79
05/04/25 09:38:54 31Z11600_001 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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 generator and should remain with the generator if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd.
05/04/25 09:39:00 31Z11600_002 INTRODUCTION Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase of one of the finest generators on the market. We want to help you get the best results from your new generator and to operate it safely. This manual contains all the information on how to do that; please read it carefully. As you read this manual, you will find information preceded by a symbol.
05/04/25 09:39:09 31Z11600_003 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. This information alerts you to potential hazards that could hurt you or others.
05/04/25 09:39:12 31Z11600_004 CONTENTS GENERATOR SAFETY .................................................................................6 IMPORTANT SAFETY INFORMATION ...................................................6 Operator Responsibility.......................................................................6 Carbon Monoxide Hazards..................................................................6 Electric Shock Hazards ........................................................................
05/04/25 09:39:16 31Z11600_005 CONTENTS OPERATION ...............................................................................................25 SAFE OPERATING PRECAUTIONS ......................................................25 STARTING THE ENGINE .......................................................................26 Starting the engine with remote control (optional part) ....................29 STOPPING THE ENGINE .......................................................................
05/04/25 09:39:19 31Z11600_006 CONTENTS TRANSPORTING .......................................................................................64 TAKING CARE OF UNEXPECTED PROBLEMS ........................................65 ENGINE PROBLEMS ..............................................................................65 GENERATOR PROBLEMS .....................................................................67 TECHNICAL & CONSUMER INFORMATION ...........................................68 TECHNICAL INFORMATION .
05/04/25 09:39:26 31Z11600_007 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. The most common hazards are discussed below, along with the best way to protect yourself and others.
05/04/25 09:39:33 31Z11600_008 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. Keep the generator dry.
05/04/25 09:39:36 31Z11600_009 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. Always store gasoline in an approved container. Make sure that any spilled fuel has been wiped up before starting the engine.
05/04/25 09:39:49 31Z11600_010 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.
05/04/25 09:39:54 31Z11600_011 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the two illustrations on these pages to locate and identify the most frequently used controls.
05/04/25 09:39:59 31Z11600_012 CONTROL & FEATURES FUEL TANK CAP FUEL GAUGE FUSE(Inside maintenance cover) SPARK PLUG INSPECTION COVER HANDLE BATTERY TRAY (Inside maintenance cover) WHEEL AIR CLEANER STAND STARTER GRIP GROUND TERMINAL MUFFLER TIP OIL DRAIN PLUG OIL FILLER CAP/DIPSTICK 11
05/04/25 09:40:08 31Z11600_013 CONTROL & FEATURES CONTROLS Fuel Valve Lever The fuel valve lever is located on the control panel. ON OFF 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 ignition system, and it operates the electric starter. OFF OFF − Stops the engine. The engine switch key can be removed/inserted.
05/04/25 09:40:16 31Z11600_014 CONTROL & FEATURES Recoil Starter STARTER GRIP Pulling the starter grip operates the recoil starter to crank the engine for starting. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. Do not let the starter rope rub against the generator body or the rope will wear out prematurely. EcoThrottleTM Switch The EcoThrottleTM system automatically reduces engine speed when all loads are turned off or disconnected.
05/04/25 09:40:25 31Z11600_015 CONTROL & FEATURES Voltage Selector Switch The voltage selector switch switches generator output to produce ‘‘120 V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position. Select the voltage before starting the engine.
05/04/25 09:40:32 31Z11600_016 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 extended handle. To Extend Handle Lift handle upward. Lock levers will lock and secure handle into place. To Fold Handle 1. Press both handle lock levers downward. 2. Lower handle.
05/04/25 09:40:37 31Z11600_017 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.
05/04/25 09:40:42 31Z11600_018 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.
05/04/25 09:40:48 31Z11600_019 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 will stop the engine (the engine switch will remain in the ON position). The i-MonitorTM display will show ‘‘OIL’’ on the screen and the Oil Alert indicator will illuminate.
