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54

SERVICING YOUR GENERATOR

SPARK PLUG SERVICE

In order to service the spark plug, you will need a spark plug wrench 
(commercially available).

Recommended spark plug:

 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 is hot, allow it to cool before servicing the spark plug.

1. Disconnect the spark plug cap, and remove any dirt from around the 

spark plug area.

2. Remove the spark plug with a spark plug wrench.

SPARK PLUG WRENCH

SPARK PLUG CAP

31Z236120.book  54 ページ  ２０１５年１２月１０日　木曜日　午前１１時４３分

Summary of Contents for EM4000SX

Page 1: ...in China 2015 Honda Motor Co Ltd All Rights Reserved GENERATOR EM4000SX EM5000SX EM6500SX Owner s Manual EM4000SX 6500SX_OM _31Z23610_F AH N FM Hi C BK DIC F101 EM4 3mm Click to Save As 2016 Honda Mo...

Page 2: ...ain 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 reserves the right however to di...

Page 3: ...ormation is intended to help you avoid damage to your generator other property or the environment We suggest you read the Distributor s Limited Warranty see page 82 to fully understand its coverage an...

Page 4: ...your own good judgment You will find important safety information in a variety of forms including Safety Labels on the generator Safety Messages preceded by a safety alert symbol and one of three sig...

Page 5: ...cuit Breaker 14 AC Circuit Protectors 15 Ground Fault Circuit Interrupter GFCI Receptacle 16 DC Terminals 17 DC Circuit Protector 17 Folding Handle 18 FEATURES 19 Oil Alert System 19 Automatic Engine...

Page 6: ...ial Requirements 42 SERVICING YOUR GENERATOR 43 THE IMPORTANCE OF MAINTENANCE 43 MAINTENANCE SAFETY 44 Safety Precautions 44 MAINTENANCE SCHEDULE 45 REFUELING 46 FUEL RECOMMENDATIONS 47 ENGINE OIL LEV...

Page 7: ...N 80 Dealer Locator Information 80 Honda Publications 80 Customer Service Information 81 Distributor s Limited Warranty 82 Emission Control System Warranty 87 ASSEMBLY 92 SAFETY 92 The Importance of P...

Page 8: ...not see or smell Breathing carbon monoxide can KILL YOU IN MINUTES To avoid carbon monoxide poisoning follow these instructions when operating a generator Only run a generator OUTSIDE far away from wi...

Page 9: ...ture or ice can cause a malfunction or short circuit in electrical components that could result in electrocution Do not connect to a building s electrical system unless an isolation switch has been in...

Page 10: ...cool if it has been in operation Refuel only outdoors in a well ventilated area and on a level surface Never smoke near gasoline and keep other flames and sparks away Do not overfill the fuel tank Mak...

Page 11: ...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 rep...

Page 12: ...e and identify the most frequently used controls VOLTAGE SELECTOR SWITCH AC CIRCUIT BREAKER DC CIRCUIT PROTECTOR ENGINE SWITCH DC TERMINALS AUTO THROTTLE SWITCH GROUND TERMINAL EM4000SX RECEPTACLES GF...

Page 13: ...AIR CLEANER FUEL VALVE LEVER SEDIMENT CUP STARTER GRIP OIL DRAIN PLUG OIL FILLER CAP DIPSTICK BATTERY COVER CONTROL PANEL HANDLE SPARK PLUG FUEL TANK CAP FUEL GAUGE WHEEL MUFFLER STAND MANUAL CHOKE LE...

Page 14: ...ed when the battery voltage is too low to turn the starter motor Pulling the starter grip operates the recoil starter to crank the engine Do not allow the starter grip to snap back against the generat...

Page 15: ...connected to the 4 prong receptacle the switch must be in the 120V 240V position If only a 120V appliance is being connected to any of the 120V 3 prong receptacles select the 120V ONLY position Select...

Page 16: ...els when no load is applied to the generator OFF The Auto Throttle system does not operate Recommended to minimize warm up time when the generator is started and when starting a load with large start...

