the GFCI TEST button: • The GFCI RESET button will pop out and the green GFCI indicator will go off. • If the GFCI does not function as described, contact an authorized Honda Power Equipment dealer. GFCI INDICATOR...
  • Page 54 6. Press the GFCI RESET button: • The green GFCI indicator will light continuously. • If the red GFCI indicator starts to blink continuously, contact an authorized Honda Power Equipment dealer. GFCI INDICATOR GFCI RESET BUTTON When the GFCI RESET button pops out or the green GFCI indicator does not lit during operation: •...

  • Page 55: Ac Operation

    OPERATION AC OPERATION If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is in the appliance or the rated load capacity of the generator has been exceeded. Substantial overloading may damage the generator.
  • Page 56 OPERATION 3. Switch ON the AC circuit breaker. 4. Plug in the appliance. Most motorized appliances require more than their rated wattage for startup. AC CIRCUIT PROTECTORS AC CIRCUIT BREAKER PLUG 5. Turn on the appliance. Do not exceed the current limit specified for any of the receptacles. If an overloaded circuit causes the AC circuit breaker or AC circuit protector to switch OFF, reduce the electrical load on the circuit, wait a few minutes and then reset the AC circuit breaker or AC circuit protector.

  • Page 57: Ac Applications

    Make sure the electrical rating of the tool or appliance does not exceed the maximum power rating of the generator. Maximum power is: EM5000SX: 5.0 kVA EM6500SX: 6.5 kVA For continuous operation, do not exceed the rated power. Rated power is: EM5000SX: 4.5 kVA...

  • Page 58: Ac Receptacle Selection

    OPERATION AC Receptacle Selection The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. TERMINAL TERMINAL VOLTAGE SELECTOR SWITCH RECEPTACLE RECEPTACLE GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE) RECEPTACLE RECEPTACLE GFCI RECEPTACLE...

  • Page 59: Voltage Selector Switch

    Total Current Available: 37.5 A (EM5000SX) / 45.8 A (EM6500SX) 120V/240V POSITION When the voltage selector switch is in the 120V/240V position, you must balance the load.

  • Page 60: Dc Operation

    OPERATION DC OPERATION The DC receptacle should ONLY be used for charging 12-volt automotive type batteries. The DC charging output is not regulated. Connecting the battery charging cable (optional equipment): 1. Before connecting the battery charging cable (optional equipment) to a battery that is installed in a vehicle, disconnect the vehicle battery ground cable from the negative (–) battery terminal.

  • Page 61: Disconnecting The Battery Charging Cable

    If this happens, wait a few minutes before pushing in the circuit protector button to resume operation. If the circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer. The DC circuit protector does not prevent overcharging the battery. DC CIRCUIT PROTECTOR Disconnecting the battery charging cable: 1.

  • Page 62: Auto Throttle® System

    OPERATION AUTO THROTTLE® SYSTEM With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the Auto Throttle system does not operate.

  • Page 63: Standby Power

    OPERATION STANDBY POWER Connections to a Building’s Electrical System Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes.

  • Page 64: Special Requirements

    OPERATION Special Requirements There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction. •...

  • Page 65: Servicing Your Generator

    Remember that an authorized Honda Power Equipment dealer knows your generator best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, Honda Genuine parts or their equivalents for repair and replacement.

  • Page 66: Maintenance Safety

    SERVICING YOUR GENERATOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

  • Page 67: Maintenance Schedule

    (1) Service more frequently when used in dusty areas. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. See "Honda PUBLICATIONS" on page 96 for ordering information.

  • Page 68: Engine Oil Change

    SERVICING YOUR GENERATOR ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap/dipstick, 12×15 mm drain plug, and sealing washer. 2.

  • Page 69: Air Cleaner Service

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

  • Page 70: Spark Plug Service

    SERVICING YOUR GENERATOR SPARK PLUG SERVICE In order to service the spark plug, you will need a spark plug wrench (commercially available). Required spark plug: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.
  • Page 71 SERVICING YOUR GENERATOR 4. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. Spark plug gap: 0.028–0.031 in (0.7–0.8 mm) SIDE ELECTRODE 0.028–0.031 in (0.7–0.8 mm) SEALING WASHER 5.