05/04/25 09:40:57 31Z11600_020 CONTROL & FEATURES i-MonitorTM The i-MonitorTM 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-MonitorTM button. i-MonitorTM at Start Up During start up, the i-MonitorTM display and all three indicators will simultaneously blink once.
05/04/25 09:41:05 31Z11600_021 CONTROL & FEATURES i-MonitorTM 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. Power output will not display until a load is connected to the generator.
05/04/25 09:41:12 31Z11600_022 CONTROL & FEATURES i-MonitorTM Low Battery Message If the engine switch is turned to the START position and ‘‘batt’’ is shown on the i-MonitorTM display, the battery voltage is too low to operate the engine’s electric starter. Use the recoil starter to start the generator. Have the battery recharged and checked (see page 57 ). i-MonitorTM System Error Messages If the generator has a system malfunction, it will show an error message on the i-MonitorTM display.
05/04/25 09:41:16 31Z11600_023 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. Check the fuel level with the generator on a level surface. Always refuel with the engine OFF and cool.
05/04/25 09:41:25 31Z11600_024 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. Know how to quickly shut off the generator in case of an emergency.
05/04/25 09:41:31 31Z11600_025 BEFORE OPERATION Check the Engine Check the oil level (see page 45 ). A low oil level will cause the Oil Alert system to shut down the engine. Check the air filter (see page 48 ). A dirty air filter will restrict air flow to the carburetor, reducing engine and generator performance. Check the fuel level (see page 43 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.
05/04/25 09:41:39 31Z11600_026 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 which can collect rapidly in an enclosed area and cause illness or death. Carbon monoxide gas is toxic.
05/04/25 09:41:47 31Z11600_027 OPERATION STARTING THE ENGINE Refer to Safe Operating Precautions on page 25 . 1. Make sure that all appliances are disconnected from the AC receptacles. The generator may be hard to start if a load is connected. 2. Set the Voltage Selector Switch to match the voltage requirements for the application. VOLTAGE SELECTOR SWITCH 120V/ 240V 120V ONLY 3. Turn the fuel valve lever to the ON position. FUEL VALVE LEVER ON OFF ECOTHROTTLETM SWITCH 4.
05/04/25 09:41:54 31Z11600_028 OPERATION 5. Start the engine Using the electric starter: 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.
05/04/25 09:42:02 31Z11600_029 OPERATION Using the recoil starter: a. Turn the engine switch to the ON position. OFF ON ENGINE SWITCH b. Pull the starter grip lightly until you feel resistance, then pull briskly. STARTER GRIP Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. Do not let the starter rope rub against the generator body or the rope will wear out prematurely. ECOTHROTTLETM SWITCH 6.
05/04/25 09:42:09 31Z11600_030 OPERATION Starting the engine with remote control (optional part) 1. Determine the voltage requirements and adjust the voltage selector switch, as needed. 2. Turn the fuel valve to the ON position. 3. Turn the engine switch to the REMOTE (far left) position. ON OFF OFF REMOTE FUEL VALVE ENGINE SWITCH 4. Press and hold the start button until the engine pilot lamp illuminates. The start button will automatically be disabled after the engine starts.
05/04/25 09:42:16 31Z11600_031 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. Unplug all appliances from all generator AC receptacles. 2. Turn the engine switch to the OFF position. ON OFF ENGINE SWITCH 3. Turn the fuel valve lever to the OFF position.
05/04/25 09:42:22 31Z11600_032 OPERATION Stopping the engine with remote control (optional part) 1. Press the stop button. STOP BUTTON PILOT LAMP 2. Turn the engine switch to the OFF position. 3. Turn the fuel valve lever to the OFF position.
05/04/25 09:42:29 31Z11600_033 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.
05/04/25 09:42:35 31Z11600_034 OPERATION 3. Plug in the appliance. Most motorized appliances require more than their rated wattage for startup. PLUG 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 come ON. The overload indicator (red) will stay ON, and after about five seconds, current to the connected appliance(s) will shut off, and the output indicator (green) will go OFF.
