EM3800SX•EM5000SX•EM6500SX K2:EM5000SX 31Z21604 00X31-Z21-6040 See page 60 for instructions on assembling your generator.
09/02/10 12:43:38 31Z21600_001 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death. Never run the generator in a closed, or even partly closed area where people may be present. The generator is a potential source of electrical shock if misused.
09/02/10 12:43:44 31Z21600_002 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 the information on how to do that; please read it carefully. As you read this manual, you will find information preceded by a symbol.
09/02/10 12:43:57 31Z21600_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.
09/02/10 12:44:02 31Z21600_004 CONTENTS GENERATOR SAFETY ............................................................................... 5 Safety Label Locations ........................................................................ 5 Important Safety Information ............................................................. 6 COMPONENT IDENTIFICATION ............................................................... 8 CONTROLS .................................................................................
09/02/10 12:44:05 31Z21600_005 MAINTENANCE ....................................................................................... 35 The Importance of Maintenance ....................................................... 35 Maintenance Safety ........................................................................... 36 Maintenance Schedule ...................................................................... 37 Engine Oil Change .............................................................................
09/02/25 16:50:48 31Z21600_006 GENERATOR SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda generator dealer for a replacement.
09/02/10 12:44:32 31Z21600_007 IMPORTANT SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls and by observing safe operating procedures. Operator Responsibility Know how to stop the generator quickly in case of emergency.
09/02/10 12:44:42 31Z21600_008 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. If the generator is stored outdoors, unprotected from the weather, check all of the electrical components on the control panel before each use.
09/02/25 16:50:54 31Z21600_009 COMPONENT IDENTIFICATION ENGINE SWITCH CONTROL PANEL CHOKE ROD AIR CLEANER FUEL VALVE LEVER STARTER GRIP OIL FILLER CAP/DIPSTICK ENGINE SERIAL NUMBER FUSE OIL DRAIN PLUG CONTROL PANEL 1:Except EM3800SX 120 ONLY 120/240 VOLTAGE SELECTOR SWITCH AC CIRCUIT PROTECTORS AC CIRCUIT BREAKER 120/240V AC RECEPTACLE DC CIRCUIT PROTECTOR 1 DC OUTPUT TERMINAL AUTO THROTTLE SWITCH 8 120V AC RECEPTACLES GROUND TERMINAL
09/02/25 16:51:00 31Z21600_010 TRANSPORT HANDLE FUEL TANK CAP FUEL GAUGE SPARK PLUG CAP FRAME SERIAL NUMBER STAND WHEEL MUFFLER *Record the engine and frame serial numbers and date of purchase for your future reference. Refer to these serial numbers when ordering parts and when making technical or warranty inquiries (see page 72 ).
09/02/10 12:45:08 31Z21600_011 CONTROLS Engine Switch To start and stop the engine. Key position: OFF: To stop the engine. Key can be removed/inserted. ON: To run the engine after starting. START: To start the engine by operating the starter motor. OFF ON START ENGINE SWITCH Starter Grip To start the engine, pull the starter grip lightly until resistance is felt, and then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
09/02/10 12:45:14 31Z21600_012 Fuel Valve Lever The fuel valve is located between the fuel tank and carburetor. When the valve lever is 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. FUEL VALVE LEVER OFF ON Choke Rod The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually.
09/02/10 12:45:24 31Z21600_013 Voltage Selector Switch (Dual Voltage System) The voltage selector switch switches the main power carrying windings of the generator 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 a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position.
09/02/10 12:45:31 31Z21600_014 DC Terminals The DC terminals may ONLY be used for charging 12-volt automotive type batteries. The terminals are colored red to identify the positive ( ) terminal and black to identify the negative ( ) terminal. The battery must be connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal).
09/02/10 12:45:40 31Z21600_015 Oil Alert System The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position). The Oil Alert system should not take the place of checking the oil level before each use.
