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Honda EU6500is, Owner'S Manual

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Honda EU6500is Owner'S Manual Download Page 61

59

SERVICING YOUR GENERATOR

FUSE

Specified fuse:

FUSE (15A)

FUSE HOLDER COVER

FUSE (1A)

COVER
SCREW

BATTERY
MAINTENANCE
COVER

In the event of fuse failure, locate the cause of failure and repair before
you continue operation. If the fuse continues to fail, discontinue
generator use and consult an authorized Honda generator dealer.

If the fuse is blown, the starter motor won’t operate.

Turn the engine switch OFF and remove the key before checking or
replacing the fuse.

1 A, 15 A

Replace the fuse with a
fuse of the same type and
rating.

Remove the fuse holder cover
and pull the fuse out.

Never operate the generator without the maintenance cover in place,
as poor engine and generator performance will result.

Loosen the cover screw and
remove the battery
maintenance cover.

Never use a fuse with a
different rating from that
specified. Serious damage to
the electrical system or fire
may result.

Install the fuse holder cover and the battery maintenance cover in
the reverse order of removal (see page

).

1.

2.

3.

4.

5.

56

06/09/12 12:26:40 31Z25600_060

Summary of Contents for EU6500is

Page 1: ...00 o2006 Honda Motor Co Ltd All Rights Reserved N2eY11000 2006 09 Printed in Japan Owner s Manual GENERATOR EU6500is Black DIC F101 31Z25600 00X31 Z25 6000 EU6500is See page 78 for instructions on assembling your generator ...

Page 2: ...uded in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 06 09 12...

Page 3: ...r generator other property or the environment When your generator needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda M...

Page 4: ...ds associated with operating or maintaining a generator You must use your own good judgement You will find important safety information in a variety of forms including on the generator preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean be or if you don t follow instructions be or if you don t follow instructions be if you don t follow ...

Page 5: ...ONS 10 CONTROLS 12 Fuel Valve Lever 12 Engine Switch 12 Recoil Starter 13 EcoThrottle Switch 13 Voltage Selector Switch 14 AC Circuit Protectors 14 Folding Handle 15 Maintenance Cover 16 FEATURES 17 Ground Terminal 17 Output Indicator 18 Overload Indicator 18 Oil Alert Indicator 19 i Monitor 20 Fuel Gauge 23 ARE YOU READY TO GET STARTED 24 Knowledge 24 IS YOUR GENERATOR READY TO GO 24 Check the En...

Page 6: ...uilding s Electrical System 39 System Ground 39 Special Requirements 40 THE IMPORTANCE OF MAINTENANCE 41 MAINTENANCE SAFETY 42 Safety Precautions 42 MAINTENANCE SCHEDULE 43 REFUELING 44 FUEL RECOMMENDATIONS 45 ENGINE OIL LEVEL CHECK 46 ENGINE OIL CHANGE 47 ENGINE OIL RECOMMENDATIONS 48 AIR CLEANER SERVICE 49 FOAM AIR FILTER CLEANING 50 SEDIMENT CUP CLEANING 51 SPARK PLUG SERVICE 52 SPARK ARRESTER ...

Page 7: ...dification for High Altitude Operation 70 Emission Control System Information 71 Air Index 73 Specifications 74 Wiring Diagram 75 CONSUMER INFORMATION 76 Honda Publications 76 Customer Service Information 77 SAFETY 78 The Importance of Proper Assembly 78 Important Safety Precautions 79 ASSEMBLY 80 Unpacking 80 Loose Parts 80 Wheel Kit Installation 81 Handle Installation 82 Rear Bar Installation 83...

Page 8: ... along with the best way to protect yourself and others Be sure that anyone who operates the generator receives proper instruction Do not let children operate the generator without parental supervision Exhaust contains poisonous carbon monoxide a colorless odorless gas Breathing exhaust can cause loss of consciousness and may lead to death Know how to stop the generator quickly in case of emergenc...

Page 9: ... can cause a malfunction or short circuit in electrical components which could result in electrocution Do not connect to a building electrical system unless an isolation switch has been installed by a qualified electrician 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 befor...

Page 10: ...or has been in operation Refuel only outdoors in a well ventilated area with the engine OFF Do not overfill the fuel tank Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container Make sure that any spilled fuel has been wiped up before starting the engine 06 09 12 12 18 09 31Z25600_009 ...