05/04/25 09:42:43 31Z11600_035 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. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded.
05/04/25 09:42:52 31Z11600_036 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.
05/04/25 09:42:56 31Z11600_037 OPERATION Example: EM5000is 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. This is a substantial overload of this circuit. To eliminate the excess power draw on circuit I, the load from receptacle 3 should be switched to receptacle 2. Now circuit I is powering the 15A load (less than 18.
05/04/25 09:43:01 31Z11600_038 OPERATION ECOTHROTTLETM 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 EcoThrottleTM system does not operate. Appliances with large start-up power demands may not allow the engine to reach normal operating rpm when they are connected to the generator.
05/04/25 09:43:07 31Z11600_039 OPERATION STAND BY POWER Connections to a Building’s Electrical System Your generator can supply power to a building’s electrical system. If the generator will be used as an alternative to utility company power, an isolation switch must be installed to disconnect the utility lines from the building when the generator is connected. Installation must be performed by a qualified electrician and must comply with all applicable laws and electrical codes.
05/04/25 09:43:12 31Z11600_040 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.
05/04/25 09:43:18 31Z11600_041 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. To help you properly care for your generator, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools.
05/04/25 09:43:26 31Z11600_042 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 seriously hurt or killed. Always follow the procedures and precautions in the owner’s manual.
05/04/25 09:43:38 31Z11600_043 SERVICING YOUR GENERATOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Check level Change Air filter Check Clean Sediment cup Clean Spark plug Check-adjust Replace Spark arrester Clean Valve clearance Check-adjust Combustion Clean chamber Fuel tank and filter Clean Fuel tube Check Each use First Every Every Every month 3 6 year or months months or 20 Hrs. or or 300 Hrs.
05/04/25 09:43:46 31Z11600_044 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. Handle fuel only outdoors. Wipe up spills immediately.
05/04/25 09:43:51 31Z11600_045 SERVICING YOUR GENERATOR FUEL RECOMMENDATIONS 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 deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
05/04/25 09:43:59 31Z11600_046 SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the engine oil level with the generator on a level surface and the engine stopped. 1. Remove the oil filler cap/dipstick and wipe it clean. 2. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick. 3. If the oil level is low, fill to the top of the oil filler neck with the recommended oil (see page 47 ). 4. Screw in the oil filler cap/dipstick securely.
05/04/25 09:44:07 31Z11600_047 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, then remove the oil filler cap/dipstick, drain plug and sealing washer. 2. Allow the used oil to drain completely, then reinstall the drain plug and sealing washer. Tighten the plug securely. Improper disposal of engine oil can be harmful to the environment.
05/04/25 09:44:12 31Z11600_048 SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 10W−30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range. SAE Viscosity Grades AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container.
05/04/25 09:44:19 31Z11600_049 SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1. Loosen the cover screws and remove the air cleaner cover. FOAM AIR FILTER AIR CLEANER COVER COVER SCREW 2. Remove the foam air filter from the air cleaner cover. 3. Check the foam air filter to be sure it is clean and in good condition. If the foam air filter is dirty, clean it as described on page 49 . Replace the foam air filter if it is damaged. 4. Reinstall the foam air filter in the air cleaner cover. 5.
05/04/25 09:44:26 31Z11600_050 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. 1. Clean the foam air filter in warm soapy water, rinse, and allow to dry thoroughly, or clean in nonflammable solvent and allow to dry. FOAM AIR FILTER 2.
05/04/25 09:44:34 31Z11600_051 SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING 1. Turn the fuel valve lever to the OFF position and remove the key. ON OFF FUEL VALVE LEVER KEY 2. Remove the sediment cup by turning it counterclockwise. 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. 3.
05/04/25 09:44:41 31Z11600_052 SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) Incorrect spark plugs can cause engine damage. 1. Loosen the cover screw and remove the spark plug inspection cover. SPARK PLUG INSPECTION COVER COVER SCREW 2. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. 3. Remove the spark plug with a 13/16-inch spark plug wrench (commercially available).