09/02/10 12:45:45 31Z21600_016 AC Circuit Breaker The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle. If the AC circuit breaker is switched OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before switching the AC circuit breaker ON again. The AC circuit breaker may be used to switch the generator power ON or OFF.
09/02/10 12:45:50 31Z21600_017 AC Circuit Protector The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at the 20A 120V, 30A 120V locking plug, or 120/240V locking plug receptacle. If an AC circuit protector switches OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before resetting the AC circuit protector ON.
09/02/10 12:45:58 31Z21600_018 GENERATOR USE Connections to a Building’s Electrical System Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers.
09/02/10 12:46:09 31Z21600_019 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 the rated load capacity of the generator has been exceeded.
09/02/10 12:46:20 31Z21600_020 AC Operation 1. Start the engine (see page 33 ). 2. Turn the voltage selector switch to either position. With the voltage selector switch in the ‘‘120/240V’’ position, you can use the 120V and 120/240V receptacles simultaneously. If you are NOT using the 120/240V receptacle, then select the ‘‘120V ONLY’’ position. 3. Switch the AC circuit breaker ON. 4. Plug in the appliance. Be sure that all appliances are in good working order before connecting them to the generator.
09/02/10 12:46:29 31Z21600_021 AC Receptacle Selection The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EM3800SX: 4B 4A 120V 30A 120V 20A (in total) 120V 20A (in total) 4A & 4B 120/240V 20A Power Producing Circuits This generator is equipped with two power generating circuits.
09/02/10 12:46:36 31Z21600_022 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 1 27.5A at 120V 2 20A at 120V 3 20A at 120V 4A 20A at 120V 4B None 1 13.8A at 120V 2 13.8A at 120V 3 13.8A at 120V 4A-4B 13.8A at 240V 120V ONLY 120V/240V 120V ONLY Position When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles.
09/02/10 12:46:45 31Z21600_023 The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EM5000SX: 4B 4A 120V 30A 120V 20A (in total) 120V 20A (in total) 4A & 4B 120/240V 30A Power Producing Circuits This generator is equipped with two power generating circuits.
09/02/10 12:46:52 31Z21600_024 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 1 30A at 120V 2 20A at 120V 3 20A at 120V 4A 30A at 120V 4B None 1 18.8A at 120V 2 18.8A at 120V 3 18.8A at 120V 4A-4B 18.8A at 240V 120V ONLY 120V/240V 120V ONLY Position When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles.
09/02/10 12:46:59 31Z21600_025 The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EM6500SX: 4B 4A 120V 30A 120V 20A (in total) 120V 20A (in total) 4A & 4B 120/240V 30A Power Producing Circuits This generator is equipped with two power generating circuits.
09/02/10 12:47:07 31Z21600_026 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 1 30A at 120V 2 20A at 120V 3 20A at 120V 4A 30A at 120V 4B None 1 22.9A at 120V 2 20A at 120V 3 20A at 120V 4A-4B 22.9A at 240V 120V ONLY 120V/240V 120V ONLY Position When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles.
09/02/10 12:47:17 31Z21600_027 DC Operation The DC terminals may ONLY be used for charging 12-volt automotive type batteries. Connecting the battery charging cables: 1. Before connecting the battery charging cables to a battery that is installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( ) terminal. The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or using batteries.
09/02/10 12:47:24 31Z21600_028 An overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit protector (PUSH button extends out). If this happens, wait a few minutes before pushing in the circuit protector to resume operation. If the DC circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer. Disconnecting the battery cables: 1. Stop the engine. 2.
09/02/10 12:47:32 31Z21600_029 Auto Throttle System With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the Auto Throttle system does not operate. The Auto Throttle system will not respond to electrical loads of less than 1 ampere or intermittent loads such as a staple gun.
09/02/10 12:47:38 31Z21600_030 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. High altitude performance can be improved by specific modifications to the carburetor.
