Honda EU6500is Owner's Manual
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Honda EU6500is Owner's Manual

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Owner's Manual
GENERATOR
EU6500is
o2006 Honda Motor Co., Ltd.
See page 78 for instructions
-All Rights Reserved
on assembling your generator

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Summary of Contents for Honda EU6500is

  • Page 1 Owner’s Manual GENERATOR EU6500is o2006 Honda Motor Co., Ltd. See page 78 for instructions -All Rights Reserved on assembling your generator...
  • 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 whatever.
  • Page 3 When your generator needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.
  • Page 4 A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS GENERATOR SAFETY ................IMPORTANT SAFETY INFORMATION ..........Operator Responsibility ..............Carbon Monoxide Hazards ..............Electric Shock Hazards ............... Fire and Burn Hazards ................ Refuel With Care ................. SAFETY LABEL LOCATIONS ..............CONTROLS & FEATURES ................ COMPONENT & CONTROL LOCATIONS ...........
  • Page 6 CONTENTS OPERATION ....................SAFE OPERATING PRECAUTIONS ............. STARTING THE ENGINE ..............Starting the engine with remote control (optional part) ....STOPPING THE ENGINE ..............Stopping the engine with remote control (optional part) ....AC OPERATION ..................AC Applications ................. AC Receptacle Selection ..............
  • Page 7 Carburetor Modification for High Altitude Operation ....Emission Control System Information ..........Air Index ..................... Specifications ..................Wiring Diagram ................. CONSUMER INFORMATION ............... Honda Publications ................Customer Service Information ............ASSEMBLY ....................SAFETY ....................The Importance of Proper Assembly ..........Important Safety Precautions ............

  • Page 8: Generator Safety

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

  • Page 9: Electric Shock Hazards

    GENERATOR SAFETY Electric Shock Hazards The generator produces enough electric power to cause a serious shock or electrocution if misused. Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution.

  • Page 10: Refuel With Care

    GENERATOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Allow the engine to cool if the generator has been in operation. Refuel only outdoors in a well-ventilated area with the engine OFF. Do not overfill the fuel tank. Never smoke near gasoline, and keep other flames and sparks away.

  • Page 11: Safety Label Locations

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

  • Page 12: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the two illustrations on these pages to locate and identify the most frequently used controls. OVERLOAD OIL ALERT i-MONITOR ECOTHROTTLE SWITCH INDICATOR INDICATOR BUTTON CIRCUIT PROTECTORS OUTPUT INDICATOR i-MONITOR ENGINE SWITCH RECEPTACLES VOLTAGE SELECTOR SWITCH FUEL VALVE LEVER...
  • Page 13 CONTROL & FEATURES FUEL GAUGE FUEL TANK CAP STARTER GRIP FUSE (inside battery maintenance cover) BATTERY (inside battery maintenance cover) OIL FILLER CAP/DIPSTICK HANDLE OIL DRAIN PLUG STAND GROUND TERMINAL RIGHT MAINTENANCE COVER SPARK PLUG INSPECTION COVER MUFFLER TIP AIR CLEANER WHEEL LEFT MAINTENANCE COVER...

  • Page 14: Controls

    CONTROL & FEATURES CONTROLS Fuel Valve Lever The fuel valve lever is located on the control panel. 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 Engine Switch The engine switch controls the...

  • Page 15: Recoil Starter

    CONTROL & FEATURES Recoil Starter Used when the battery voltage is STARTER GRIP too low to turn the starter motor. Pulling the starter grip operates the recoil starter to crank the engine for starting. 20° Do not exceed 20 degrees from horizontal when pulling the starter grip.

  • Page 16: Voltage Selector Switch

    CONTROL & FEATURES Voltage Selector Switch The voltage selector switch changes generator output to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4- prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only the 120V 3-prong receptacles are being used, select the ‘‘120V ONLY’’...

  • Page 17: Folding Handle

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

  • Page 18: Maintenance Cover

    CONTROL & FEATURES Maintenance Cover Open and close the maintenance cover for maintenance of the EU6500is. Open the maintenance cover, too, to use the recoil starter when the battery is discharged. Be sure to close the maintenance cover while the generator is running. Work made with the right maintenance cover open: Engine oil inspection/replacement Work made with the left maintenance cover open:...