Page 17: ...orking properly and does not exceed the rated load capacity of the circuit before resetting the AC circuit protector ON AC CIRCUIT PROTECTOR for Receptacle AC CIRCUIT PROTECTOR for Receptacle AC CIRCU...

Page 18: ...ame time is in contact with an electrical ground such as a plumbing fixture wet floor or earth The GFCI will protect against current flowing through that person The GFCI will not protect against short...

Page 19: ...ry positive to generator red terminal and battery negative to the generator black terminal DC Circuit Protector The DC circuit protector automatically shuts off the DC battery charging circuit when th...

Page 20: ...rator is stationary Do not rest objects on the extended handle To Extend The Handle Lift handle upward Lock lever will lock and secure the handle into place To Fold The Handle 1 Press handle lock leve...

Page 21: ...n During operation the engine will automatically stop if there is not enough oil in the tank Moreover if the generator is on a slope the oil alert function may operate and stop the engine Overspeed De...

Page 22: ...rocedure iAVR Intelligent Auto Voltage Regulator This generator is equipped with an intelligent automatic voltage regulator The iAVR provides power in excess of the maximum rating for up to ten second...

Page 23: ...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 electr...

Page 24: ...generator s load rating see page 34 IS YOUR GENERATOR READY TO GO For your safety to ensure compliance with environmental regulations and to maximize the service life of your equipment it is very imp...

Page 25: ...around and underneath the engine for signs of oil or gasoline leaks Check the oil level see page 48 A low oil level will cause the Oil Alert system to shut down the engine or prevent it from starting...

Page 26: ...ltiple tools and appliances with built in noise filters Such use may activate the GFCI Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for...

Page 27: ...or proper cooling allow at least 3 feet 1 meter of empty space above and around the generator Refer to SAFE OPERATING PRECAUTIONS on page 24 and perform the IS YOUR GENERATOR READY TO GO checks see pa...

Page 28: ...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 Using the electric starter for more than 5 seco...

Page 29: ...turn 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 Be careful not to hit your hand against the handle when...

Page 30: ...ditions use the following procedure 1 Turn off or disconnect all appliances that are connected to the generator 2 Move the AC circuit breaker to the OFF position 3 Turn the engine switch to the OFF po...

Page 31: ...n against electric shock as designed An electric shock can result in serious injury or death Always perform the GFCI system inspection before using the generator If the GFCI system fails the test the...

Page 32: ...once green Light once red Blink once green Lights continuously If the green indicator does not light on press the RESET button If the red indicator starts to blink continuously contact an authorized H...

Page 33: ...ss the RESET button If the GFCI cannot be reset the GFCI is faulty Contact an authorized Honda generator dealer If the RESET button extends this usually indicates a faulty power tool appliance or cord...

Page 34: ...he generator 1 Turn the voltage selector switch to either position With the voltage selector switch in the 120V 240V position you can use the 120V and 120V 240V receptacles simultaneously If you are N...

Page 35: ...the electrical load on the circuit wait a few minutes and then reset the AC circuit breaker or AC circuit protector If the generator is overloaded and the internal circuit is overheated current to the...

Page 36: ...tartup Make sure the electrical rating of the tool or appliance does not exceed the maximum power rating of the generator Maximum power is EM4000SX 4 0 kVA EM5000SX 5 0 kVA EM6500SX 6 5 kVA For contin...

Page 37: ...producing circuits supplies power to specific receptacles When the voltage selector switch is in the 120V ONLY position the power producing circuits operate in parallel sharing the total load connecte...

Page 38: ...le above and the total load does not exceed the total current available Total Current Available 30 0 A EM4000SX 37 5 A EM5000SX 45 8 A EM6500SX Switch Position Receptacle Available Power EM4000SX EM50...

Page 39: ...receptacles shown below Balancing is necessary because each set of receptacles is powered by only one power producing circuit that can produce a maximum of amps 15 0 A EM4000SX 18 8 A EM5000SX 22 9 A...