09/02/10 12:47:48 31Z21600_031 PRE-OPERATION CHECK Engine Oil Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped. Use 4-stroke motor oil that meets or exceeds the requirements for API service category SJ or later (or equivalent). Always check the API SERVICE label on the oil container to be sure it includes the letters SJ or later (or equivalent). AMBIENT TEMPERATURE SAE 10W-30 is recommended for general, all-temperature use.
09/02/10 12:47:59 31Z21600_032 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 engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately. Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Refuel carefully to avoid spilling fuel.
09/02/10 12:48:07 31Z21600_033 Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty. After refueling, reinstall the fuel tank cap securely. Fuel Recommendations This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
09/02/10 12:48:20 31Z21600_034 STARTING THE ENGINE/STOPPING THE ENGINE Starting the Engine For your safety, do not operate 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. Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death.
09/02/10 12:48:34 31Z21600_035 With electric starter: 1. Connect the battery cables to the generator. (page 68 ) 2. Turn the engine switch to the START position and hold it there for 5 seconds or until the engine starts. Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.
09/02/10 12:48:40 31Z21600_036 MAINTENANCE The Importance of Maintenance Good maintenance is essential for safe, economical, and trouble free operation. It will also help reduce air pollution. Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
09/02/10 12:48:52 31Z21600_037 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.
09/02/10 12:49:06 31Z21600_038 Maintenance Schedule REGULAR SERVICE PERIOD (3) ITEM Performed at every indicated month or operating hour interval, whichever comes first. Engine oil Air cleaner Canister (California type) Purge tube (California type) Charge tube (California type) Sediment cup Spark plug Spark arrester Idle speed Valve clearance Combustion chamber Fuel tank and filter Fuel tube Each use First month or 20 Hrs. Every Every Every year 3 months 6 months or or or 50 Hrs. 100 Hrs. 300 Hrs.
09/02/10 12:49:15 31Z21600_039 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 oil, then remove the oil drain plug and sealing washer, remove the oil filler cap/dipstick, and drain the oil. 2. Reinstall the oil drain plug and a new sealing washer. Tighten the plug securely. 3. Refill with the recommended oil (see page 30 ) and check the oil level.
09/02/10 12:49:28 31Z21600_040 Air Cleaner Service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty. 1.
09/02/10 12:49:36 31Z21600_041 Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water that may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1. Turn the fuel valve lever to the OFF position. Remove the sediment cup, O-ring, and filter. 2. Clean the sediment cup and filter in nonflammable or high flash point solvent. 3. Reinstall the filter, new O-ring, and sediment cup. 4.
09/02/10 12:49:49 31Z21600_042 Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: BPR5ES (NGK) , W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. An incorrect spark plug can cause engine damage. If the engine has been running, let it to cool before servicing the spark plug. 1. Remove the spark plug cap. 2. Clean any dirt from around the spark plug base.
09/02/10 12:50:02 31Z21600_043 6. Check that the spark plug sealing washer is in good condition, and thread the spark plug in by hand to prevent cross-threading. 7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. If installing a new spark plug, tighten 1/2 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.
09/02/10 12:50:11 31Z21600_044 Fuse Replacement If the fuse is blown, the starter motor won’t operate. 1. Turn the engine switch to the OFF position. 2. Remove the fuse holder cover and replace the fuse. The specified fuse is 10A. FUSE HOLDER If frequent fuse failure occurs, determine the cause and correct the problem before attempting to operate the generator further. Never use a fuse with a different rating from that specified. Serious damage to the electrical system or fire may result.
09/02/10 12:50:21 31Z21600_045 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.
09/02/10 12:50:26 31Z21600_046 Service according to the table below: STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasoline stabilizer *. Fill with fresh gasoline and add gasoline 2 months to 1 year stabilizer *. Drain the carburetor float bowl (page 46 ). Drain the fuel sediment cup (page 40 ). Fill with fresh gasoline and add gasoline stabilizer *. Drain the carburetor float bowl (page 46 ).