  • Page 19: Features

    CONTROL & FEATURES FEATURES Ground Terminal The ground terminal is connected to the frame of the generator, 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 20: Output Indicator

    CONTROL & FEATURES Output Indicator The output indicator (green) is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the receptacles. OUTPUT INDICATOR (GREEN) Overload Indicator If the generator is overloaded, or if there is a short circuit in a connected appliance, or if the inverter is overheated, the overload indicator (red) will go ON.

  • Page 21: Oil Alert Indicator

    CONTROL & FEATURES Oil Alert Indicator 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 indicator comes on and the Oil Alert system automatically stops engine (the engine switch will remains the ON position).

  • Page 22: I-Monitor Tm

    CONTROL & FEATURES i-Monitor The i-Monitor is a user interface that allows the operator to view (when the generator is running) total operating time in hours, generator output, engine RPM, battery voltage and error messages. The different display modes are selected by pressing the i-Monitor button. i-Monitor at Startup During start up, the i-Monitor display and all three indicators will simultaneously blink once.
  • Page 23 CONTROL & FEATURES i-Monitor Display Mode 2 Power Output This mode displays an approximate generator output on the display screen. The output is expressed in VA (volt-amperes). The output value is not an exact measurement and should be regarded as a reference only.
  • Page 24 Normal remote control operation will be restored after the E-01 error message clears. If the E-01 error message will not clear or if any other error message displays, contact an authorized Honda generator dealer. OVERLOAD INDICATOR LIGHT ERROR MESSAGE...

  • Page 25: Fuel Gauge

    CONTROL & 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 26: Before Operation

    BEFORE OPERATION ARE YOU READY TO GET STARTED? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Knowledge Read and understand this manual. Know what the controls do and how to operate them. Familiarize yourself with the generator and its operation before you begin using it.

  • Page 27: Check The Engine

    BEFORE OPERATION Check the Engine Check the oil level (see page ). A low oil level will cause the Oil Alert system to shut down the engine. Check the air filter (see page ). A dirty air filter will restrict air flow to the carburetor, reducing engine and generator performance.

  • Page 28: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time, please review the GENERATOR SAFETY section and the chapter titled BEFORE OPERATION . For your safety, avoid starting or operating the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

  • Page 29: Starting The Engine

    OPERATION STARTING THE ENGINE Refer to Safe Operating Precautions on page Make sure that all appliances are disconnected from the AC receptacles. The generator may be hard to start if a load is connected. Set the Voltage Selector Switch VOLTAGE SELECTOR SWITCH to match the voltage requirements for the application.
  • Page 30 OPERATION Turn the engine switch to the START position, and hold it there until the engine starts. When the engine starts, release the key, allowing the switch to return to the ON position. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again.
  • Page 31 OPERATION Use the recoil starter when the battery voltage is too low to turn the starter motor. Turn the engine switch to the ON position. Open the right maintenance cover by turning its latch counterclockwise. ENGINE SWITCH Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the allow as...

  • Page 32: Starting The Engine With Remote Control (Optional Part)

    OPERATION Starting the engine with remote control (optional part) Determine the voltage requirements and adjust the voltage selector switch, as needed. Turn the fuel valve to the ON position. Turn the engine switch to the REMOTE (far left) position. REMOTE ENGINE SWITCH FUEL VALVE LEVER Press and hold the start button until the engine pilot lamp...

  • Page 33: 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. Unplug all appliances from the generator AC receptacles. Turn the engine switch to the OFF position.

  • Page 34: Stopping The Engine With Remote Control (Optional Part)

    OPERATION Stopping the engine with remote control (optional part) Press the stop button. STOP BUTTON PILOT LAMP Turn the engine switch to the OFF position. Turn the fuel valve lever to the OFF position. REMOTE ENGINE SWITCH FUEL VALVE LEVER...

  • Page 35: 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 if the rated load capacity of the generator has been exceeded. Substantial overloading that continuously lights the overload indicator (red) may damage the generator.
  • Page 36 When an electric motor is started, the overload indicator (red) may come on. This is normal if the overload indicator (red) goes off after about five seconds. If the overload indicator (red) stays on, consult an authorized Honda generator dealer.

  • Page 37: Ac Applications

    OPERATION AC Applications Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock. If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.

