Honda Em3500Sx Ea6 1111465 Through 9999999 Owners Manual

2014-11-13

: Honda Honda-Em3500Sx-Ea6-1111465-Through-9999999-Owners-Manual-108373 honda-em3500sx-ea6-1111465-through-9999999-owners-manual-108373 honda pdf

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Page Count: 63

COVER
A FEW WORDS ABOUT SAFETY
CONTENTS
SAFETY
- SAFETY LABEL LOCATIONS
- SAFETY INFORMATION
COMPONENT IDENTIFICATION
CONTROLS
GENERATOR USE
PRE-OPERATION CHECK
- ENGINE OIL
- FUEL RECOMMENDATION
STARTING THE ENGINE
STOPPING THE ENGINE
MAINTENANCE
TRANSPORTING/STORAGE
TROUBLESHOOTING
WIRING DIAGRAM
SPECIFICATIONS
INSTALLATION OF OPTIONAL PARTS
WARRANTY SERVICE INFORMATION
INDEX

The generator is a potential source of electrical shock if misused. Do

not expose the generator to moisture, rain or snow. Do not let the

generator get wet, and do not operate it with wet hands.

Keep this owner’s manual handy, so you can refer to it at any time.

This owner’s manual is considered a permanent part of the generator

and should remain 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 discontinue or change specifications or

design at any time without notice and without incurring any obligation

whatever. No part of this publication may be reproduced without

written permission.

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

01/07/23 12:05:54 31ZB4800_001

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. That information is intended to help you avoid

damage to your generator, other property, or the environment.

We suggest you read the warranty policy to fully understand its

coverage and your responsibilities of ownership. The warranty policy

is a separate document that should have been given to you by your

dealer.

When your generator needs scheduled maintenance, keep in mind

that your Honda servicing dealer is specially trained in servicing

Honda generators. Your authorized Honda servicing dealer is

dedicated to your satisfaction and will be pleased to answer your

questions and concerns.

Best Wishes,

Honda Motor Co., Ltd.

01/07/23 12:06:00 31ZB4800_002

−

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

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.

Of course, it is not practical or possible to warn you about all the

hazards 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 instruc-

tions.

such as

This entire book is filled with important safety information please

read it carefully.

Your safety and the safety of others are very important. And using

this generator safely is an important responsibility.

how to use this generator correctly and safely.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

IMPORTANT SAFET Y

INFORMATION.

GENERATOR SAFETY.

01/07/23 12:06:13 31ZB4800_003

CONTENTS

......................................................................................................SAFETY . 5

..............................................................SAFETY LABEL LOCATIONS . 5

.....................................................................SAFETY INFORMATION . 7

..............................................................COMPONENT IDENTIFICATION . 9

..............................................................................................CONTROLS . 11

....................................................................................Engine Switch . 11

.....................................................................................Recoil Starter . 11

................................................................................Fuel Valve Lever . 12

..........................................................................................Choke Rod . 12

...................................................................................Circuit Breaker . 13

................................................................................Circuit Protector . 13

...............................................................................Ground Terminal . 13

..............................................................................Oil Alert System . 14

........................................................................Auto-throttle System . 14

..........................................................................................Pilot Lamp . 15

..........................................................................................Volt Meter . 15

............................Voltage Selector Switch (Dual Voltage System) . 15

.....................................................................................DC Terminals . 16

..........................................................................DC Circuit Protector . 16

...................................................................................GENERATOR USE . 17

..................................Connections to a Building Electrical System . 17

.................................................................................Ground System . 17

.................................................................................AC Applications . 18

.....................................................................................AC Operation . 19

...................................................................AC Receptacle Selection . 20

.....................................................................................DC Operation . 21

....................................................Disconnecting the battery cables . 22

........................................................................Auto-throttle System . 23

....................................................................High Altitude Operation . 24

.......................................................................PRE-OPERATION CHECK . 25

..........................................................................................Engine Oil . 25

.....................................................................Fuel Recommendation . 26

........................................................................STARTING THE ENGINE . 29

........................................................................STOPPING THE ENGINE . 30

01/07/23 12:06:18 31ZB4800_004

......................................................................................MAINTENANCE . 31

......................................................The Importance of Maintenance . 31

..........................................................................Maintenance Safety . 32

............................................Emission Control System Information . 33

.............................................................................................Air Index . 36

.....................................................................Maintenance Schedule . 37

............................................................................Engine Oil Change . 38

...........................................................................Air Cleaner Service . 39

