Thank you for purchasing a Honda generator. 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. This owner’s manual describes the operation and maintenance of the EX1000 EX650 Honda Generator. All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd.
CONTENTS .4 SAFETY ..................................................................................................... Safety Label Locations .......................................................................... .4 Safety Information .................................................................................. 6 COMPONENT IDENTIFICATION ............................................................... 8 CONTROLS ......................................................................................
MAINTENANCE ....................................................................................... Maintenance Schedule ......................................................................... Tool Kit ................................................................................................ Engine Oil Change .............................................................................. Air Cleaner Service .............................................................................
SAFETY SAFETY LABEL LOCATION 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. E BEFORE FllllNC FUEL TANK. W NOT FILL OVER ICONTR~LER QU’IL N’Y ANI FIJITE NESSENCE REPANDUE SUR L’APPAREIL AVANT DE REFAIRE LE PLEIN: ARRiTER LE MOTEUR NE PAS FAIRE LE PLEIN AU DESSUS DU REPERE DE NlVF.AU MAXIMUM.
HONDA EXIOOO HONDA MOTOR CO., LTD. CONTAINS lLUBRlCANT : 0.431 POISONOUS MADEINJAPAN&I CAREON MONOXIDE. HOUSE WIRING. THIS CAN DAMAGE THE GENERATOR OR ELECTORICAL APPLIANCES.
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 0 Know how to stop the generator quickly in case of emergency. Understand the use of all generator controls, output receptacles, and connections.
Fire and Burn Hazards l l l l The exhaust system gets hot enough to ignite some materials. - Keep the generator at least 1 meter (3 feet) away from buildings and other equipment during operation. - Do not enclose the generator in any structure. - Keep flammable materials away from the generator. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors.
COMPONENT ODENTUFICATION FRAME SERIAL NUMBER I J/ I TOP COVER TOOL KIT I SPARK PLUG CAP ENGINE SWITCH I CIRCUITBREAKERS w PILOT LAMP FREQUENCY METER LEFT SIDE COVER AC RECEPTACLES GROUND TERMINAL I RECOIL STARTER l 8 ENGINE SERIAL NUMBER GRIP I OIL FILLER CAP Record the engine and frame serial numbers for your future reference.
CARRYING HANDLE FUEL GAUGE \ I FUEL TANK CAP RIGHT SIDE, COVER CHOKE LEVER AIR CLEANER CASE EXHdUST OUTLET MUFFLER COVER 9
CONTROLS Engine Switch To start and stop the engine. Switch position: OFF: To stop the engine. ON: To run the engine. 0 -3 ENGINE SWITCH Recoil Starter To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly. (1 Do not allow the starter to snap back against the engine. Return it gently to prevent damage to the starter.
Choke Lever 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 lever manually. Move the lever to the CLOSED position to enrich the mixture. ‘CLOSED Pilot Lamp The pilot lamp is illuminated when the generator is operating normally. It indicateds that the generator is producing electrical power. If the pilot light is illuminated, the frequency meter should be displaying 60Hz.
Ground Terminal The gernerator ground terminal is connected to the frame of the generater, the metal non-current carrying parts of the generator, and the ground terminals of each receptacle.
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 the ON position). If the engine stops and will not restart, check the engine oil level (p.20) before trouble shooting in other areas.
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.
GENERATOR Connections to a Building’s USE 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. m Improper connections to a building’s electrical system can allow electrical current from the generator to backfeed into the utility lines.
AC Operation 1. Start the engine (refer to page 24) and make sure the pilot lamp comes on. If not, the filament may be burnt out. 2. Plug in the appliance. CAUTION: Substantial overloading will switch off the circuit breaker. Marginal overloading may not switch off the circuit breaker, but it will shorten the service life off the generator. Be sure that all appliances are in good working order before connecting them to the generator.
DC Operation The DC terminals may ONLY be used for charging 12 volt automotive-type batteries. Connecting the battery cables: 1. Before connecting charging cables to a battery that is installed in a vehicle, disconnect the vehicle’s ground cable from the battery. m The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using batteries. 2. Connect the positive (+) battery cable to the battery positive (+) terminal. 3.
Disconnecting the battery cables: 1. Stop the engine, 2. Disconnect the negative (-) battery cable from the generator negative (-) terminal. 3. Disconnect the other end of the negative (-) battery cable from the battery negative (-) terminal. 4. Disconnect the positive (+) battery cable from the generator positive (+) terminal. 5. Disconnect the other end of the positive (+) battery cable to the battery positive(+) terminal. 6. Connect the vehicle ground cable to the battery negative (-) terminal.
High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw. If you always operate the engine at altitudes higher than 6,000 feet above sea level, have an authorized Honda generator dealer perform this carburetor modification.
PRE-OPERAT0ON CHIECK Engine Oil 1 NOTICE 1 Engine oil is a major factor affecting engine performance and service life. Non-detergent and P-stroke engine oils will damage the engine and are not recommended. Check the oil level BEFORE EACH USE with the generator on a level surface with the engine stopped. Use Honda4-stroke oil, oran equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for Service Classification SG, SF/CC CD.
Fuel Recommendation 1. Check the fuel level gauge. 2. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer. Gasoline is extremely flammable and is explosive under certain conditions. l Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored. l Do not overfill the fuel tank (there should be no fuel in the filler neck).