Page 11: ... LOCATIONS These labels warn you of potential hazards that can cause serious injury Read them carefully If a label comes off or becomes hard to read contact your Honda servicing dealer for a replacement 06 09 12 12 18 26 31Z25600_010 ...

Page 12: ...RS FUEL VALVE LEVER VOLTAGE SELECTOR SWITCH ECOTHROTTLE SWITCH ENGINE SWITCH i MONITOR i MONITOR BUTTON OIL ALERT INDICATOR OVERLOAD INDICATOR RECEPTACLES Use the two illustrations on these pages to locate and identify the most frequently used controls 06 09 12 12 18 33 31Z25600_011 ...

Page 13: ...MINAL STAND OIL DRAIN PLUG OIL FILLER CAP DIPSTICK FUEL GAUGE HANDLE WHEEL MUFFLER TIP SPARK PLUG INSPECTION COVER LEFT MAINTENANCE COVER RIGHT MAINTENANCE COVER FUSE inside battery maintenance cover BATTERY inside battery maintenance cover 06 09 12 12 18 39 31Z25600_012 ...

Page 14: ...fter stopping the engine turn the fuel valve to the OFF position The fuel valve lever is located on the control panel The engine switch controls the ignition system and it operates the electric starter OFF Stops the engine The engine switch key can be removed inserted REMOTE For using the remote control kit optional parts START Operates the electric starter ON Running position and for starting wit...

Page 15: ... automatically reduces engine speed when all loads are turned off or disconnected When appliances are turned on or reconnected the engine returns to the proper speed to power the electrical load Do not let the starter rope rub against the generator body or the rope will wear out prematurely Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the star...

Page 16: ...F 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 Select the voltage before starting the engine The 120V and 120 240V receptacles can be used simultaneously ONLY the 120V receptacles can be used Do not use the 120 240V receptacle in this position The most power will be available at th...

Page 17: ...tionary position The foldable handle is intended for ease of transportation and should be folded when the generator is stationary Do not rest objects on the extended the handle Lift handle upward Lock levers will lock and secure the handle into place Lower the handle Press both handle lock levers downward 2 1 06 09 12 12 19 28 31Z25600_016 ...

Page 18: ...ver too to use the recoil starter when the battery is discharged Be sure to close the maintenance cover while the generator is running Turn the ratch 90 to unlock and open the maintenance cover Turn the ratch 90 to lock while pushing the cover Engine oil inspection replacement Spark plug inspection replacement Air cleaner inspection cleaning Sediment cup cleaning Open and close the maintenance cov...

Page 19: ...he metal non current carrying parts of the generator and the ground terminals of each receptacle Before using the ground terminal consult a qualified electrician electrical inspector or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator 06 09 12 12 19 48 31Z25600_018 ...

Page 20: ... electrical power at the receptacles If the generator is overloaded or if there is a short circuit in a connected appliance or if the inverter is overheated the overload indicator red will go ON When the generator is operating overloaded the overload indicator red will stay ON and after about five seconds current to the connected appliance s will shut off and the output indicator green will go OFF...

Page 21: ...ition If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to START or pull the starter grip check the engine oil level see page before troubleshooting in other areas Even when oil is added to the engine the generator will not restart until the Oil Alert indicator is reset To reset the Oil Alert indicator turn the engine switch OFF add the proper amount of oil se...

Page 22: ...he single digit screen displays the i Monitor mode which is represented by a number 1 through 4 The four digit screen displays the four mode values or any activated error messages This mode displays the total operating hours of the generator When the generator is running the total operating time accumulates If the total operating time is less than one hour the numeric display will be 0 When the op...

Page 23: ...en The output is expressed in VA volt amperes The output value is not an exact measurement and should be regarded as a reference only Power output will not display until a load is connected to the generator When the i Monitor is in this mode the engine s speed expressed in revolutions per minute RPM is displayed This mode displays the battery condition expressed in Volts DC 06 09 12 12 20 27 31Z25...

Page 24: ...ge the engine will stay running and the electrical output may stay constant Normal remote control operation will be restored after the E 01 error message clears If the E 01 error message will not clear or if any other error message displays contact an authorized Honda generator dealer If the engine switch is turned to the START position and batt is shown on the i Monitor display the battery voltag...