...........................................................Fuel Sediment Cup Cleaning . 40

............................................................................Spark Plug Service . 41

............................................................Spark Arrester Maintenance . 42

..................................................................TRANSPORTING/STORAGE . 43

.............................................................................TROUBLESHOOTING . 45

.................................................................................WIRING DIAGRAM . 47

....................................................................................SPECIFICATIONS . 48

.................................................INSTALLATION OF OPTIONAL PARTS . 49

.................................................WARRANTY SERVICE INFORMATION . 55

......................................................................................................INDEX . 56

01/07/23 12:06:21 31ZB4800_005

SAFETY

SAFETY LABEL LOCATIONS

If a label comes off or becomes hard to read, contact your Honda

generator dealer for a replacement.

These labels warn you of potential hazards that can cause serious

injury. Read them carefully.

01/07/23 12:06:50 31ZB4800_006

01/07/23 12:07:04 31ZB4800_007

SAFETY INFORMATION

Operator Responsibility

Carbon Monoxide Hazards

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.

If you run the generator in an area that is confined, or even partially

enclosed, the air you breathe could contain a dangerous amount of

exhaust gas. To keep exhaust gas from accumulating, provide

adequate ventilation.

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles,

and connections.

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 and

odorless gas. Breathing exhaust can cause loss of consciousness

and may lead to death.

01/07/23 12:07:12 31ZB4800_008

−

Electric Shock Hazards

Fire and Burn 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 electrical components on the control panel, before each

use. Moisture or ice 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 exhaust system gets hot enough to ignite some materials.

Keep the generator at least 3 feet (1 meter) 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.

Gasoline is extremely flammable and is explosive under certain

conditions. Do not smoke or allow flames or sparks where the

generator is refueled or where gasoline is stored. Refuel in a well-

ventilated area with the engine stopped.

Fuel vapors are extremely flammable and may ignite after the

engine has started. Make sure that any spilled fuel has been wiped

up before starting the generator.

01/07/23 12:07:23 31ZB4800_009

COMPONENT IDENTIFICATION

ENGINE SWITCH

OIL FILLER CAP

OIL DRAIN PLUG

ENGINE SERIAL NUMBER

CHOKE ROD

VOLT METER PILOT LAMP

GROUND TERMINAL

AC CIRCUIT BREAKER

VOLTAGE SELECTOR SWITCH

FUEL

VALVE

LEVER

AIR

CLEANER AC

RECEPTACLES

AUTO-THROTTLE

SWITCH

DC OUTPUT

TERMINAL

DC CIRCUIT

PROTECTOR

RECOIL

STARTER

GRIP

AC CIRCUIT

PROTECTOR

01/07/23 12:07:38 31ZB4800_010

MUFFLER

FRAME SERIAL NUMBER

FUEL TANK CAP FUEL METER

SPARK PLUG

CAP

Engine serial number:

Frame serial number:

Record the engine and frame serial numbers for your future

reference. Refer to these serial numbers when ordering parts, and

when making technical or warranty inquiries (see page ).

01/07/23 12:07:47 31ZB4800_011

CONTROLS

ENGINE SWITCH

RECOIL STARTER

Key position:

OFF:

ON:

START:

ENGINE SWITCH

START

OFF

STARTER GRIP

To start and stop the engine.

To stop the engine. Key can be removed/inserted.

To run the engine after starting.

To start the engine by operating the starter motor.

Return the key to the ON position once the engine has started. Do not

use the starter for more than 5 seconds at a time. If the engine fails to

start, release the switch and wait 10 seconds before operating the

starter again.

To start the engine, pull the starter grip lightly until resistance is felt,

then pull briskly.

Do not allow the starter grip to snap back against the engine. Return it

gently to prevent damage to the starter.

01/07/23 12:08:00 31ZB4800_012

CHOKE ROD

FUEL VALVE LEVER

OPEN

CLOSED

OFF

FUEL VALVE LEVER

CHOKE ROD

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.

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. Pull the rod out toward CLOSED to enrich the mixture for

cold starting.

01/07/23 12:08:09 31ZB4800_013

CIRCUIT BREAKER

CIRCUIT PROTECTOR

GROUND TERMINAL

AC CIRCUIT BREAKER

GROUND TERMINAL

OOFFFF

OFF

AC CIRCUIT PROTECTOR

The AC circuit breaker will automatically switch OFF if there is a short

circuit or an overload of the generator at the AC 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

AC circuit before switching the AC circuit breaker ON again.