05/04/25 09:44:50 31Z11600_053 SERVICING YOUR GENERATOR 4. Inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked, chipped or fouled. 0.028−0.031 in (0.70−0.80 mm) SEALING WASHER 5. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.028−0.031 in (0.70−0.80 mm) 6.
05/04/25 09:44:56 31Z11600_054 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. 1. Remove the two 8 mm flange bolts, and remove the rear bar. 2. Remove the six 6 mm flange nuts, and remove the muffler protector.
05/04/25 09:45:03 31Z11600_055 SERVICING YOUR GENERATOR 3. Remove the three 6 mm flange bolts, and remove the exhaust tail pipe and the spark arrester. 6 mm FLANGE BOLTS EXHAUST TAIL PIPE SPARK ARRESTER 6 mm FLANGE BOLT 4. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. 5. Inspect the screen for breaks or tears and replace it if necessary. 6.
05/04/25 09:45:10 31Z11600_056 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. Getting electrolyte in your eyes or on your skin can cause serious burns.
05/04/25 09:45:18 31Z11600_057 SERVICING YOUR GENERATOR Battery Removal WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. 1. Lift handle upward. Lock levers will lock and secure handle into place. 2. Loosen the cover screw and remove the maintenance cover. COVER SCREW MAINTENANCE COVER 3. Remove the negative (−) cable from the battery negative (−) terminal, then remove the positive (＋) cable from the battery positive (＋) terminal. 4.
05/04/25 09:45:30 31Z11600_058 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. The battery is rated at 11.2Ah (ampere-hours). Charging current should equal 10% of the battery’s ampere-hour rating.
05/04/25 09:45:40 31Z11600_059 SERVICING YOUR GENERATOR FUSE If the fuse is blown, the starter motor won’t operate. 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. 1. Turn the engine switch OFF and remove the key before checking or replacing the fuse. 2. Loosen the cover screw and remove the maintenance cover. 3.
05/04/25 09:45:46 31Z11600_060 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.
05/04/25 09:45:51 31Z11600_061 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. 1. Add fuel stabilizer following manufacturer’s instructions. 2.
05/04/25 09:45:59 31Z11600_062 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. DRAIN SCREW 1. Place a suitable gasoline container below the carburetor drain hose. 2. Loosen the carburetor drain screw and drain the gasoline from the carburetor. 3.
05/04/25 09:46:05 31Z11600_063 STORAGE Engine Oil 1. Change the engine oil (see page 46 ). 2. Remove the spark plug (see page 51 ). 3. Pour a tablespoon (5 − 10 cc) of clean engine oil into the cylinder. 4. Pull the starter rope several times to distribute the oil in the cylinder. 5. Reinstall the spark plug. 6. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed.
05/04/25 09:46:15 31Z11600_064 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.
05/04/25 09:46:20 31Z11600_065 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. Move the fuel valve to the OFF position.
05/04/25 09:46:26 31Z11600_066 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE PROBLEMS Engine Will Not Start 1. Check control positions. 2. Check fuel. 3. Check engine oil level. 4. Remove and inspect spark plug. 5. Take generator to an authorized Honda servicing dealer, or refer to shop manual. Possible Cause Correction Fuel valve lever OFF. Engine switch OFF. Turn lever ON. Out of fuel. Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline.
05/04/25 09:46:32 31Z11600_067 TAKING CARE OF UNEXPECTED PROBLEMS Engine Lacks Power 1. Check air filter. Possible cause Correction Air filter restricted. 2. Check fuel. Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Clean or replace air filter (p. 48). Drain fuel tank and carburetor (p. 61). Refuel with fresh gasoline (p. 43). 3.