Page 25: ...uel level in the tank The red indicator in the window will reference the level in relation to full or empty To provide increased operating time start with a full tank before beginning operation Check the fuel level with the generator on a level surface Always refuel with the engine OFF and cool 06 09 12 12 20 41 31Z25600_024 ...

Page 26: ... take care of any problem you find or have your servicing dealer correct it before you operate the generator Improperly maintaining this generator or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks be sure t...

Page 27: ...ter see page A dirty air filter will restrict air flow to the carburetor reducing engine and generator performance Check the fuel level see page Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Never operate the generator without the battery maintenance cover in place as poor engine and generator performance will result 46 49 44 06 09 12 12 21 02 31Z...

Page 28: ...bon monoxide Before connecting an AC appliance or power cord to the generator Use grounded 3 prong extension cords tools and appliances or double insulated tools and appliances Inspect cords and plugs and replace if damaged Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for electric shock Make sure the electrical rating of the tool or ...

Page 29: ...sure that all appliances are disconnected from the AC receptacles The generator may be hard to start if a load is connected Set the Voltage Selector Switch to match the voltage requirements for the application Turn the fuel valve lever to the ON position Make sure the EcoThrottle switch is in the OFF position or more time will be required for warm up 1 2 3 25 4 06 09 12 12 21 26 31Z25600_028 ...

Page 30: ... the engine starts release the key allowing the switch to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the starter again Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it 5 06 09 12 12 21 33 31Z25600_029 ...

Page 31: ...s latch clockwise Do not let the starter rope rub against the generator body or the rope will wear out prematurely Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter Do not exceed 20 degrees from horizontal when pulling the starter grip Pull the starter grip lightly until you feel resistance then pull briskly in the direction of the allo...

Page 32: ...urn the engine switch to the REMOTE far left position Press and hold the start button until the engine pilot lamp illuminates The start button will automatically be disabled after the engine starts Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it If the engine fails to start within 5 seconds release the button and wait at least 10 secon...

Page 33: ...he engine in an emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure Turn the fuel valve lever to the OFF position Turn the engine switch to the OFF position Unplug all appliances from the generator AC receptacles 1 2 3 06 09 12 12 22 06 31Z25600_032 ...

Page 34: ...ol optional part O OF FF F ENGINE SWITCH REMOTE STOP BUTTON PILOT LAMP O OF FF F FUEL VALVE LEVER O ON N Turn the engine switch to the OFF position Turn the fuel valve lever to the OFF position Press the stop button 1 2 3 06 09 12 12 22 14 31Z25600_033 ...

Page 35: ...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 but require more power from the 120V locking plug receptacle then select the 120V ONLY position Substantial overloading that continuously lights the overload indicator red may damage the generator Marginal overloading...

Page 36: ...he appliance power cord If the generator is overloaded or if there is a short circuit in a connected appliance or if the inverter is overheated the overload indicator red will come ON The overload indicator red will stay ON and after about five seconds current to the connected appliance s will shut off and the output indicator green will go OFF Stop the engine and investigate the problem When an e...

Page 37: ...maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes Limit operation requiring maximum power to 30 minutes Maximum power is Substantial overloading will open the circuit breaker Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF but wil...

Page 38: ...verloading by dividing the load between the two power circuits The chart below shows the rated load in amperes that can be connected to each receptacle to balance the generator when the 120 240 V locking plug receptacle is used for 120 V The total rated ampere draw is 45 8 A Main power circuit Main Circuit I Main Circuit II Receptacles powered by each main circuit 1 3 and 4 2 and 5 Power distribut...

Page 39: ...ower circuit I The equation tells us that the total power draw on circuit I is 25A This is a substantial overload of this circuit To eliminate the excess power draw on circuit I the load from receptacle 3 should be switched to receptacle 2 Now circuit I is powering the 15A load less than 18 8A and circuit II is powering the 10A load less than 18 8A 06 09 12 12 22 55 31Z25600_038 ...

Page 40: ...cal loads are connected simultaneously turn the EcoThrottle switch to the OFF position to reduce voltage changes The EcoThrottle system is not effective for use with appliances that require only momentary power If the tool or appliance will be turned ON and OFF quickly the EcoThrottle switch should be in the OFF position With the switch in the ON position engine speed is automatically lowered when...