  • Page 38: Ac Receptacle Selection

    OPERATION AC Receptacle Selection The generator has separate main power producing circuits. These two circuits supply power to different receptacles shown when the voltage selector switch is in the 120/240 V position. When two or more receptacles are used, prevent overloading by dividing the load between the two power circuits.
  • Page 39 OPERATION Receptacle 1 has a 15A load connected to it. Receptacle 3 has a 10A load connected to it. Both receptacles are powered by main power circuit I. The equation tells us that the total power draw on circuit I is 25A.

  • Page 40: Ecothrottle System

    OPERATION ECOTHROTTLE SYSTEM With the switch in the ON position, engine speed is automatically lowered when loads are reduced, turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to the proper speed to power the electrical load. In the OFF position, the EcoThrottle system does not operate.

  • Page 41: Stand By Power

    Check local regulations for proper registration and use procedures. System Ground Honda portable generators have a system ground that connects the generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire.

  • Page 42: 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. In some areas, generators are required to be registered with local utility companies.

  • Page 43: Servicing Your Generator

    Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions. If...

  • Page 44: 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. Failure to properly follow maintenance instructions and precautions can cause you to be...

  • Page 45: Maintenance Schedule

    Service more frequently when used in dusty areas. These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to Honda shop manual for service procedures. For commercial use, log hours of operation to determine proper maintenance intervals.

  • Page 46: Refueling

    SERVICING YOUR GENERATOR REFUELING With the engine stopped, check the fuel level gauge. Refill the fuel tank if the fuel level is low. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away.

  • Page 47: Fuel Recommendations

    SERVICING YOUR GENERATOR FUEL RECOMMENDATIONS Use regular unleaded gasoline with a pump octane rating of 86 or higher. You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume. In addition, Methanol must contain cosolvents and corrosion inhibitors.

  • Page 48: Engine Oil Level Check

    SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the engine oil level with the generator on a level surface and the engine stopped. Open the right maintenance cover by turning its latch counterclockwise. Remove the oil filler cap/dipstick and wipe it clean. Insert and remove the dipstick without screwing it into the filler neck.

  • Page 49: Engine Oil Change

    SERVICING YOUR GENERATOR ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. Open the right maintenance cover by turning its latch counterclockwise. Reach under the generator and remove the black rubber seal located below the oil drain plug.

  • Page 50: Engine Oil Recommendations

    SAE Viscosity Grades AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container. Honda recommends that you use API SERVICE category SJ or later oil.

  • Page 51: Air Cleaner Service

    SERVICING YOUR GENERATOR AIR CLEANER SERVICE Open the left maintenance cover by turning its latch counterclockwise. Loosen the cover screws and remove the air cleaner cover. FOAM AIR FILTER AIR CLEANER COVER COVER SCREW Remove the foam air filter from the air cleaner cover. Check the foam air filter to be sure it is clean and in good condition.

  • Page 52: Foam Air Filter Cleaning

    SERVICING YOUR GENERATOR FOAM AIR FILTER CLEANING A dirty foam air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in very dusty areas, clean the foam air filter more frequently than specified in the Maintenance Schedule.

  • Page 53: Sediment Cup Cleaning

    SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING Turn the fuel valve lever to the OFF position and remove the key. Open the left maintenance cover by turning its latch counterclockwise. FUEL VALVE LEVER Unscrew the sediment cup and remove it. Remove the O-ring. Gasoline is highly flammable and explosive.

  • Page 54: Spark Plug Service

    SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) An incorrect spark plug can cause engine damage. Open the left maintenance cover by turning its latch counterclockwise. Loosen the cover screw and remove the spark plug inspection cover. SPARK PLUG INSPECTION COVER COVER SCREW...
  • Page 55 SERVICING YOUR GENERATOR Inspect the spark plug. Replace 0.028 0.031 in (0.70 0.80 mm) it if the electrodes are worn or if the insulator is cracked, SEALING WASHER chipped or fouled. Measure the spark plug electrode gap with a wire-type feeler gauge.

  • Page 56: 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. Remove the two 5 14 mm pan head screws, and remove the spark arrester.