05/04/25 09:46:38 31Z11600_068 TAKING CARE OF UNEXPECTED PROBLEMS GENERATOR PROBLEMS No Power at the AC Receptacles 1. Check output and overload indicator. Possible Cause Correction Output indicator is OFF, and overload indicator is ON. 2. Check circuit protectors. Circuit protector(s) tripped. 3. Check the power tool or appliance at a known, good AC power source. 4. Take generator to an authorized Honda servicing dealer, or refer to shop manual. Faulty power tool or appliance. Check AC load.
05/04/25 09:46:43 31Z11600_069 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.
05/04/25 09:46:48 31Z11600_070 TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
05/04/25 09:46:57 31Z11600_071 TECHNICAL & CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
05/04/25 09:47:04 31Z11600_072 TECHNICAL & CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
05/04/25 09:47:10 31Z11600_073 TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your authorized Honda servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
05/04/25 09:47:18 31Z11600_074 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. The lower the Air Index, the less pollution.
05/04/25 09:47:34 31Z11600_075 TECHNICAL & CONSUMER INFORMATION Specifications EM5000is Dimensions Model (Type) Power product description code Length [Handle in up position] Width Height [Handle in up position] Dry weight＊ EM5000is EAJJ 31.9 in (810 mm) [ 45.5 in (1,155 mm) ] 26.4 in (670 mm) 27.2 in (690 mm) [ 28.0 in (710 mm) ] 209 lbs (95 kg) ＊ Without battery Engine GX340K1 4-stroke, overhead valve, single cylinder 20.6 cu-in (337 cm ) 3.2 × 2.5 in (82 × 64 mm) 8.
05/04/25 09:47:51 31Z11600_076 TECHNICAL & CONSUMER INFORMATION EM7000is Dimensions Model (Type) Power product description code Length [Handle in up position] Width Height [Handle in up position] Dry weight＊ EM7000is EAHJ 31.9 in (810 mm) [ 45.5 in (1,155 mm) ] 26.4 in (670 mm) 27.2 in (690 mm) [ 28.0 in (710 mm) ] 209 lbs (95 kg) ＊ Without battery Engine GX390K1 4-stroke, overhead valve, single cylinder 23.7 cu-in (389 cm ) 3.5 × 2.5 in (88 × 64 mm) 8.
05/04/25 09:48:15 31Z11600_077 TECHNICAL & CONSUMER INFORMATION Wiring Diagram 76
05/04/25 09:48:20 31Z11600_078 TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your generator. You may order them from your Honda generator dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Parts Catalog This manual provides complete, illustrated parts lists.
05/04/25 09:48:25 31Z11600_079 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. The Service Manager or General Manager can help. Almost all problems are solved in this way.
05/04/25 09:48:30 31Z11600_080 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. Improper assembly can cause an unsafe condition that can lead to serious injury or death. Follow the procedures and precautions in the assembly instructions carefully.
05/04/25 09:48:37 31Z11600_081 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. Make sure the engine is off before you begin any maintenance or repairs.
05/05/17 13:20:22 31Z11600_082 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: 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. Contact your dealer if any of the loose parts shown below are not included with your generator. Ref. No.
05/04/25 09:48:56 31Z11600_083 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. Always operate the generator with the wheel kit installed. 1. Install the two wheels on the axle shaft using the washers and cotter pins. 2.
05/04/25 09:49:04 31Z11600_084 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) HANDLE HOLDER BOLT (2) SPRING WASHER (2) 12 mm WASHER (2) HANDLE ASSEMBLY Operation must be checked after attaching a handle. To Extend Handle: Raise handle to horizontal position. The handle will click into place when locked.
05/04/25 09:49:08 31Z11600_085 ASSEMBLY Rear Bar Installation Install the rear bar on the generator frame using the two 8 × 45 mm flange bolts. TORQUE: 17−22 lbf·ft (24−29 N·m , 2.4−3.
05/04/25 09:49:17 31Z11600_086 ASSEMBLY Battery The battery is either standard parts or optional parts for this generator. Battery: standard part 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. 1. Remove the maintenance cover (see page 56 ). 2. Remove the battery strap from the bottom hook, and then remove the battery. 3.