Page 41: ... to a building s electrical system can allow current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause fires when utility power is restored Consult the utility company or a qualified electrician prior to making any power connections Your genera...

Page 42: ...ply to the intended use of the generator Please consult a qualified electrician electrical inspector or the local agency having jurisdiction In some areas generators are required to be registered with local utility companies If the generator is used at a construction site there may be additional regulations that must be observed 06 09 12 12 23 16 31Z25600_041 ...

Page 43: ...lly performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your generator under unusual conditions such as sustained high load or high temperature operation or use it in dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Improper maintenance or failure to ...

Page 44: ...ays follow the procedures and precautions in the owner s manual Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Be sure there is adequate ventilation whenever you operate the engine Let the engine and exhaust system cool before touching Do not run the engine unless instructed to do so Read the instructions before you begin and m...

Page 45: ...r every 500 Hrs 2 Every 2 years Replace if necessary 2 Service more frequently when used in dusty areas These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures For commercial use log hours of operation to determine proper maintenance intervals Failure to follow this maintenance schedu...

Page 46: ...gauge Refill the fuel tank if the fuel level is low Refuel in a well ventilated area before starting the engine If the engine has been running allow it to cool Refuel carefully to avoid spilling fuel Do not fill the fuel tank above the fuel strainer shoulder Never refuel the engine inside a building where gasoline fumes may reach flames or sparks Keep gasoline away from appliance pilot lights barb...

Page 47: ...gine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty 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 system Never use stale or contaminated gasoline or an o...

Page 48: ...k without screwing it into the filler neck Check the oil level shown on the dipstick If the oil level is low fill to the top of the oil filler neck with the recommended oil see page Screw in the oil filler cap dipstick securely Close the right maintenance cover by turning its latch clockwise The Oil Alert system will automatically stop the engine before the oil level falls below safe limits Howeve...

Page 49: ...h the generator in a level position fill to the outer edge of the oil filler hole with the recommended oil see page Open the right maintenance cover by turning its latch counterclockwise Reach under the generator and remove the black rubber seal located below the oil drain plug Place a suitable container underneath the generator to catch the used oil Remove the oil filler cap dipstick Remove the o...

Page 50: ...omotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SJ or later oil 06 09 12 12 24 42 31Z25600_049 ...

Page 51: ...foam air filter is dirty clean it as described on page Replace the foam air filter if it is damaged 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 Open the left maintenance cover by turning its latch counterclockwise Loosen the cover screws...

Page 52: ...m air filter in warm soapy water rinse and allow to dry thoroughly or clean in nonflammable solvent and allow to dry Dip the foam air filter in clean engine oil then squeeze out all excess oil The engine will smoke when started if too much oil is left in the filter Wipe dirt from the air cleaner housing and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to...

Page 53: ...e sediment cup and remove it Remove the O ring Close the left maintenance cover Reinstall the O ring and sediment cup Wash the sediment cup and O ring in nonflammable solvent and dry them thoroughly Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Gasoline is highly flammable and explosive You can be burned or seriously injured when handling ...

Page 54: ...park plug can cause engine damage Open the left maintenance cover by turning its latch counterclockwise Loosen the cover screw and remove the spark plug inspection cover Remove the spark plug with a 13 16 inch spark plug wrench commercially available Disconnect the spark plug cap and remove any dirt from around the spark plug area 1 2 3 4 06 09 12 12 25 24 31Z25600_053 ...

Page 55: ... plug in by hand prevent cross threading After the spark plug seats tighten with a 13 16 inch spark plug wrench to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads i...

Page 56: ...t is damaged Be careful to avoid damaging the screen Use a brush to remove carbon deposits from the spark arrester screen The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester Remove the two 5 14 mm pan head screws and remove the spark arrester ...

Page 57: ...isonous Getting electrolyte in your eyes or on your skin can cause serious burns Wear protective clothing and eye protection when working near the battery KEEP CHILDREN AWAY FROM THE BATTERY Flush with water from a cup or other container for at least fifteen minutes Water under pressure can damage the eye Immediately call 911 USA only or a physician Remove contaminated clothing Flush the skin with...