09/02/10 12:50:34 31Z21600_047 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. 1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. DRAIN SCREW 2. Place a suitable gasoline container below the sediment cup, and use a funnel to avoid spilling gasoline. 3.
09/02/10 12:50:42 31Z21600_048 Engine Oil 1. Change the engine oil (see page 38 ). 2. Remove the spark plug (see page 41 ). 3. Pour a teaspoon (5 10 cc) of clean engine oil into the cylinder. 4. Pull the starter grip 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.
09/02/10 12:50:54 31Z21600_049 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.
09/02/25 16:51:05 31Z21600_050 TRANSPORTING When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator. Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.
09/02/10 12:51:08 31Z21600_051 TROUBLESHOOTING When the engine will not start: Is there fuel in the tank? NO Refill the fuel tank (page 31). YES Is there enough oil NO in the engine? Add the recommended oil (page 30). YES Is the spark plug in NO good condition? YES Is the fuel reaching NO the carburetor? YES If the engine still does not start, take the generator to an authorized Honda generator dealer. 50 Readjust gap and dry the spark plug. Replace it if nec es s a ry (p age 41).
09/02/10 12:51:13 31Z21600_052 No electricity at the AC receptacles: Is the AC circuit breaker ON. YES NO Turn the AC circuit breaker ON (page 15). NO DEFECTS Check the electrical appliance or equipment for any defects. DEFECTS Take the generator to an authorized Honda generator dealer. Replace the electrical appliance or equipment. Take the electrical appliance or equipment to an electrical shop for repair.
09/02/10 12:51:23 31Z21600_053 TECHNICAL 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 are 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.
09/02/10 12:51:30 31Z21600_054 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, and certified to conform with applicable emission regulations.
09/02/10 12:51:42 31Z21600_055 Air Index (Models certified for sale in California) An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.
09/02/10 12:52:05 31Z21600_056 WIRING DIAGRAM EM3800SX 55
09/02/10 12:52:28 31Z21600_057 EM5000SX, EM6500SX 56
09/02/10 12:52:44 31Z21600_058 SPECIFICATIONS Dimensions Model EM3800SX California type Non-California type (AC type) (AN type) EAMC 40.9 in (1,040 mm) 27.2 in (691 mm) 28.4 in (721 mm) 193.1 lbs (87.6 kg) 192.0 lbs (87.
09/02/10 12:53:01 31Z21600_059 Dimensions Model EM5000SX California type Non-California type (AC, ACH type) (AN, ANH type) EANC 41.3 in (1,049 mm) 27.2 in (691 mm) 28.4 in (721 mm) 222.9 lbs (101.1 kg) 221.8 lbs (100.
09/02/10 12:53:19 31Z21600_060 Dimensions Model EM6500SX California type Non-California type (AC, ACH type) (AN, ANH type) EAPC 41.9 in (1,064 mm) 27.2 in (691 mm) 28.4 in (721 mm) 228.4 lbs (103.6 kg) 227.3 lbs (103.
09/02/10 12:53:25 31Z21600_061 ASSEMBLY 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.
09/02/10 12:53:33 31Z21600_062 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.
09/02/25 16:51:14 31Z21600_063 Unpacking 1. Remove the generator and loose parts box from the carton. 2. Compare the loose parts with the inventory list below. Tools Required: 12 mm wrench (2), pliers Loose Parts (Wheel kit and handle) 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.
09/02/10 12:53:50 31Z21600_064 Handle Installation Install the right and left handles on the generator upper frame using the handle brackets and four flange bolts. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.
09/02/25 16:51:21 31Z21600_065 Wheel Kit Installation 1. Apply grease to the axle shaft as shown below, and install the two wheels on the axle shaft using the washers and split pins. 2. Install the axle assembly on the generator using four 8 flange bolts and 8 mm flange nuts. 16 mm 3. Install the two stands on the under frame using four 8 flange bolts. 16 mm TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.
