The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the generator get wet, and do not operate it with wethands. Keep this owner's manual handy, so you can refer to it at any time.
CongratulationsonyourselectionofaHondagenerator.We certain you will be pleased with your purchase of one generators on the market. are of the finest the best results from your newgenerator and We want to help you get to operate it safely. This manual contains the information on how to do that; please read it carefully. As you read this manual, youwill find information preceded bya symbol.Thatinformationisintendedtohelpyouavoid damage to yourgenerator, other property, orthe environment.
A FEW WORDS ABOUTSAFETY 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 operatingproceduresandotherinformationonlabelsandinthis manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining a generator.
CONTENTS SAFETY ....................................................................................................... 5 SAFETY LABEL LOCATIONS ............................................................... 5 SAFETY INFORMATION ...................................................................... 7 COMPONENT IDENTIFICATION ............................................................. .9 CONTROLS ...............................................................................................
MAINTENANCE ....................................................................................... The Importance of Maintenance....................................................... Maintenance Safety ........................................................................... Emission Control System Information............................................. Air Index .............................................................................................. Maintenance Schedule .........................
SAFETY SAFETY LABELLOCATIONS These labels warn you of potential injury. Read them carefully. hazards that can cause serious If a labelcomes off or becomes hard to generator dealer for a replacement. read, contact your Honda A WARNING ELECTROCUTION OR w o m v DAMAGE CAN oaun.
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SAFETY INFORMATION Honda generators are designed to givesafe and dependable service if operated according to instructions.Read and understand this owner’s manualbeforeoperatingyourgenerator.You can helpprevent accidents bybeingfamiliarwithyourgenerator’scontrols,andby observing safe operating procedures. Operator Responsibility Know how to stop the generator quicklycase in of emergency. Understand the use of all generator controls, output and connections.
Electric Shock Hazards The generator produces enough electric power shock or electrocution if misused. to cause a serious 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. If the generator is stored outdoors, unprotected from the weather, check all electrical components on the control panel, before each use.
COMPONENT IDENTIFICATION IGNITION SWITCH CHOKE LEVER I OIL DRAIN PLUG RECOIL STARTER GRIP ENGINE SERIAL NUMBER 9
FUEL FILLER CAP AC RECEPTACLES *Record theengine and frame seriaO numbersforyourfuture reference. Refer to these serial numbers when ordering parts, and when making technical or warranty inquiries (see page44 ).
CONTROLS IGNITION SWITCH To start and stopthe engine. Switch position: OFF: To stop the engine. ON: To start and run the engine. IGNITION SWITCH RECOIL STARTER To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly. Do not allow thestarter grip to snap back against the engine. Return it gently to prevent damageto thestarter.
FUEL VALVE LEVER The fuel valve is located on the carburetor. When the fuel valve leve in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the OFF position after stopping the engine. I FUEL VALVE LEVER CHOKE LEVER The choke is used to provide proper starting mixture when the engine iscold. It can beopenedandclosedbyoperatingthechokelever manually. Move the choke lever to theCLOSED position to enrich the mixture for cold starting.
AC CIRCUIT PROTECTOR The AC circuit protector will automatically shut OFF the AC output a significantoverloadofthe powerifthereisashortcircuitor generator a t the generator receptacle. The AC circuit protector button will pop out to show that the AC circuit protector has switched off. Push the button in to reset the AC circuit protector, and then restart the engine.
OIL ALERT@SYSTEM The Oil Alert? system is designed to prevent engine damage caused by an insufficient amountof oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert@ system will automatically stop the engine(the engine switch will remain in theON position). If the engine stops and will notrestart, check the engine oil level (see page 19 ) before troubleshooting in otherareas.
GENERATOR USE CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM Connections for standby power to a building electrical system must be madeby a qualifiedelectrician.Theconnectionmustisolatethe generatorpowerfromutilitypower,andmustcomplywithall applicable laws and electrical codes. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers.
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 cancreate a potential for electricalshock. 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 theappliance, or if therated load capacity of the generator has been exceeded.
AC OPERATION 1. Start the engine(see page23). 2. Plug in the appliance. Be sure that all appliances are ingoodworkingorderbefore connecting them to the generator. If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly,turn off the ignition switch immediately. Thendisconnect the appliance and examineit for signs ofmalfunction. Most motorized appliances require more than their rated wattage for startup. Do not exceed the current limit specified for any one receptacle.
HIGH ALTITUDE OPERATION At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumptionwill increase. A very rich mixturewill also foul thespark plug andcause hard starting. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 1,500 meters (5,000 feet),have your dealerperformthis carburetor modification.