  • Page 72: Spark Arrester Service

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

  • Page 73: Sediment Cup Cleaning

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

  • Page 74: Battery Service

    SERVICING YOUR GENERATOR BATTERY SERVICE Your generator’s engine charging system charges the battery while the engine is running. However, if the generator is only used periodically, the battery must be charged monthly to maintain the battery service life. The battery contains sulfuric acid (electrolyte), which is highly corrosive and poisonous.

  • Page 75: Battery Removal

    SERVICING YOUR GENERATOR The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic perform the battery maintenance.

  • Page 76: Battery Charging

    SERVICING YOUR GENERATOR 4. Remove the battery from the battery tray. BATTERY This symbol on the battery means that this product must not be treated as household waste. An improperly disposed of battery can be harmful to the environment and human health.
  • Page 77 SERVICING YOUR GENERATOR 5. Install the battery holder band. 6. Install the battery cover in the reverse order of removal (see page 73). Never operate the generator without the battery cover in place, as poor engine and generator performance will result. BATTERY HOLDER BAND NEGATIVE (–) CABLE...

  • Page 78: Fuse

    In the event of fuse failure, locate the cause of failure and repair it before you continue operation. If the fuse continues to fail, discontinue generator use and consult an authorized Honda Power Equipment dealer. 1. Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse.

  • Page 79: Storage

    STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your generator’s function and appearance, and will make the engine easier to start when you use the generator again. Cleaning Wipe the generator with a moist cloth.
  • Page 80 After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting. Use gasoline stabilizers that are formulated to extend storage life. Follow the manufacturer’s instructions for use. Contact your authorized Honda Power Equipment dealer for stabilizer recommendations.
  • Page 81 STORAGE DRAINING THE FUEL TANK AND CARBURETOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and let it cool before handling fuel. • Keep heat, sparks, and flame away. •...

  • Page 82: Engine Oil

    STORAGE 4. After all the gasoline has drained into the container, tighten the drain screw securely. 5. Place a suitable gasoline container below the sediment cup, and use a funnel to avoid spilling gasoline. 6. Remove the sediment cup (see page 71), and then turn the fuel valve lever to the ON position.

  • Page 83: Storage Precautions

    STORAGE STORAGE PRECAUTIONS If your generator will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.

  • Page 84: Transporting

    TRANSPORTING An engine that has been running will remain very hot for a period of time. A hot engine and exhaust system can burn you and ignite some material. If the generator has been used, allow it to cool for at least 15 minutes before loading the generator on the transport vehicle.
  • Page 85 TRANSPORTING To lift the generator Lift the generator by the lifting hanger. Do not try to lift the generator by and other part.

  • Page 86: Taking Care Of Unexpected Problems

    Dry and reinstall spark plug. (flooded engine). Fuel strainer restricted, carburetor Take the generator to an authorized malfunction, ignition malfunction, Honda Power Equipment dealer, or valves stuck, etc. refer to the shop manual. CO-MINDER (CO Shut-off System) is Review the location of the generator,...

  • Page 87: Engine Lacks Power

    Refuel with fresh gasoline (see page 19). Fuel strainer restricted, carburetor Take the generator to an authorized malfunction, ignition malfunction, Honda Power Equipment dealer, or valves stuck, etc. refer to the shop manual. NO POWER AT THE AC RECEPTACLES Possible Cause...

  • Page 88: No Power At The Dc Terminals

    DC circuit protector OFF. Turn DC circuit protector ON (see page 32). Faulty generator. Take the generator to an authorized Honda Power Equipment dealer, or refer to the shop manual. ENGINE AUTOMATICALLY STOP AND THE CO ALARM INDICATOR FLASHING Possible Cause Correction...

  • Page 89: Technical Information

    TECHNICAL INFORMATION SERIAL NUMBER LOCATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER QR CODE Record the frame serial number and date purchased in the spaces below. You will need this information when ordering parts and when making technical or warranty inquiries. Engine serial number: Frame serial number: Date purchased:...