The AC circuit breaker may be used to switch the generator AC power

ON or OFF.

The circuit protectors will automatically switch OFF if there is a short

circuit or a significant overload of the generator at the 120V 20A or

120/240V 20A locking plug receptacle. If a 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 circuit protector to the ON position.

The generator ground terminal is connected 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,

electrical inspector or local agency having jurisdiction for local codes

or ordinances that apply to the intended use of the generator.

01/07/23 12:08:20 31ZB4800_014

OIL ALERT SYSTEM

Auto-throttle System

AUTO:

OFF:

AUTO

OFF

OIL FILLER HOLE

AUTO-THROTTLE

SWITCH

UPPER

LEVEL

OIL FILLER CAP

The auto-throttle system automatically reduces engine speed when all

loads are turned off or disconnected. When appliances are turned on

or reconnected, the engine returns to the rated speed.

Recommended to minimize fuel consumption and further

reduce noise levels when no load is applied to the generator.

The auto-throttle system does not operate.

Recommended to minimize warm-up time when the

generator is started.

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).

If the engine stops and will not restart, check the engine oil level (see

page ) before troubleshooting in other areas.

01/07/23 12:08:33 31ZB4800_015

VOLTAGE SELECTOR SWITCH (DUAL VOLTAGE SYSTEM)

Pilot Lamp

Volt Meter

120/240V:

120V ONLY:

120V

VOLT METER

VOLTAGE SELECTOR

SWITCH

112200224400VV

PILOT LAMP

The voltage selector 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.

The pilot lamp is illuminated when the generator is operating normally.

It indicates that the generator is producing electrical power at the 120

or 120/240 volt receptacles. If the pilot light is illuminated, the volt

meter should be displaying 120 or 240 volts depending on the position

of the voltage selector switch.

When the auto-throttle is in the AUTO position, and there is no load

connected to the generator, the engine will run slower and the pilot

light will be dimmer than at normal operating speed.

The volt meter displays the voltage the generator is producing

depending on the position of the voltage selector switch. If the voltage

selector switch is in the ‘‘120/240V’’ position, the volt meter will

display 240 volts. If the voltage selector switch is in the ‘‘120V ONLY’’

position, the volt meter will display 120 volts.

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. Rated power will

be available at the 120V twist lock receptacle.

01/07/23 12:08:42 31ZB4800_016

＋

−

DC Terminals

DC CIRCUIT PROTECTOR

DC CIRCUIT

PROTECTOR

NEGATIVE TERMINAL

(BLACK) POSITIVE TERMINAL

(RED)

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).

The DC circuit protector automatically shuts off the DC battery

charging circuit when the DC charging circuit is overloaded, when

there is a problem with the battery, or when the connections between

the battery and the generator are improper.

01/07/23 12:08:50 31ZB4800_017

GENERATOR USE

CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM

Improper connections to a building electrical system can allow

electrical 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.

GROUND SYSTEM

SPECIAL REQUIREMENTS

There may be Federal or State Occupational Safety and Health

Administration (OSHA) regulations, local codes, or ordinances that

apply to the intended use of the generator. Please consult a qualified

electrician, electrical inspector, or the local agency having jurisdiction.

Connections for standby power to a building 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.

Honda portable generators have a system ground that connects

generator frame components to the ground terminals in the AC output

receptacles. The system ground is not connected to the AC neutral

wire. If the generator is tested by a receptacle tester, it will not show

the same ground circuit condition as for a home receptacle.

If the generator is used at a construction site, there may be

additional regulations which must be observed.

In some areas, generators are required to be registered with local

utility companies.

01/07/23 12:08:58 31ZB4800_018

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 if the rated

load capacity of the generator has been exceeded.

Make sure that the electrical rating of the tool or appliance does not

exceed that of the generator. Never exceed the 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:

For continuous operation, do not exceed the rated power.

Rated power is:

The total power requirements (VA) of all appliances connected must

be considered. Appliance and power tool manufacturers usually list

rating information near the model number or serial number.

3.5 kVA

3.0 kVA

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 OFF, but will shorten the

service life of the generator.

01/07/23 12:09:08 31ZB4800_019

AC OPERATION

VOLTAGE SELECTOR

SWITCH AC CIRCUIT

BREAKER

Start the engine (see page ).

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, but require more power from the 120V

locking plug receptacle, then select the ‘‘120V ONLY’’ position.

Switch ON the AC circuit breaker.

Plug in the appliance.

Most motorized appliances require

more than their rated wattage for

startup.