05/05/17 13:20:35 31Z11600_087 ASSEMBLY Battery : optional part Part Number: 31500-MCR-D02 WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. 1. Remove the maintenance cover (see page 56 ). 2. Remove the battery strap from the bottom hook. 3. Remove the red cable and the black cable from the twist clip, and set the battery. 4.
05/04/25 09:49:35 31Z11600_088 ASSEMBLY Engine Oil The generator is shipped WITHOUT OIL in the engine. SAE Viscosity Grades Place the generator on a level surface. Add enough of the recommended oil to bring the oil level to the top of the oil filler neck. Use a 4-stroke motor oil that meets the requirements for API service classification SJ. AMBIENT TEMPERATURE OIL FILLER HOLE SAE 10W-30 is recommended for general, all-temperature use.
05/04/25 09:49:42 31Z11600_089 ASSEMBLY BEFORE OPERATION Before using your generator, you should become familiar with information contained in the following chapters and sections: GENERATOR SAFETY (page 6 ) CONTROLS & FEATURES (page 10 ) OPERATION (page 25 ) STARTING THE ENGINE (page 26 ) STOPPING THE ENGINE (page 30 ) 88
05/04/25 09:49:48 31Z11600_090 OPTIONAL PARTS Remote Control Kit 1. Remove the maintenance cover (see page 56 ). 2. Remove the plug from the 6-pin connector. PLUG 3. View the back of the maintenance cover and locate the knockout near the top center of the cover. Carefully remove the knockout.
05/04/25 09:49:56 31Z11600_091 OPTIONAL PARTS 4. Pass the remote control cable through the supplied wire grommet and fit the grommet into the maintenance cover knockout. 5. Plug the remote control cable into the 6-pin connector. 6. Install the maintenance cover and tighten the cover screw. REMOTE CONTROL CABLE REMOTE CONTROL CABLE REMOTE CONTROL BOX MAINTENANCE COVER GROMMET 7. To avoid accidentally unplugging the remote control cable, secure the cable to the generator frame with a cable tie as shown.
05/04/25 09:50:02 31Z11600_092 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: 17−22 lbf·ft (24−29 N·m , 2.4−3.
05/04/25 09:50:07 31Z11600_093 INDEX A AC Applications .................................................................................... 34 AC Circuit Protectors ........................................................................... 14 AC OPERATION .................................................................................... 32 AC Receptacle Selection ..................................................................... 35 AIR CLEANER SERVICE .................................................
05/04/25 09:50:14 31Z11600_094 INDEX F FEATURES ............................................................................................ 16 Fire and Burn Hazards ........................................................................... 7 Folding Handle ..................................................................................... 15 FOAM AIR FILTER CLEANING ............................................................ 49 Fuel .....................................................................
05/04/25 09:50:19 31Z11600_095 INDEX M Maintenance Cover .............................................................................. 24 MAINTENANCE SAFETY ..................................................................... 41 MAINTENANCE SCHEDULE ............................................................... 42 O Oil Alert Indicator ............................................................................... 18 OPERATION .............................................................................
05/04/25 09:50:24 31Z11600_096 INDEX S SAFE OPERATING PRECAUTIONS .................................................... 25 SAFETY ................................................................................................. 79 SAFETY LABEL LOCATIONS ................................................................. 9 Safety Precautions ............................................................................... 41 SEDIMENT CUP CLEANING ................................................................
05/04/25 09:50:27 31Z11600_097 MEMO 96
05/04/25 09:50:32 31Z11600_098 QUICK REFERENCE INFORMATION Fuel Type Spark Plug Type Battery Electrode Gap Part Number Maintenance Before each use First 20 hours Subsequent Unleaded gasoline with a pump octane rating of 86 or higher NGK: BPR5ES DENSO: W16EPR-U 0.028−0.031 in (0.70−0.80 mm) Honda P/N: 31500-MCR-D02 Yuasa Model: YTZ14S Check engine oil level. Check air filter. Change engine oil.
31Z11603