  • Page 90: Carburetor Modification For High Altitude Operation

    High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 2,000 feet (610 meters), have your authorized Honda servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

  • Page 91: Emission Control System Information

    Carbon monoxide does not react in the same way, but it is toxic. Honda utilizes appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
  • Page 92 Honda recommends that you retain all receipts covering maintenance on your power equipment engine, but Honda cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure that all scheduled maintenance has been completed.

  • Page 93: Air Index

    TECHNICAL INFORMATION AIR INDEX (Models sold in California) An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines.

  • Page 94: Specification

    TECHNICAL INFORMATION SPECIFICATION Dimensions Model EM5000SXK3 EM6500SXK2 Type AG type Description code EBMC EBJC Length 28.7 in (728 mm) 29.0 in (736 mm) [Handle in up position] [41.1 in (1,043 mm)] [41.4 in (1,051 mm)] Width 27.8 in (706 mm) Height 30.4 in (771 mm) [Handle in up position]...
  • Page 95 0.028–0.031 in (0.7–0.8 mm) Refer to page 68 Valve clearance (cold) IN: 0.15±0.02 mm See your authorized EX: 0.20±0.02 mm Honda dealer. Other specifications No other adjustments needed. Specifications may vary according to the types, and are subject to change without notice.

  • Page 96: Wiring Diagram

    TECHNICAL INFORMATION WIRING DIAGRAM Abbreviations Wire color code Symbol Part name BLACK AC O AC Outlet YELLOW AC CB AC Circuit Breaker BLUE AC CP AC Circuit Protector GREEN Au Sw Auto Throttle Switch Battery WHITE Control Box Block BROWN Charge Coil LIGHT GREEN Current Transformer...
  • Page 97 TECHNICAL INFORMATION...

  • Page 98: Consumer Information

    Parts Catalog This manual provides complete, illustrated parts lists for your generator. Visit peparts.honda.com for free online access to the parts catalog. It is also available for purchase in paper form through your Honda dealer. Accessories Catalog Your authorized Honda Power Equipment dealer offers a wide selection of accessories (optional equipment) to make your generator even more useful.

  • Page 99: Customer Service Information

    The Service Manager or General Manager can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Power Equipment Customer Relations Office. You can write American Honda Motor Co., Inc. Power Equipment Division...

  • Page 100: Distributor's Limited Warranty

    What American Honda will Repair or Replace Under Warranty: American Honda will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period.
  • Page 101 You must, at your expense, take the Honda Power Equipment product, accessory, replacement part, apparel, or the power equipment on which the accessory or replacement part is installed, and proof of purchase to any Honda Power Equipment dealer in the United States, Puerto Rico, or the U.S. Virgin Islands who is authorized to sell that product, during the dealer’s normal...
  • Page 102 Disclaimer of Consequential Damage and Limitation of Implied Warranties: American Honda disclaims any responsibility for loss of time or use of the product, transportation, commercial loss, or any other incidental or consequential damage.
  • Page 103 1. The accessories, replacement parts, or apparel must be purchased from American Honda, or a dealer, distributor, or distributor’s dealer authorized by American Honda to sell those products in the United States, Puerto Rico, and the U.S. Virgin Islands. Parts and Accessories must be purchased for installation on original Honda equipment or engines to be eligible for warranty coverage.
  • Page 104 You must, at your expense, take the Honda Power Equipment accessory, replacement part, apparel, or the Honda Power Equipment on which the accessory or replacement part is installed, and proof of purchase to any Honda Power Equipment dealer, distributor, or distributor’s dealer in the United States, Puerto Rico, or the U.S.

  • Page 105: Emission Control System Warranty

    MANUFACTURER'S WARRANTY COVERAGE: The exhaust and evaporative emissions control system on your Honda power equipment engine is warranted for two years. If any emissions-related part on your Honda power equipment engine is defective, the part will be repaired or replaced by Honda.
  • Page 106 • As the power equipment engine owner, you should however be aware that Honda may deny you warranty coverage if your power equipment engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
  • Page 107 (including durability) could result in denial of coverage. If such a non-Honda replacement part is used in the repair or maintenance of your engine, and an authorized Honda dealer determines it is defective or causes a failure of a warranted part, your claim for repair of your engine may be denied.
  • Page 108 Honda Power Equipment dealer who is authorized by Honda to sell and service that Honda product during their normal business hours. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.
  • Page 109 DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES: American Honda Motor Co., Inc. and Honda Canada Inc. disclaim any responsibility for incidental or consequential damages such as loss of time or the use of the power equipment, or any commercial loss due to the failure of the equipment;...