PRE-OPERATION CHECK ENGINE OIL I NOTICE I Engine oil is a major factoraffecting engine performance and service life. Non detergent and 2-stroke engine oils will damage the engine and arenot recommended. SAE Viscosity Grades Check the oil level BEFORE EACH USE with the generator on a levelsurface andtheengine stopped. Use 4-stroke motor oil that meets or exceeds the requirementsfor API serviceclassification SJ. Always check the API SERVICE label on the oil container to be sure it includes the letters SJ.
REFUELING Fuel tank capacity: 1.85 US gal (7.00 , 1.54 Imp gal) With the engine stopped, removethe fuel tank cap and check the fuel level. Refill the fuel tank if the fuel level is low. Gasoline is highly flammable and explosive. You seriously injured whenhandling fuel. can be burned or Stop theengine and keep heat,sparks, and flame away. Handle fuel only outdoors. Wipe upspills immediately. Refuel in a well-ventillated area with the engine stopped. Ifthe engine hasbeenrunning, allow it to coolfirst.
FUEL RECOMMENDATIONS Use unleaded gasoline witha pump octane rating of86 or higher. This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine andspark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oiI/gasoline mixture. Avoid getting dirt or water in the fuel tank. Occasionallyyoumahear a light"sparkknock"or"ping-ing" (metallic rapping noisewhile operating under heavy loads. This IS no cause for concern.
Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ethercompound. Thesegasolines are collectivelyreferredto as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada useoxygenatedfuels tohelp reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel's contents.
STARTING THE ENGINE STARTING THE ENGINE 1. Makesurethatallappliances receptacles. are disconnected fromthe AC 2. Turn the fuel valve lever to ON theposition. 3. Turn the choke lever to the CLOSED position. 4. Turn the engine switch to ON the position. 5. Pull the starter grip lightly until resistance is felt, then pull briskly. Do not allow thestarter grip to snap back against the engine. Return it gently to prevent damageto the starter or housing. 6.
STOPPING THE ENGINE STOPPING THE ENGINE To stop the enginein an emergency, simply turn the ignition switch to the OFF position. Under normal conditions, use the following procedure. 1. Unplug appliances from thegenerator receptacles. 2. Turn the ignition switch to OFF the position. 3. Move the fuel valve lever to OFF the position.
MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is 'essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. I Improper maintenance, or failure t o correctaproblembefore hurt operation, can cause a malfunction in which you can be seriously or killed. Always follow the inspection and maintenance recommendations and schedules in this owner's manual.
MAINTENANCE SAFETY Some of the most important safety precautions follow. However, w e cannotwarnyouofeveryconceivable hazard that canarise in performing maintenance. Only you can decide whether or not you should performa giventask. Failure to properly follow maintenance instructions and precautions can cause you to beseriously hurt or killed. Always followthe procedures and precauuions in theowner's manual. Safety Precautions Make sure the engine is off before you begin any maintenance repairs.
EMISSION CONTROL SYSTEM INFORMATION Source of Emissions ~ The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogenisveryimportant because, undercertainconditions,they react to form photochemical smog when subjected to sunlight. Carbon monoxide does notreact in thesame way, but it is toxic. I Honda utilizes lean carburetor settings and other systems the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
, Replacement Parts The emission control systems on your Honda engine were designed, built,andcertified toconformwith EPA andCaliforniaemission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacementparts are manufactured to the samestandards as the original parts, so you can be confident of their performance.
AIR INDEX An Air Index Information hang tag/label was applied to this engine in accordance withtherequirementsoftheCaliforniaAir 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 AirIndex, the less pollution. The durability description is intended to provide youwith information relating to the engine's emission durability period.
MAINTENANCE SCHEDULE Emission related items. (1)Service more frequently when used in dusty areas. (2)These items should be serviced by an authorized Honda generatordealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop Manual. (3)For commercialuse, log hours of operation to determine proper maintenance intervals.
ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the drain plug and sealing washer, remove the oil cap/ filler dipstick, and drain the oil. 2. Reinstallthedrainplugandsealingwasher.Tightentheplug securely. 3. Refill with the recommended oil level. (see page 19 ) and check the oil Oil capacity: 1.2 US qt (1.1 0 , 1.0 Imp qt) , OIL DRAIN PLUG Wash your hands with soap and water after handling used oil.
~ AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, servicethe air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. m Never run the generator without the air filter. Rapid engine wear will result. 1. Removethewingnutand the aircleanercover.Remove the elements and separate them.Carefully check bothelementsfor holes or tears and replace if damaged. 2.
FUEL SEDIMENT CUPCLEANING The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. Ifthe engine has not been run fora long time, the sediment cup should be cleaned. 1. Turn the fuel valve lever to the OFF position. Remove the sediment cup and O-ring. 2.Clean the sediment cup and O-ring in nonflammable or high flash point solvent. 3. Reinstall the O-ring and sediment cup. 4. Turn the fuel valve lever ON and check for leaks.