  • Page 57: 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 58 SERVICING YOUR GENERATOR Battery Removal WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Lift handle upward. Lock levers will lock and secure handle into place. HANDLE HANDLE LOCK LEVER Loosen the cover screw and remove the battery maintenance cover. COVER SCREW BATTERY MAINTENANCE COVER...
  • Page 59 SERVICING YOUR GENERATOR Remove the negative ( ) cable from the battery negative ( ) terminal, then remove the positive ( ) cable from the battery positive ( ) terminal. Unhook the battery strap from the bottom hook of the generator. BATTERY STRAP NEGATIVE ( ) CABLE POSITIVE ( ) CABLE...
  • Page 60 SERVICING YOUR GENERATOR Battery Charging 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 do the battery maintenance.

  • Page 61: Fuse

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

  • Page 62: Storage

    STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your generator’s function and appearance, and will make the engine easier to start when you use the generator again.
  • Page 63 STORAGE Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline.

  • Page 64: Draining Fuel Tank/Carburetor

    STORAGE Draining the Fuel Tank and Carburetor Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Open the right maintenance cover by turning its latch counterclockwise.

  • Page 65: Engine Oil

    STORAGE Engine Oil Change the engine oil (see page Remove the spark plug (see page Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder. Pull the starter rope several times to distribute the oil in the cylinder. Reinstall the spark plug.

  • Page 66: 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. Also avoid any area with a spark-producing electric motor, or where power tools are operated.

  • Page 67: Transporting

    TRANSPORTING If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the generator level when transporting to reduce the possibility of fuel leakage.

  • Page 68: Taking Care Of Unexpected Problems

    (p. 52). improperly gapped. Spark plug wet with fuel Dry and reinstall spark plug. (flooded engine). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.

  • Page 69: Engine Lacks Power

    (p. 62). gasoline, or refueled with bad Refuel with fresh gasoline gasoline. (p. 44). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.

  • Page 70: No Power At The Receptacles

    Check AC load and reset circuit protector(s) (p. 14). Faulty power tool or Replace or repair power tool or appliance. appliance. Stop and restart the engine. Faulty generator. Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.

  • Page 71: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location FRAME SERIAL NUMBER Record the frame serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquiries. Frame serial number: Date purchased:...

  • Page 72: Carburetor Modification For High Altitude Operation

    High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 5,000 feet (1,500 meters), have your authorized Honda servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

  • Page 73: Emission Control System Information

    Carbon monoxide does not react in the same way, but it is toxic. Honda uses lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
  • Page 74 Afterburning (backfiring). Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your new Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done.

  • Page 75: Air Index

    TECHNICAL & CONSUMER INFORMATION Air Index An Air Index Information hang tag/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 76: Specifications

    0.028 0.031 in (0.70 0.80 mm) Refer to page: 52 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 77: Wiring Diagram

    TECHNICAL & CONSUMER INFORMATION Wiring Diagram...

  • Page 78: Consumer Information

    Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Available through your Honda dealer or through Helm Inc. at 1 888- 292-5395 or visit www.hondapowerequipment.com Parts Catalog This manual provides complete, illustrated parts lists. Available...

  • Page 79: Customer Service Information

    TECHNICAL & CONSUMER INFORMATION Customer Service Information Honda Power Equipment dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management.

  • Page 80: Assembly

    ASSEMBLY SAFETY The Importance of Proper Assembly Proper assembly is essential to operator safety and the reliability of the machine. Any error or oversight made by the person assembling and servicing a unit can easily result in faulty operation, damage to the machine, or injury to the operator.

  • Page 81: Important Safety Precautions

    ASSEMBLY Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing this assembly, be especially careful of the following: Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely.

  • Page 82: Assembly

    ASSEMBLY ASSEMBLY Unpacking Remove the generator and loose parts box from the carton. Compare the loose parts with the inventory list below. Tools Required: 14 mm wrench (2), 10 mm wrench or Phillips head screwdriver for battery connections, pliers (not included) Loose Parts Check all loose parts against the following list.

  • Page 83: Wheel Kit Installation

    ASSEMBLY Wheel Kit Installation Do not operate the generator without the wheel kit installed. The wheel kit provides an air space between the ground and the generator air intake. If the wheel kit is not installed, it may be possible for dirt and debris to be drawn into the generator air intake causing possible generator damage.