Do not exceed the current limit specified for any one receptacle. If an

overloaded circuit causes the AC circuit breaker to switch OFF, reduce

the electrical load on the circuit, wait a few minutes and then reset the

AC circuit breaker.

01/07/23 12:09:18 31ZB4800_020

＋

AC RECEPTACLE SELECTION

Main power circuit

Main Circuit I

Main Circuit II

Receptacles powered

by each main circuit Power distribution

120V 30A

120V 20A

120/240V 20A

(LOCKING PLUG)

The generator has two separate main power producing circuits.

These two circuits supply equal power to different receptacles

shown when the voltage selector switch is in the 120/240V

position.

When two or more receptacles are used; prevent overloading 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.

The total rated ampere draw is 25.0A.

The table shows the specifications when the 120/240V locking

plug receptacle is used for 120V.

2and3

2 4=12.5A max.

1=12.5A max.

Example:

Receptacle 2 has a 10A load connected to it. Receptacle 3 has a 10

A load connected to it. Both receptacles are powered by main

power circuit I. The equation tells us that the total power draw on

circuit I is 20A. This is a substantial overload of this circuit. To

eliminate the excess power draw on circuit I, the load from

receptacle 2 should be switched to receptacle 1. Now circuit I is

powering the 10A load (less than 12.5A) and circuit II is powering

the 10A load (less than 12.5A).

01/07/23 12:09:27 31ZB4800_021

−

＋＋

＋

−−

−

DC OPERATION

Connecting the battery cables:

The battery gives off explosive gases; keep sparks, flames and

cigarettes away. Provide adequate ventilation when charging or

using batteries.

Wash hands after handling.

DC CIRCUIT

PROTECTOR

POSITIVE TERMINAL

(RED)

NEGATIVE TERMINAL

(BLACK)

The DC terminals may ONLY be used for charging 12 volt automotive

type batteries.

Before connecting the battery charging cable to a battery that is

installed in a vehicle, disconnect the vehicle ground battery cable

from the battery negative ( ) terminal.

Connect the positive ( ) battery cable to the battery positive ( )

terminal.

Connect the other end of the positive ( ) battery cable to the

generator positive ( ) terminal.

Battery posts, terminals and related accessories contain lead and

lead compounds.

Start the generator.

Connect the negative ( ) battery cable to the battery negative ( )

terminal.

Connect the other end of the negative ( ) battery cable to the

generator negative ( ) terminal.

Do not start the vehicle while the battery charging cable is connected

and the generator is running. The vehicle or the generator may be

damaged.

01/07/23 12:09:38 31ZB4800_022

−

＋

−

Disconnecting the battery cables:

DC CIRCUIT

PROTECTOR

NEGATIVE TERMINAL

(BLACK) POSITIVE TERMINAL

(RED)

Reconnect the vehicle grounded battery cable.

Connect the vehicle ground battery cable to the battery negative ( )

terminal.

Disconnect the positive ( ) battery cable from the generator

positive ( ) terminal.

Disconnect the other end of the positive ( ) battery cable from the

battery positive ( ) terminal.

Disconnect the negative ( ) battery cable from the generator

negative ( ) terminal.

Disconnect the other end of the negative ( ) battery cable from the

battery negative ( ) terminal.

Stop the engine.

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 circuit protector continues to go

OFF, discontinue charging and see your authorized Honda generator

dealer.

01/07/23 12:09:47 31ZB4800_023

Auto-throttle System

OFF

AUTO-THROTTLE

SWITCH

AUTO

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. Turn the auto-throttle to the OFF position to operate

loads of less than 1 amp.

Appliances with large start-up power demands may not allow the

engine to reach normal operating rpm when they are connected to the

generator. Turn the auto-throttle to the OFF position and connect the

appliance to the generator. If the engine still will not reach normal

operating speed, check that the appliance does not exceed the rated

load capacity of the generator.

To avoid extended warm-up periods, keep the switch OFF until the

engine reaches operating temperature.

The auto-throttle 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 auto-throttle switch should be in the OFF

position.

01/07/23 12:09:56 31ZB4800_024

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. If you always operate your generator at altitudes

above 5,000 feet (1,500 meters), have your servicing dealer 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 ef-

fect of altitude on horsepower will be greater than this if no carburetor

modification is made.

When the carburetor has been modified for high altitude operation,

the air-fuel mixture will be too lean for low altitude use. Operation at

altitudes below 5,000 feet (1,500 meters) with a modified carburetor

may cause the engine to overheat and result in serious engine damage.