Page 58: ...LE HANDLE LOCK LEVER BATTERY MAINTENANCE COVER Battery posts terminals and related accessories contain lead and lead compounds Lift handle upward Lock levers will lock and secure handle into place Loosen the cover screw and remove the battery maintenance cover 1 2 06 09 12 12 26 05 31Z25600_057 ...

Page 59: ...RAP Remove the negative cable from the battery negative terminal then remove the positive cable from the battery positive terminal Unhook the battery strap from the bottom hook of the generator Remove the battery from the battery tray 3 4 5 06 09 12 12 26 12 31Z25600_058 ...

Page 60: ...ive terminal first and tighten the bolt securely Install the battery into the generator Clean the outside of the battery and the battery compartment with a solution of baking soda and water Connect the battery charger following the manufacturer s instructions The battery is rated at 11 2 Ah ampere hours Charging current should equal 10 of the battery s ampere hour rating A battery charger should b...

Page 61: ... the key before checking or replacing the fuse 1 A 15 A Replace the fuse with a fuse of the same type and rating Remove the fuse holder cover and pull the fuse out Never operate the generator without the maintenance cover in place as poor engine and generator performance will result Loosen the cover screw and remove the battery maintenance cover Never use a fuse with a different rating from that s...

Page 62: ...etor and other fuel system components serviced or replaced You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor The does not cover fuel system damage or engine performance problems resulting from neglected storage preparation The length of time that gasoline can be ...

Page 63: ... storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Add fuel stabilizer following manufacturer s instructions After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor Stop the engine and turn the fuel valve lever to the OFF position 1 2 3 06 09 12 ...

Page 64: ... Open the right maintenance cover by turning its latch counterclockwise Place a suitable gasoline container below the carburetor drain hose After all the fuel has drained into the container tighten the drain screw securely Loosen the carburetor drain screw and drain the gasoline from the carburetor and tank Remove the sediment cup and empty it Reinstall the sediment cup see page Move the fuel valv...

Page 65: ...istribute the oil in the cylinder Reinstall the spark plug 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 Storing the engine in this position will help to protect it from internal corrosion Return the starter grip gently 1 2 3 6 5 4 47 52 06 09 12 12 27 17 31Z25600_064 ...

Page 66: ...arge the battery once a month see page Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the generator promoting rust and corrosion With the engine and exhaust system cool cover the generator to keep out dust A hot engine and exhaust system can ignite or melt some materials Place the generator on a level surface Tilting can cause fuel or oil leakage Unless all fu...

Page 67: ...nite some materials Keep the generator level when transporting to reduce the possibility of fuel leakage Move the fuel valve to the OFF position When using ropes or tie down straps to secure the generator for transportation be sure to only use the frame bars as attachment points Do not fasten ropes or straps to any portions of the generator body or the folding transport handle 06 09 12 12 27 35 31...

Page 68: ...or improperly gapped Spark plug wet with fuel flooded engine Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Turn lever ON Turn engine switch to ON Refuel p 44 Drain fuel tank and carburetor p 62 Refuel with fresh gasoline p 44 Add oil p 46 Turn engine switch to OFF and restart the engine Gap or replace spark plug p 52 Dry and reinstall spark plug Take the gener...

Page 69: ... draining gasoline or refueled with bad gasoline Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Clean or replace air filter p 49 Drain fuel tank and carburetor p 62 Refuel with fresh gasoline p 44 Take the generator to an authorized Honda servicing dealer or refer to the shop manual 06 09 12 12 27 48 31Z25600_068 ...

Page 70: ...t the engine Check AC load and reset circuit protector s p 14 Replace or repair power tool or appliance Stop and restart the engine Take the generator to an authorized Honda servicing dealer or refer to the shop manual Output indicator is OFF and overload indicator is ON Circuit protector s tripped Faulty power tool or appliance Faulty generator 06 09 12 12 27 54 31Z25600_069 ...

Page 71: ...RAME SERIAL NUMBER Serial Number Location Record the frame serial number in the space below You will need this serial number when ordering parts and when making technical or warranty inquiries Frame serial number Date purchased 06 09 12 12 28 01 31Z25600_070 ...

Page 72: ...er 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 Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carbu...

Page 73: ...issions of carbon monoxide oxides of nitrogen and hydrocarbons EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards Tampering with or altering the emission contro...