  • Page 84: Handle Installation

    ASSEMBLY Handle Installation Install the handle assembly on the generator upper frame using the 12 mm washers, spring washers and handle holder bolts. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) SPRING WASHER (2) HANDLE HOLDER BOLT (2) 12 mm WASHER (2) HANDLE ASSEMBLY Operation must be checked after attaching a handle.

  • Page 85: Rear Bar Installation

    ASSEMBLY Rear Bar Installation Install the rear bar on the generator frame using the two 6 30 mm bolts and two cap nuts. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) CAP NUT (2) REAR BAR 6 30 mm BOLT (2)
  • Page 86 ASSEMBLY Battery WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. The battery is disconnected and strapped into the battery tray for shipment. Remove the battery maintenance cover (see page Remove the battery strap from the bottom hook, and then remove the battery.

  • Page 87: Engine Oil

    ASSEMBLY Engine Oil SAE Viscosity Grades The generator is shipped WITHOUT OIL in the engine. Place the generator on a level surface. Open the right maintenance cover by turning its latch counterclockwise. Add enough of the recommended oil to bring the AMBIENT TEMPERATURE oil level to the top of the oil filler neck.

  • Page 88: Battery Voltage

    ASSEMBLY Battery Voltage Check the battery voltage with the i-Monitor (see page The battery voltage should be 12.3 V or more. If the battery voltage is low, charge the battery until the battery voltage will be 12.3 V or more. BEFORE OPERATION Before using your generator, you should become familiar with information contained in the following chapters and sections:...

  • Page 89: Optional Parts

    OPTIONAL PARTS Remote Control Kit Remove the battery maintenance cover (see page Remove the plug from the 6-pin connector. PLUG View the back of the maintenance cover and locate the knockout near the top center of the cover. Carefully remove the knockout. BATTERY MAINTENANCE COVER KNOCKOUT...
  • Page 90 OPTIONAL PARTS Pass the remote control cable through the supplied wire grommet and fit the grommet into the battery maintenance cover knockout. Plug the remote control cable into the 6-pin connector. Install the battery maintenance cover and tighten the cover screw. REMOTE GROMMET CONTROL CABLE...

  • Page 91: Hanger Kit

    OPTIONAL PARTS Hanger Kit Protect the fuel tank and frame pipe with the protector films during installation of the hanger. Insert the bracket installation part at one end of the hanger into the clearance between the frame pipe and fuel tank. Slide the hanger and insert another bracket installation part of the hanger into the gap between the frame pipe and fuel tank on the other side.

  • Page 92: Index

    INDEX AC Applications ..................35 AC Circuit Protectors ................14 AC OPERATION ..................33 AC Receptacle Selection ..............36 AIR CLEANER SERVICE ............... 49 Air Index ....................73 ARE YOU READY TO GET STARTED? ..........
  • Page 93 . 59 GENERATOR SAFETY ................Ground Terminal ................. . 17 Handle Installation ................83 Hanger Kit .................... . 89 Honda Publications ................76 i-Monitor ................... . 20 IMPORTANT SAFETY INFORMATION ..........Important Safety Precautions ............. 79 INDEX ....................
  • Page 94 INDEX Maintenance Cover ................16 MAINTENANCE SAFETY ..............42 MAINTENANCE SCHEDULE .............. . 43 NO POWER AT THE RECEPTACLES ........... 68 Oil Alert Indicator ................19 OPERATION ..................26 Operator Responsibility ............... OPTIONAL PARTS ................
  • Page 95 INDEX SAFE OPERATING PRECAUTIONS ........... . 26 SAFETY ....................78 SAFETY LABEL LOCATIONS ..............Safety Precautions ................42 SEDIMENT CUP CLEANING ..............51 Serial Number Location ..............69 SERVICING YOUR GENERATOR ............41 SPARK ARRESTER SERVICE ..............
  • Page 96 MEMO...

  • Page 99: Quick Reference Information

    Spark Plug Type NGK: BPR5ES DENSO: W16EPR-U Electrode Gap 0.028 0.031 in (0.70 0.80 mm) Battery Part Number Honda P/N: 31500-MCR-D02 Yuasa Model: YTZ14S Maintenance Before each use Check engine oil level. Check air filter. First 20 hours Change engine oil.
  • Page 100 2eY11000.2006.09 31Z25600 00X31-Z25-6000 Printed in Japan...

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