For use at low altitudes, have your servicing dealer return the

carburetor to original factory specifications.

01/07/23 12:10:02 31ZB4800_025

PRE-OPERATION CHECK

ENGINE OIL

OIL FILLER HOLE

OIL FILLER CAP

UPPER LEVEL

AMBIENT TEMPERTURE

SAE Viscosity Grades

Engine oil is a major factor affecting engine performance and service

life. Non detergent and 2-stroke engine oils will damage the engine

and are not recommended.

ChecktheoillevelBEFORE

EACH USE with the generator on

a level surface and the engine

stopped.

SAE 10W-30 is recommended for general, all-temperature use. Other

viscosities shown in the chart may be used when the average

temperature in your area is within the indicated range.

Remove the oil filler cap and wipe the dipstick clean.

Check the oil level by inserting the dipstick into the filler neck

without screwing it in.

If the level is low, fill to the top of the oil filler neck with the

recommended oil.

Use 4-stroke motor oil that

meets or exceeds the require-

ments for API service classifi-

cation SJ. Always check the API

SERVICE label on the oil contain-

er to be sure it includes the let-

ters SJ.

01/07/23 12:10:14 31ZB4800_026

Gasoline is extremely flammable and is explosive under certain

conditions.

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.

Do not overfill the fuel tank (there should be no fuel in the filler

neck). After refueling, make sure the tank cap is closed properly and

securely.

Fuel tank capacity:

Avoid repeated or prolonged contact with skin or breathing of

vapor.

KEEP OUT OF REACH OF CHILDREN.

Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor

may ignite. If any fuel is spilled, make sure the area is dry before

starting the engine.

FUEL RECOMMENDATION

FUEL STRAINERFUEL TANK CAP

FUEL LEVEL GAUGE

Check the fuel level gauge.

Refill the tank if the fuel level is low. Do not fill above the shoulder of

the fuel strainer.

Never use stale or contaminated gasoline or an oil/gasoline mixture.

Avoid getting dirt or water in the fuel tank.

Use unleaded gasoline with a pump octane rating of 86 or higher.

This engine is certified to operate on unleaded gasoline.

Unleaded gasoline produces fewer engine and spark plug deposits

and extends exhaust system life.

4.49 US gal (17.0 , 3.74 Imp gal)

01/07/23 12:10:28 31ZB4800_027

Occasionally you may hear a 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.

Running the engine with persistent spark knock or pinging can cause

engine damage.

Running the engine with persistent spark knock or pinging is misuse,

and the

Distributor’s Limited Warranty

does not cover parts damaged

by misuse.

01/07/23 12:10:34 31ZB4800_028

Oxygenated Fuels

ETHANOL

MTBE

METHANOL

Some conventional gasolines are being blended with alcohol or an

ether compound. These gasolines are collectively referred to as

oxygenated fuels. To meet clean air standards, some areas of the

United States and Canada use oxygenated fuels to help reduce

emissions.

If you use an oxygenated fuel, be sure it is unleaded and meets the

minimum octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents.

Some states/provinces require this information to be posted on the

pump.

The following are the EPA approved percentages of oxygenates:

(methyl or wood alcohol) 5% by volume

Youmayusegasolinecontainingupto5%

methanol by volume as long as it also contains

cosolvents and corrosion inhibitors to protect the

fuel system. Gasoline containing more than 5%

methanol by volume may cause starting and/or

performance problems. It may also damage metal,

rubber, and plastic parts of your fuel system.

If you notice any undesirable operating symptoms, try another service

station or switch to another brand of gasoline.

Fuel system damage or performance problems resulting from the use

of an oxygenated fuel containing more than the percentages of

oxygenates mentioned above are not covered under warranty.

(methyl tertiary butyl ether) 15% by volume

You may use gasoline containing up to 15% MTBE

by volume.

(ethyl or grain alcohol) 10% by volume

You may use gasoline containing up to 10% ethanol

by volume. Gasoline containing ethanol may be

marketed under the name ‘‘Gasohol’’.

01/07/23 12:10:44 31ZB4800_029

STARTING THE ENGINE

Make sure that the AC circuit breaker is in the OFF position. The

generator may be hard to start if a load is connected.

Do not allow the starter grip to snap back against the engine. Return it

gently to prevent damage to the starter or housing.

The automatic choke will be closed if the engine is cold. If you want

to operate the choke manually, pull the choke rod out to the CLOSED

position.

Make sure the auto-throttle switch is in the OFF position, or more

time will be required for warm up.