Page 74: ...lacement parts 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 effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacture...

Page 75: ... 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 control system See your Emission Control System Warranty for additional information Descriptive Term Moderate Intermediate Extended Applicable to Emissions Durability Period 50 hours 0 65 cc 125 hours greater than 65 cc 125 hours 0 65 cc ...

Page 76: ...em Ignition System Oil Capacity Fuel Tank Capacity Spark Plug Type Rated voltage Rated frequency AC output Rated Ampere Rated Output Maximum Output IN 0 15 0 02 mm W16EPR U DENSO BPR5ES NGK 4 36 US gal 16 5 1 18 US qt 1 12 Full transistor Forced air 8 0 1 23 7 cu in 389 cm GX390K1 254 lbs 115 kg 28 2 in 716 mm 27 5 in 699 mm 26 5 in 672 mm 47 0 in 1 195 mm 33 5 in 850 mm 4 stroke overhead valve si...

Page 77: ...75 TECHNICAL CONSUMER INFORMATION Wiring Diagram 06 09 12 12 29 32 31Z25600_076 ...

Page 78: ...overs 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 1 888 292 5395 or visit www Honda engines com product manuals This manual provides complete illustrated parts lists Available through your Honda dealer Call 800 426 7701 or visit our web site www hondapowerequipment com dealer 06 09 12 12 2...

Page 79: ...ied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 When you write or call please give us this information Model and serial numbers see page Name of the dealer who sold the generator to you Na...

Page 80: ...on assembling and servicing a unit can easily result in faulty operation damage to the machine or injury to the operator Some of the most important safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing this assembly Only you can decide whether or not you should perform a given task Failure to properly follow instructions and precauti...

Page 81: ... instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure there is adequate ventilation whenever you run the engine Do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away Do not run the engine when any protective guard or shield is removed Let the engine and exhaust system cool ...

Page 82: ...ncluded with your generator 14 mm wrench 2 10 mm wrench or Phillips head screwdriver for battery connections pliers not included 1 2 Ref No 1 2 3 4 5 6 7 8 Ref No 9 10 11 12 13 14 15 Qty 2 2 2 8 4 4 2 Description Spring Washer Handle holder bolt 6 mm Cap nut Description Wheel Axle Handle assy Stand Rear pipe 20 mm Washer 12 mm Washer Qty 2 1 1 2 1 2 2 2 6 30 mm Flange bolt 8 16 mm Flange bolt 8 mm...

Page 83: ...nstalled it may be possible for dirt and debris to be drawn into the generator air intake causing possible generator damage Always operate the generator with the wheel kit installed Do not operate the generator without the wheel kit installed The wheel kit provides an air space between the ground and the generator air intake Install the axle assembly on the generator using four 8 mm washers and 8 ...

Page 84: ...E HOLDER BOLT 2 17 22 lbf ft 24 29 N m 2 4 3 0 kgf m Operation must be checked after attaching a handle Raise handle to horizontal position The handle will click into place when locked Install the handle assembly on the generator upper frame using the 12 mm washers spring washers and handle holder bolts 06 09 12 12 30 36 31Z25600_083 ...

Page 85: ...ar Bar Installation TORQUE REAR BAR CAP NUT 2 6 30 mm BOLT 2 17 22 lbf ft 24 29 N m 2 4 3 0 kgf m Install the rear bar on the generator frame using the two 6 30 mm bolts and two cap nuts 06 09 12 12 30 41 31Z25600_084 ...

Page 86: ... generator Connect the black cable to the battery negative terminal Remove the protective cover from the battery positive terminal connect the red cable to the battery positive terminal Remove the red cable and the black cable from the twist clip and reinstall the battery Remove the battery strap from the bottom hook and then remove the battery Remove the battery maintenance cover see page The bat...

Page 87: ... the oil level to the top of the oil filler neck Use a 4 stroke motor oil that meets the requirements for API service classification SJ or later SAE 10W 30 is recommended for general all temperature use Other viscosities in the chart may be used when the temperature in your area is within the indicated range Do not overfill engine oil If the engine is overfilled the excess oil may get transferred ...

Page 88: ...h the i Monitor see page The battery voltage should be 12 3 V or more If the battery voltage is low charge the battery until the battery voltage will be 12 3 V or more page page Before using your generator you should become familiar with information contained in the following chapters and sections page page page 10 6 26 27 31 21 06 09 12 12 31 19 31Z25600_087 ...