SPARK PLUG SERVICE In order to service the spark plug, youwill need a spark plug wrench (commercially available). Recommended spark plugs: BPR5ES (NGK) WIGEPR-U (DENSO) , To ensure proper engine operation, the gappedandfreeofdeposits. spark plug must be properly If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler. 1. Remove thespark plug cap. 2. Clean any dirt from around the spark plug base. spark plug. 3. Use a spark plug wrench to remove the 4.
6. Check that the spark plug washer is in good condition, and thread the spark plugin by hand to prevent cross-threading. 7.After the spark plug is seated, tighten with a spark plug wrench to compress the washer. -If installing a new spark plug, tighten1/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten 1/8-1/4 turn after the spark plug seats to compress the washer. lX5iZ-l The spark plug must be securely tightened.
SPARK ARRESTERMAINTENANCE If the generator has been running, the muffler will be very hot. Allowit to cool before proceeding. The spark arrester must be serviced every 100 hours to maintain its efficiency. 1. Remove the two 8 m m nuts 0 , and remove the muffler@ from the cylinder. 2. Remove the six 5 mm screws @ from the muffler protector@ , and remove the muffler protector. 3. Remove the 4 m m screw @ from thespark arrester 0, and remove the spark arrester from the muffler. 4.
TRANSPORTING/STORAGE TRANSPORTING If the generator has been used, allow it cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust systemcan burn youand can ignite some material. When transporting the generator, turn the ignition switch and the fuel valve OFF, and keep the generator level to reduce the possibility of fuel leakage. Take care not to drop strike or the generator when transporting. Do not place heavy objects on thegenerator.
Storage Procedure 1.Drain thecarburetorbylooseningthedrainscrew.Drainthe gasoline intoa suitable container. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe upspills immediately. 2.Change the engine oil (page 32 1. 3.Remove the sparkplug, andpourabout a tablespoonof clean engine oil into the cylinder.
TROUBLESHOOTING When the enginewill not start: Is there fuel in the tank? NO Is there enough oil in the engine? NO - Refill the fuel tank. I ~~ I A d dt h er e c o m mended oil. I YES Is there spark a f r o mt h es p a r k plug? NO - Still NO spark Replace the spark plug. - Take the generator t o an authorized Honda generator dealer. To check: 1)Removethespark plug cap and clean . Be sure there is no any dirt from around spilled fuel around the the spark plug. spark plug.
. Appliance does not operate: Is the AC circuit protector ON. NO ~ Press the AC circuit protector button to the ON position. I YES I NO DEFECTS -t I I Check the electrical appliance or equipment for any defects. DEFECTS Take thegeneratorto authorizedHondagenerator dealer. an Replace the electrical appliance or equipment. Taketheelectricalappliance or equipment to an electrical shop for repair.
!- ! I I I I I I I I i AC RECEPTACLE ! I i ! I i IAlN /INDING MAIN WINDING EXCITER WINDING FIELD WINDING I ! I GENERATOR BLOCK SPARK PLUG IGNITION COIL ENGINE SWITCH OIL LEVEL SWITCH . i1 I I I I I I 1 I I I I BI Black W I White i - ..-.. -..-. .-. -..-..-..-. .-..-. .-..-..-. .-..-.. -..-..-.
SPECIFICATIONS Dimensions EN5000 Model Power product description code EZGC 26.6 in (675 m m ) Length 20.1 in (510 m m ) Width 22.0 in (560 mm) Height 134.5 Ibs (61.0 kg) Dry weight Engine GX340K1 4-stroke, overhead valve, single cylinder 20.6 cu-in (337 cm3) [3.2 X 2.5 in (82 X 64 m m ) ] 8.0 : 1 3,600 rpm Forced air Transistorized magneto 1.2 US qt (1.IJ! , 1.O Imp qt) 1.85 US gal (7.0 0, 1.
WARRANTY SERVICE INFORMATION Servicingdealershippersonnel are trainedprofessionals.They shouldbeabletoansweranyquestionyoumay have.If you encounter a problemthatyour dealerdoes notsolvetoyour satisfaction,pleasediscuss it with the dealership'smanagement. TheServiceManager or General Managercanhelp.Almost all problems are solved in this way. If you are dissatisfied with thedecisionmadebythedealership's management, contact the Honda Power Equipment Customer Relations Office.
INDEX COMPONENT IDENTIFICATION ............................................................... CONTROLS ............................................................................................... AC Circuit Protector ........................................................................... Choke Lever ........................................................................................ Engine Switch .....................................................................................
PRE-OPERATION CHECK ........................................................................ 19 Engine Oil ........................................................................................... 19 Fuel Recommendation ...................................................................... 21 22 Oxygenated Fuels .............................................................................. Refueling ............................................................................................. 20 SAFETY ...
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