  • Page 110: Registration

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

  • Page 111: Optional Parts

    OPTIONAL PARTS REMOTE CONTROL KIT 1. Remove the plug from the 4-pin connector. 2. Connect the remote control cable to the back of the control panel and remote control box. 4-PIN CONNECTOR REMOTE CONTROL CABLE REMOTE CONTROL BOX • When the remote control is not being used, replace it with the plug on the connector.

  • Page 112: Remote Control Box

    OPTIONAL PARTS Remote Control Box ENGINE START BUTTON PILOT LAMP MAIN SWITCH STARTING THE ENGINE WITH REMOTE CONTROL 1. Turn the fuel valve on the generator to the ON position. 2. Turn the Auto Throttle switch on the generator to the OFF position. 3.

  • Page 113: Hanger Kit

    OPTIONAL PARTS HANGER KIT 1. Position the hanger at the generator’s balance point as shown below. 2. Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely. Torque: 19.5 lbf·ft (26.5 N·m, 2.7 kgf·m) HANGER 8×16 mm FLANGE BOLT (4) HANGER BRACKET (2)

  • Page 114: Reference Information

    “QR Code” is registered trademark of DENSO WAVE INCORPORATED. The Bluetooth word mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Honda Motor Co., Ltd., is under license. Other trademarks and trade names are those of their respective owners.

  • Page 115: Index

    INDEX AC Appliance and Power Cord..................39 AC Applications ........................55 AC Circuit Breaker........................ 29 AC Circuit Protectors ......................30 AC OPERATION ........................53 AC Receptacle Selection....................56 AIR CLEANER SERVICE ......................67 AIR FILTER CHECK ........................ 41 AIR INDEX..........................91 ARE YOU READY TO GET STARTED? ................
  • Page 116 INDEX DC Circuit Protector ......................32 DC OPERATION ........................58 DC Terminals ......................... 32 DEALER LOCATOR INFORMATION ................. 96 Disconnecting the battery charging cable:..............59 Distributor’s Limited Warranty ..................98 Electric Shock Hazards ......................9 Emergency Procedures...................... 72 EMISSION CONTROL SYSTEM INFORMATION............89 Emission Control System Warranty ................
  • Page 117 Ground Fault Circuit Interrupter (GFCI) Receptacle ..........31 Ground Terminal........................36 Handle Installation ......................14 HANGER KIT ........................111 Honda PUBLICATIONS......................96 HOW TO RESTART WHEN STOPPED BY CO-MINDER (CO SHUT-OFF SYSTEM) ............................... 49 iAVR (Intelligent Auto Voltage Regulator) ..............35 IMPORTANT SAFETY INFORMATION................
  • Page 118 INDEX QUICK REFERENCE INFORMATION ...........inside back cover REFERENCE INFORMATION ................... 112 Refuel With Care........................10 REGISTRATION ........................108 Remote Control Box......................110 REMOTE CONTROL KIT....................109 REMOVAL FROM STORAGE....................81 SAFE OPERATING PRECAUTIONS ................... 43 SAFETY LABEL LOCATIONS....................11 Safety Precautions....................... 64 SAFETY.............................
  • Page 119 INDEX Unpacking ..........................13 Vehicles and Transportation Hazards................10 Voltage Selector Switch....................28, 57 Wheel Kit Installation......................15 WIRING DIAGRAM........................ 94...
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  • Page 123: Quick Reference Information

    QUICK REFERENCE INFORMATION Fuel Type Regular unleaded gasoline with an ethanol content of no more than 10% and a pump octane rating of 86 or higher (see page 21) Engine Oil Type SAE 10W-30, API SJ or later (or equivalent), for general use (see page 18) Maximum oil capacity: 1.2 US qt (1.1 L)
  • Page 124 31Z23620 AH 英 00X31-Z23-6200 Printed in China...

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