Page 40: ...RNING Battery posts terminals and related accessories contain lead and lead components Wash hands after handling 2 Connect the red lead of battery charging cable into the positive DC terminal of the g...

Page 41: ...ear circuit protector button will pop out If this happens wait a few minutes before pushing in the circuit protector button to resume operation If the circuit protector continues to go OFF discontinue...

Page 42: ...large start up power demands may not allow the engine to reach normal operating rpm when they are connected to the generator Push the Auto Throttle switch to the OFF position and connect the appliance...

Page 43: ...and use procedures System Ground This generator has a system ground that connects generator frame components to ground terminals in the AC output receptacles The system ground is not connected to the...

Page 44: ...hat 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 registere...

Page 45: ...gh temperature operation or use it in dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Remember that an authorized Honda servicing dealer...

Page 46: ...from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you...

Page 47: ...lures REGULAR SERVICE PERIOD 3 Perform at every indicated month or operating hour interval whichever comes first Each use First month or 20 Hrs Every 3 months or 50 Hrs Every 6 months or 100 Hrs Every...

Page 48: ...per level mark see page 47 or fuel may flow into the charcoal canister causing fuel spillage This overflow may also prevent the fuel tank from venting properly Never refuel the engine inside a buildin...

Page 49: ...osion inhibitors Use of fuels with content of ethanol or methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel...

Page 50: ...the oil level shown on the dipstick 3 If the oil level is low fill with the recommended oil see page 50 to the upper limit on the oil filler cap dipstick 4 Reinstall the oil filler cap dipstick secure...

Page 51: ...3 With the generator in a level position fill with the recommended oil to the upper limit on the oil filler cap dipstick see page 48 Maximum oil capacity 1 2 US qt 1 1 L 4 Reinstall the oil filler ca...

Page 52: ...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 The SAE oil viscosity and service category...

Page 53: ...e of the frame pipe taking care not to damage the air cleaner cover 3 Remove the air cleaner element from the air cleaner case 4 Check the air cleaner element to be sure it is clean and in good condit...

Page 54: ...at the cover is set securely There must be no clearance between the air cleaner cover and air cleaner case Operating the engine without an air filter or with a damaged air filter will allow dirt to en...

Page 55: ...air filter in warm soapy water rinse and allow to dry thoroughly or clean in non flammable solvent and allow to dry 2 Dip the foam air filter in clean engine oil and then squeeze out all excess oil T...

Page 56: ...nsure 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 is hot allow it to cool before servicing the spa...

Page 57: ...spark plug in by hand to prevent cross threading 6 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 spa...

Page 58: ...spark arrester Clean the spark arrester as follows 1 Remove the two 5 mm screws and remove the spark arrester 2 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid...

Page 59: ...ove the sediment cup and the O ring Discard the O ring 3 Clean the sediment cup in nonflammable solvent and dry it thoroughly 4 Reinstall a new O ring and sediment cup and tighten the sediment cup sec...

Page 60: ...essure can damage the eye Immediately call 911 USA only or a physician Skin Remove contaminated clothing Flush the skin with large quantities of water Call a physician immediately Swallowing Drink wat...

Page 61: ...and then remove the positive cable from the battery positive terminal 3 Remove the battery holder band 4 Remove the battery from the battery tray This symbol on the battery means that this product mus...

Page 62: ...e the battery 5 10 hours 3 Clean the outside of the battery and the battery tray compartment with a solution of baking soda and water The battery will expel explosive hydrogen gas when overcharged A s...

Page 63: ...the positive cable and terminal 4 Connect the battery negative cable to the battery negative terminal and tighten the bolt securely 5 Install the battery holder band 6 Install the battery cover in th...

Page 64: ...erator dealer 1 Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse 2 Remove the fuse holder cover and pull the fuse out 3 Replace the fuse with a fuse...

Page 65: ...g and it leaves gum deposits that clog the fuel system If the gasoline in your generator deteriorates during storage you may need to have the carburetor and other fuel system components serviced or re...