09/02/10 12:54:04 31Z21600_066 Hanger Kit Installation (optional) 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.
09/02/25 16:51:26 31Z21600_067 Remote Control Kit (optional) 1. Remove the blind 6-P connector from the back of the control panel. 2. Connect the remote control cable to the back of the control panel and remote control box. 3. Install the two cable ties as shown. REMOTE CONTROL CABLE CABLE TIES REMOTE CONTROL CABLE REMOTE CONTROL BOX Connect the blind connector when not using the remote control. Engine will not start unless the blind connector is connected.
09/02/10 12:54:21 31Z21600_068 Remote Control Box PILOT LAMP START BUTTON STOP BUTTON Starting the engine with remote control 1. Turn the fuel valve on the generator to the ON position. 2. Turn the Auto Throttle switch on the generator to the OFF position. 3. Turn the engine switch on the generator to the ON position. 4. Press the start button until engine starts and the pilot lamp comes on. Stopping the engine with remote control 1. Press the stop button. 2.
09/02/10 12:54:29 31Z21600_069 Battery Tray Kit (optional) 1. Follow the instructions that come with the battery tray kit and install the kit on the generator frame. 2. Route the starter cable under the tank and connect it to the starter solenoid. 3. Connect the ground cable to the generator rear housing. 4. Set the battery on the battery tray and secure with the battery bracket. Connect the starter cable to the battery positive ( ) terminal first, then to the negative ( ) terminal.
09/02/25 16:51:45 31Z21600_070 CABLE TIE STARTER SOLENOID STARTER CABLE (positive) GROUND CABLE BATTERY BRACKET STARTER CABLE CABLE TIE GROUND CABLE BATTERY Use a battery rated at 51R BATTERY GUARD BATTERY GUARD BATTERY TRAY BATTERY GUARD PLATE 69
09/02/10 12:54:51 31Z21600_071 Engine Oil The generator is shipped WITHOUT OIL in the engine. 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 category SJ or later (or equivalent). AMBIENT TEMPERATURE OIL FILLER HOLE SAE 10W-30 is recommended for general, all-temperature use.
09/02/10 12:54:58 31Z21600_072 BEFORE OPERATION Before using your generator, you should become familiar with information contained in the following chapters and sections: GENERATOR SAFETY (page 5 ) CONTROLS (page 10 ) GENERATOR USE (page 17 ) STARTING THE ENGINE (page 33 ) STOPPING THE ENGINE (page 33 ) 71
09/02/10 12:55:08 31Z21600_073 WARRANTY SERVICE INFORMATION DEALER LOCATOR INFORMATION To find an authorized Honda Servicing Dealer anywhere in the United States: visit our web site: www.hondapowerequipment.com CUSTOMER SERVICE INFORMATION Servicing dealership personnel are trained professionals. They should be able to answer most questions 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.
09/02/10 12:55:15 31Z21600_074 Honda PUBLICATIONS 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 888292-5395 or visit www.hondapowerequipment.com Parts Catalog This manual provides complete, illustrated parts lists. Available through your Honda dealer.
09/02/10 12:55:20 31Z21600_075 INDEX ASSEMBLY ............................................................................................... 60 COMPONENT IDENTIFICATION ............................................................... 8 CONTENTS ................................................................................................. 3 CONTROLS ............................................................................................... 10 AC Circuit Breaker .......................................
09/02/10 12:55:24 31Z21600_076 PRE-OPERATION CHECK ........................................................................ 30 Engine Oil ........................................................................................... 30 Fuel Recommendations ..................................................................... 32 Refueling ............................................................................................. 31 SPECIFICATIONS ..............................................................
09/02/10 12:55:26 31Z21600_077 MEMO 76
EM3800SX•EM5000SX•EM6500SX K2:EM5000SX 00X31-Z21-6050 See page 57 for instructions on assembling your generator.