Occasionally you may hear light “spark knock” or “pinging” (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda generator dealer. (1 Running theenginewith can cause engine damage.
STARTING/STOPPING THE ENGINE Starting the engine 1. 2. 3. 4. The generator may be hard to start if a load is connected. Turn the choke lever to the CLOSE position. Turn the engine switch to the ON position. Pull the starter grip until compression is felt, then pull briskly. -1 by hand. Do not allow the starter grip to snap back. Return it slotily 5. Turn the choke lever to the OPEN position as the engine warms up.
Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. Perform the service and inspection at the intervals shown in the Maintenance schedule below. Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. [SI Use only genuine HONDA parts or their equivalent for maintenance or repair.
Tool Kit The tools supplied with the generator will help you to perform the owner maintenance procedures listed on the following pages. Always keep this tool kit with the generator.
Engine Oit Change Drain the oil while the engine is warm to assure complete and rapid draining. 1. Remove the oil filler cap. 2. Turn the engine switch OFF and tilt the generator to drain the oil. 3. Refill with the recommended oil (see page 18 and check the oil level. Oil capacity: 0.43 Q (0.46 US qt, 0.38 imp qt) OIL FILLER HOLE Oli FILLER CAP m Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
Air Cleaner Service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly (page 25). Service more frequently when operating the generator in extremely dusty areas. m Usinggasolineorflammablesolventtocleanthefilterelement can cause a fire or explosion. Use only soapy water or nonflammable solvent. pzmq Never run the generator engine wear will result. without the air cleaner. Rapid 1.
Spark Plug Service Recommended spark plugs: BW4HS (NGK) or Wi$FR-U (NIPPON DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler. 1. Remove the spark plug cap. 2. Clean any dirt from around the spark plug base. 3. Use the wrench supplied in the tool kit to remove the spark plug. 4. Visually inspect the spark plug.
6. Check that the spark plug 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 plus, tighten l/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten l/8 - l/4 turn after the spark plug seats to compress the washer. -1 The spark plug must be securely tightened.
Spark Arrester Maintenance If the generator has been running, the muffler will be very hot. Allow to cool before proceeding. ps7EE-j The spark arrester must be serviced every 100 hours to maintain its efficiency. 1. Remove the two 6 mm bolts and the two 6 mm cap nuts. Remove the cover. 6 mm BOLTS 6 mm CAP NUTS 2. Remove the two 6 mm nuts and the 6 mm bolts. Remove the muffler from the exhaust pipe carefully to avoid damaging the spark arrester screen.
3. Use a brush to remove carbon deposits from the spark arrester screen. Inspect the screen for holes, and replace it if necessary. NOTE: Take care not to damage the wire mesh. 4. Check the exhaust pipe gaskets; replace if damaged. Reinstall the muffler and the cover.
TRANSPORTBNG/STORAGE 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. m 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. Before storing the unit for an extended period: 1.
1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. m Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure. 2. Drain the fuela. With the engine switch ON, remove the fuel filler cap. b. Loosen the drain screw and drain the fuel into a suitable container. Retighten the screw. c.
TROUBLESHOOTW+ilG When the engine will not start: Is there fuel in the tank? NO Refill the fuel tank. NO Turn the engine switch on. NO Add the recommended the engine? oil. I ze the Replace spark plug mlml Be sure there the- is no spiller’ spilled fuel ’ ’ around the spark plug. sf Spilled fuel may Spille !--!.ignite. YES Still No spark To check: 1) Remove the rear cover and spark plug cap, and clean any dirt from around the spark plug.
No electricity at the AC receptacles: NO Check the electrical appliance or equipment for any defects NO DEFECTS Push the AC circuit breaker button in. b Take the generator to an authorized HONDA dealer. Replace the electrical appliance or equipment. l Take the electrical appliance or equipment to an electrical shop for repair. l DEFECTS No electricity at the DC terminals Is the DC circuit breaker on? NO YES Push the DC circuit breaker button in.
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SPECIFICATIONS Dimensions Length x Width x Height 430 x 285 x 390 mm (16.9x11.2~15.4in) Dry Weight 26 kg (57.3 lb) Engine Engine Type 4-stroke, side valve, 1 cylinder Displacement [Bore x Stroke] 97 cc (5.93 cu in) [52 x 46 mm (2.05 x 1.81 in)] Compression 6.5 : 1 Ratio Engine Speed 3.600 r.p.m Cooling System Forced air cooling Ignition System Transistorized magneto Oil Capacity 1 0.43 1 (0.46 US qt) Fuel Tank Capacity 1 3.1 1 (0.
CUSTOMER SERVBCE DNFORMATOON 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.
Current customer service contact information: United States, Puerto Rico, and U.S. Virgin Islands: 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.
INDEX COMPONENT IDENTIFICATION ............................................................... 8 10 CONTROLS .............................................................................................. AC Circuit Breaker.. ............................................................................. .13 Choke Lever ......................................................................................... 11 DC Circuit Breaker ...............................................................................
INQEX PRE-OPERATION CHECK ...................................................................... Engine Oil ............................................................................................ Fuel Recommendation ........................................................................ SAFETY ..................................................................................................... Safety Information .................................................................................