Page 66: ...asoline stabilizer Drain the carburetor float bowl see page 65 Drain the fuel sediment cup see page 57 Remove the spark plug Put a teaspoon of engine oil into the cylinder Turn the engine slowly with...

Page 67: ...and use a funnel to avoid spilling fuel 3 Loosen the carburetor drain screw and drain the gasoline from the carburetor Gasoline is highly flammable and explosive You can be burned or seriously injure...

Page 68: ...7 Engine Oil Change the engine oil see page 49 Engine Cylinder 1 Remove the spark plug and pour a teaspoon 5 cc of clean engine oil into the cylinder Crank the engine several revolutions to distribute...

Page 69: ...he generator on a level surface Tilting or laying it on its side can cause fuel or oil leakage With the engine and exhaust system cool cover the generator to keep out dust A hot engine and exhaust sys...

Page 70: ...e 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 lever to the OFF p...

Page 71: ...and carburetor see page 65 Refuel with fresh gasoline see page 46 Low oil level caused Oil Alert to stop engine Add oil see page 48 Turn engine switch to OFF and then restart the engine Spark plug fa...

Page 72: ...generator stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor see page 65 Refuel with fresh gasoline see page 46 Fuel filter restricted carbureto...

Page 73: ...AC load and reset AC circuit protector see page 15 Faulty power tool or appliance Replace or repair power tool or appliance Stop and restart the engine Internal circuit overheated Stop the engine Redu...

Page 74: ...erial number and date purchased in the spaces below You will need this information when ordering parts and when making technical or warranty inquiries Engine serial number Frame serial number Date pur...

Page 75: ...ler perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life...

Page 76: ...hnologies to reduce evaporative emissions The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and ma...

Page 77: ...are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the ef...

Page 78: ...e durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine s emission...

Page 79: ...0 mm Compression ratio 8 5 1 8 2 1 Engine speed 3 600 rpm Cooling system Forced air Ignition system CDI magneto Oil capacity 1 2 US qt 1 1 L Fuel tank capacity 6 21 US gal 23 5 L Spark plug BPR5ES NG...

Page 80: ...r Digital CDI DC Diode DC Circuit Protector DC Terminal DC Winding Engine Control Unit Engine Switch Engine Block Exciter Winding Frame Block Fuse Field Winding Generator Block Ground Fault Circuit In...

Page 81: ...9 14 16 17 82 18 15 20 80 79 74 78 77 76 75 9 7 5 2 1 6 11 10 12 13 8 49 33 34 50 55 51 53 65 66 67 68 69 70 71 72 73 3 4 R R Bu Bu Bl Lg Bu W R W W W W Bl R G G G Y Gr Bu Br Br W R G AC CB AuSw DC T...

Page 82: ...chnician Available through your Honda dealer or visit http powerequipment honda com support shop manuals Parts Catalog This manual provides complete illustrated parts lists Available through your Hond...

Page 83: ...ed with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Rela...

Page 84: ...da to sell those products This warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period What American Honda will Repair or Replace Under Warr...

Page 85: ...business hours To locate a dealer near you visit our web site at http powerequipment honda com dealer locator If you are unable to obtain warranty service or are dissatisfied with the warranty service...

Page 86: ...heel bearing recoil starter rope cable belt cutter blade Lubricant oil and grease 3 Cleaning adjustment and normal periodic maintenance work carburetor cleaning engine oil draining blade sharpening be...

Page 87: ...ipment accessories replacement parts or apparel that are proven to be defective in material or workmanship under normal use during the applicable warranty time period Anything replaced under warranty...

Page 88: ...is warranty does not extend to accessories parts or apparel affected or damaged by collision normal wear use in an application for which the product was not designed or any other misuse neglect incorp...

Page 89: ...ped to meet the State s stringent anti smog standards Specific Honda products that do not meet the California emissions regulations can be identified by a Not for sale in California decal Other States...

Page 90: ...part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your power equipment engine to a Honda Power Equipment dealer as soon as a prob...