Page 89: ...ENANCE COVER Remove the plug from the 6 pin connector View the back of the maintenance cover and locate the knockout near the top center of the cover Carefully remove the knockout Remove the battery maintenance cover see page 1 2 3 56 06 09 12 12 31 27 31Z25600_088 ...

Page 90: ...tor frame with a cable tie as shown When the remote control is not being used replace the plug on the connector Pass the remote control cable through the supplied wire grommet and fit the grommet into the battery maintenance cover knockout Install the battery maintenance cover and tighten the cover screw Never operate the generator without the battery maintenance cover in place as poor engine and ...

Page 91: ...between the frame pipe and fuel tank Slide the hanger and insert another bracket installation part of the hanger into the gap between the frame pipe and fuel tank on the other side Slide the hanger along the frame pipe to align the center of the hanger with the recessed part on the rear side of the fuel tank Install the hanger brackets on both ends of the hanger and tighten the 8 16 mm flange bolt...

Page 92: ...h Altitude Operation 70 Check the Engine 25 Cleaning 60 COMPONENT CONTROL LOCATIONS 10 Connections to a Building s Electrical System 39 CONSUMER INFORMATION 76 CONTROLS 12 CONTROLS FEATURES 10 Customer Service Information 77 EcoThrottle Switch 13 ECOTHROTTLE SYSTEM 38 Electric Shock Hazards 7 Emission Control System Information 71 ENGINE LACKS POWER 67 Engine oil 63 ENGINE OIL CHANGE 47 ENGINE OIL...

Page 93: ...UEL RECOMMENDATIONS 45 Fuel Valve Lever 12 FUSE 59 GENERATOR SAFETY 6 Ground Terminal 17 Handle Installation 83 Hanger Kit 89 Honda Publications 76 i Monitor 20 IMPORTANT SAFETY INFORMATION 6 Important Safety Precautions 79 INDEX 90 IS YOUR GENERATOR READY TO GO 24 Knowledge 24 Loose Parts 80 TM 06 09 12 12 32 02 31Z25600_092 ...

Page 94: ...Oil Alert Indicator 19 OPERATION 26 Operator Responsibility 6 OPTIONAL PARTS 87 Output Indicator 18 Overload Indicator 18 QUICK REFERENCE INFORMATION Inside back cover Rear Bar Installation 83 Ricoil Starter 13 REFUELING 44 Refuel With Care 8 Remote Control Kit 87 REMOVAL FROM STORAGE 64 06 09 12 12 32 08 31Z25600_093 ...

Page 95: ...1 SPARK ARRESTER SERVICE 54 SPARK PLUG SERVICE 52 Special Requirements 40 Specifications 74 STAND BY POWER 39 STARTING THE ENGINE 27 STOPPING THE ENGINE 31 STORAGE 60 STORAGE PRECAUTIONS 64 STORAGE PREPARATION 60 System Ground 39 TAKING CARE OF UNEXPECTED PROBLEMS 66 TECHNICAL CONSUMER INFORMATION 69 TECHNICAL INFORMATION 69 THE IMPORTANCE OF MAINTENANCE 41 The Importance of Proper Assembly 78 TRA...

Page 96: ...94 MEMO 06 09 12 12 32 19 31Z25600_095 ...

Page 97: ...06 09 12 12 32 20 31Z25600_096 ...

Page 98: ...06 09 12 12 32 22 31Z25600_097 ...

Page 99: ... gasoline with a pump octane rating of 86 or higher Check engine oil level Check air filter Change engine oil See Maintenance Schedule page 43 0 028 0 031 in 0 70 0 80 mm NGK Honda P N Yuasa Model BPR5ES W16EPR U DENSO 31500 MCR D02 YTZ14S Electrode Gap First 20 hours Before each use 06 09 12 12 32 28 31Z25600_098 ...

Page 100: ...00 o2006 Honda Motor Co Ltd All Rights Reserved N2eY11000 2006 09 Printed in Japan Owner s Manual GENERATOR EU6500is Black DIC F101 31Z25600 00X31 Z25 6000 EU6500is See page 78 for instructions on assembling your generator ...

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