Turn the engine switch to the ON position.

Pull the starter grip lightly until resistance is felt, then pull briskly.

With electric starter:

Connect the battery cables to the generator. (page )

Turn the engine switch to the START position and hold it there for 5

seconds or until the engine starts.

When the engine starts, allow the engine switch to return to the ON

position.

If you have manually closed the choke, push it to the OPEN position

as the engine warms up.

If you wish to use the auto-throttle system, turn the auto-throttle

switch to the AUTO position after the engine has warmed up for 2

or 3 minutes.

Turn the fuel valve lever to the ON position.

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.

If the speed of the starter motor drops after a period of time, it is an

indication that the battery should be recharged.

(Optional kit) 53

01/07/23 12:10:59 31ZB4800_030

STOPPING THE ENGINE

In normal use:

In an emergency:

To stop the engine in an emergency, move the engine switch to the

OFF position.

Disconnect DC battery charging cables.

Turn the AC circuit breaker to the OFF position.

Turn the engine switch to the OFF position.

Turn the fuel valve lever to the OFF position.

01/07/23 12:11:06 31ZB4800_031

MAINTENANCE

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement, or repair of the emission control devices

and systems may be performed by any engine repair establishment

or individual, using parts that are ‘‘certified’’ to EPA standards.

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.

Good maintenance is essential for safe, economical, and trouble-free

operation. It will also help reduce air pollution.

The maintenance schedule applies to normal operating conditions. If

you operate your generator under severe conditions, such as

sustained high-load or high-temperature operation, or use it in

unusually wet or dusty conditions, consult your servicing dealer for

recommendations applicable to your individual needs and use.

To help you properly care for your generator, the following pages

include a maintenance schedule, routine inspection procedures, and

simple maintenance procedures using basic hand tools. Other service

tasks that are more difficult, or require special tools, are best handled

by professionals and are normally performed by a Honda technician

or other qualified mechanic.

01/07/23 12:11:14 31ZB4800_032

−

MAINTENANCE SAFETY

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.

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

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.

Read the instructions before you begin, and make sure you have the

tools and skills required.

To reduce the possibility of fire or explosion, be careful when

working around gasoline. Use only a nonflammable solvent, not

gasoline, to clean parts. Keep cigarettes, sparks, and flames away

from all fuel-related parts.

Remember that your servicing dealer knows your generator best and

is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, genuine

Honda parts or their equivalents for repair or replacement.

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.

01/07/23 12:11:25 31ZB4800_033

EMISSION CONTROL SYSTEM INFORMATION

Source of Emissions

The U.S. and California Clean Air Acts

Tampering and Altering

The combustion process produces carbon monoxide, oxides of

nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of

nitrogen is 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.

Honda utilizes lean carburetor settings and other systems to reduce

the emissions of carbon monoxide, oxides of nitrogen, and

hydrocarbons.

Tampering with or altering the emission control system may increase

emissions beyond the legal limit. Among those acts that constitute

tampering are:

EPA and California regulations require all manufacturers to furnish

written instructions describing the operation and maintenance of emis-

sion control systems.

The following instructions and procedures must be followed in order

to keep the emissions from your Honda engine within the emission

standards.

Removal or alteration of any part of the intake, fuel, or exhaust

systems.

Altering or defeating the governor linkage or speed-adjusting

mechanism to cause the engine to operate outside its design

parameters.

01/07/23 12:11:34 31ZB4800_034

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.

01/07/23 12:11:38 31ZB4800_035

Replacement Parts

Maintenance

Follow the maintenance schedule on page . Remember that this

schedule is based on the assumption that your machine will be used

for its designed purpose. Sustained high-load or high-temperature

operation, or use in unusually wet or dusty conditions, will require

more frequent service.

The emission control systems on your Honda engine were designed,

built, and certified to conform with EPA and California emission

regulations. We recommend the use of genuine Honda parts

whenever you have maintenance done. These original-design

replacement 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

manufacturer or rebuilder of the part must certify that use of the part

will not result in a failure of the engine to comply with emission

regulations.

01/07/23 12:11:43 31ZB4800_036

−

AIR INDEX

An Air Index Information hang tag/label was applied to this engine 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.

The 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 control

system. See your

Emission Control Warranty

for additional

information.

The Air Index Information hang tag must remain on the generator until

it is sold. Remove the hang tag before operating the generator.