Page 91: ...formance of any warranty repairs and must be provided without charge to the owner A list of warranted parts is on page 91 Normal maintenance items such as spark plugs and filters that are on the warra...

Page 92: ...da office in your region American Honda Motor Co Inc Honda Canada Inc Power Equipment Customer Power Equipment Relations Customer Relations 4900 Marconi Drive or 180 Honda Blvd Alpharetta Georgia 3000...

Page 93: ...overed up to the first required replacement only See the MAINTENANCE SCHEDULE on page 45 SYSTEMS COVERED BY THIS WARRANTY PARTS DESCRIPTION Fuel Metering Carburetor assembly includes starting enrichme...

Page 94: ...or Some of the most important safety precautions are given in the Important Safety Precautions chapter However we cannot warn you of every conceivable hazard that can arise in performing this assembly...

Page 95: ...eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Operate outside away from open windows or doors Burns from hot parts Let the engine and exhaust system cool before tou...

Page 96: ...damage the engine or your property 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 Description Q...

Page 97: ...after attaching the handle Check that the handle can be folded smoothly Check that the handle does not hang down by its own weight To extend handle Raise the handle to the horizontal position The han...

Page 98: ...r installing the split pins bend the pins to ensure that the wheels are secured to the axle 3 Install the axle assembly on the generator using four 8 16 mm flange bolts and 8 mm flange nuts TORQUE 17...

Page 99: ...il dipstick SAE 10W 30 API service category SJ or later or equivalent is recommended for general use for additional recommendations see page 50 Maximum oil capacity 1 2 US qt 1 1 L Do not overfill the...

Page 100: ...d gasoline with a pump octane rating of 86 or higher Refer to page 46 for additional fuel recommendations 1 Remove the fuel tank cap 2 Fuel carefully to avoid spilling fuel Do not fill the fuel tank a...

Page 101: ...e battery is disconnected for shipment 1 Remove the cover see page 59 2 Connect the battery positive cable to the battery positive terminal first and tighten the bolt securely 3 Slide the battery boot...

Page 102: ...N Please Register Your Generator If your dealer did not collect registration information from you please take a few minutes and register your purchase with Honda This allows us to contact you with any...

Page 103: ...connector 2 Connect the remote control cable to the back of the control panel and remote control box When the remote control is not being used replace it with the plug on the connector PLUG REMOTE CO...

Page 104: ...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 s...

Page 105: ...oint 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 0 kgf m 8 16 mm FLANGE BOLT...

Page 106: ...14 40 Auto Choke and Throttle Control System 20 B BATTERY SERVICE 58 BEFORE OPERATION 22 100 C Carbon Monoxide Hazards 6 Carburetor Modification for High Altitude Operation 73 Check the Engine 23 Chec...

Page 107: ...TURES 19 Fire and Burn Hazards 7 Folding Handle 18 Fuel 63 98 Fuel Gauge 21 FUEL RECOMMENDATIONS 47 Fuel Valve Lever 13 FUSE 62 G GENERATOR SAFETY 6 GFCI OPERATION CHECK 29 Ground Fault Circuit Interr...

Page 108: ...71 O Oil Alert Function 19 Oil Alert System 19 OPERATION 24 Operator Responsibility 6 OPTIONAL PARTS 101 Overspeed Detection Function 19 P Power Producing Circuits 35 Q QUICK REFERENCE INFORMATION Ins...

Page 109: ...ents 42 Specifications 77 STANDBY POWER 41 Starter Grip 12 STARTING THE ENGINE 25 STOPPING THE ENGINE 28 STORAGE 63 STORAGE PRECAUTIONS 67 STORAGE PREPARATION 63 System Ground 41 T TAKING CARE OF UNEX...

Page 110: ...108 MEMO 31Z236120 book 108...

Page 111: ...2015 Honda Motor Co Ltd All Rights Reserved GENERATOR EM4000SX EM5000SX EM6500SX Owner s Manual See page 81 for instructions on assembling your generator EM4000SX 6500SX_OM _31Z23610_F AH N FM Hi C BK...

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