300 hours (0 65 cc)

500 hours (greater than 65 cc)

125 hours (0 65 cc)

250 hours (greater than 65 cc)

50 hours (0 65 cc)

125 hours (greater than 65 cc)

Extended

Intermediate

Moderate

Applicable to Emissions Durability PeriodDescriptive Term

01/07/23 12:11:54 31ZB4800_037

MAINTENANCE SCHEDULE

ITEM Before

each

use

First

month

20 Hrs.

Every

3 months

50 Hrs.

(1)

Performed at every indicated

month or operating hour inter-

val, whichever comes first.

REGULAR SERVICE PERIOD (3) Every

year

300 Hrs.

(2)

Every

6 months

100 Hrs.

(2)

Engine oil

Air cleaner

Sediment Cup

Spark pulg

Spark arrester

Idle speed

Valve clearance

Combustion

chamber

Fuel tank and filter

Fuel tube

Check

Change

Check

Clean

Clean-Adjust

Replace

Clean

Clean-Adjust

Check-Adjust

Clean

Check

Emission related items.

Service more frequently when used in dusty areas.

These items should be serviced by an authorized Honda generator dealer, unless the owner

has the proper tools and is mechanically proficient. See the Honda Shop Manual.

For commercial use, log hours of operation to determine proper maintenance intervals.

After every 500 Hrs. (2)

Every 2 years (Replace if necessary) (2)

(1)

(2)

(3)

01/07/23 12:12:09 31ZB4800_038

ENGINE OIL CHANGE

Oil capacity:

OIL DRAIN PLUG UPPER LEVEL

Drain the oil while the engine is warm to assure rapid and complete

draining.

Remove the drain plug and sealing washer, remove the oil filler cap,

and drain the oil.

Reinstall the drain plug and sealing washer. Tighten the plug

securely.

Refill with the recommended oil (see page ) and check the oil

level.

Wash your hands with soap and water after handling used oil.

Please dispose of used motor oil and containers in a manner that is

compatible with the environment. We suggest you take it in a sealed

container to your local service station or recycling center for

reclamation. Do not throw it in the trash, pour it on the ground or

down a drain.

1.2 US qt (1.1 , 1.0 Imp qt)

3. 25

01/07/23 12:12:21 31ZB4800_039

AIR CLEANER SERVICE

AIR CLEANER COVER CLIP

CLIP

AIR CLEANER ELEMENT

ELEMENT

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.

Never run the generator without the air filter. Rapid engine wear will

result.

Unsnap the air cleaner cover clips,

remove the air cleaner cover, and

remove the element.

Wash the air filter in a solution of

household detergent and warm

water, then rinse thoroughly, or

wash in nonflammable or high

flashpoint solvent. Allow the air

filter to dry thoroughly.

Soak the air filter in clean engine

oil and squeeze out the excess oil.

The engine will smoke during

initial startup if too much oil is left

in the air filter.

Reinstall the air cleaner element

and the cover.

01/07/23 12:12:35 31ZB4800_040

FUEL SEDIMENT CUP CLEANING

SEDIMENT CUP

O-RING

SEDIMENT CUP

FUEL FILTER

OFF

FUEL VALVE LEVER

The sediment cup prevents dirt or water which 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.

Clean the sediment cup, O-ring, and filter in nonflammable or high

flash point solvent.

Turn the fuel valve lever to the OFF position. Remove the sediment

cup, O-ring, and filter.

Reinstall the filter, O-ring, and sediment cup.

Turn the fuel valve lever ON and check for leaks.

01/07/23 12:12:46 31ZB4800_041

−−

SPARK PLUG SERVICE

The gap should be:

Recommended spark plugs:

PLUG WRENCH

PLUG CAP

0.028 0.031 in (0.70 0.80 mm)

Measure the plug gap with a feeler gauge.

Correct as necessary by carefully bending the side electrode.

Visually inspect the spark plug. Discard it if the insulator is cracked

or chipped. Clean the spark plug with a wire brush if it is to be

reused.

0.028 0.031 in (0.70 0.80 mm)

In order to service the spark plug, you will need a spark plug wrench

(commercially available).

Use a spark plug wrench to remove the spark plug.

Remove the spark plug cap.

Clean any dirt from around the spark plug base.

If the engine has been running, the muffler will be very hot. Be careful

not to touch the muffler.

To ensure proper engine operation, the spark plug must be properly

gapped and free of deposits.

W16EPR-U (DENSO)

BPR5ES (NGK)

01/07/23 12:12:58 31ZB4800_042

−

SPARK ARRESTER MAINTENANCE

SPARK ARRESTER

SCREEN

SPARK ARRESTER

Check that the spark plug washer is in good condition, and thread

the spark plug in by hand to prevent cross-threading.

Afterthesparkplugisseated,tightenwithasparkplugwrenchto

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.

Never use spark plugs which have an improper heat range. Use only

the recommended spark plugs or equivalent.

The spark plug must be securely tightened. An improperly tightened

spark plug can become very hot and could damage the engine.

If the generator has been running, the muffler will be very hot. Allow it

to cool before proceeding.

Use a brush to remove carbon deposits from the spark arrester

screen.

Inspect the screen for breaks or tears and replace it if necessary.

Install the spark arrester in the reverse order of removal.

Clean the spark arrester as follows:

Loosen the screw by the exhaust port of the muffler and remove the

spark arrester.

The spark arrester must be serviced every 100 hours to maintain its

efficiency.

01/07/23 12:13:13 31ZB4800_043

＊

TRANSPORTING/STORAGE

Contact with a hot engine or exhaust system can cause serious burns

or fires. Let the engine cool before transporting or storing the

generator.

STORAGE TIME

When transporting the generator, turn the engine switch OFF and keep

the generator level to prevent fuel spillage. Fuel vapor or spilled fuel

may ignite.

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. Be sure the storage area is free of excessive humidity and dust.

2. Service according to the table below:

Less than 1 month

1 to 2 months

2 months to 1 year

1 year or more

Use gasoline conditioners that are formulated to extend storage

life.

Contact your authorized Honda generator dealer for conditioner

recommendations.

RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

No preparation required

Fill with fresh gasoline and add gasoline

conditioner .

Fill with fresh gasoline and add gasoline

conditioner .

Drain the carburetor float bowl. (page 44 ).

Drain the fuel sediment cup. (page 40 ).

Fill with fresh gasoline and add gasoline

conditioner .

Drain the carburetor float bowl. (page 44 ).

Drain the fuel sediment cup. (page 40 ).

Remove the spark plug. Put a tablespoon of

engine oil into the cylinder. Turn the engine

slowly with the pull rope to distribute the oil.

Reinstall the spark plug.

Change the engine oil. (page 38 ).

After removal from storage, drain the stored

gasoline into a suitable container, and fill

with fresh gasoline before starting.

01/07/23 12:13:21 31ZB4800_044

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.

DRAIN SCREW

Align the notch on the starter pulley

with the hole at the top of recoil starter.

Drain the carburetor by loosening the drain screw. Drain the

gasoline into a suitable container.

Change the engine oil. (page )

Remove the spark plug, and pour about a tablespoon of clean

engine oil into the cylinder. Crank the engine several revolutions to

distribute the oil, then 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.

01/07/23 12:13:32 31ZB4800_045

TROUBLESHOOTING

Be sure there is no

spilled fuel around the

spark plug. Spilled fuel

may ignite.

DRAIN SCREW

Is there fuel in the

tank?

Is there enough oil

in the engine?

Isthereaspark

from the spark

plug?

When the engine will not start:

Is the fuel reaching

the carburetor?

If the engine still

does not start, take

the generator to an

authorized Honda

generator dealer.

Replace the

spark plug.

Refill the fuel tank.

Add the recom-

mended oil.

Take the generator

to an authorized

Honda generator

dealer.

Remove the spark

plug cap and clean

any dirt from around

the spark plug.

Remove the spark

plug and install the

sparkpluginthe

plug cap.

Set the plug side

electrode on the

cylinder head.

Crank the engine,

sparks should jump

across the gap. Clean the fuel

sediment cup.

Turn off the engine

switch and loosen

the drain screw.

Turn the fuel valve to

ON. Fuel should flow

from the drain when

the fuel valve is

turned ON.

To check:

YES

Still NO spark

01/07/23 12:13:45 31ZB4800_046

Is the AC circuit breaker

ON.

Check the electrical ap-

pliance or equipment for

any defects.

Turn the AC circuit breaker

ON.

Take the generator to an

authorized Honda generator

dealer.

Replace the electrical ap-

pliance or equipment.

Take the electrical ap-

pliance or equipment to an

electrical shop for repair.

No electricity at the AC receptacles:

YES

DEFECTS

NO DEFECTS

01/07/23 12:13:50 31ZB4800_047

WIRING DIAGRAM

01/07/23 12:14:07 31ZB4800_048

〔〕 ××

−−

SPECIFICATIONS

Dimensions

Engine

Generator

ITEM SPECIFICATION MAINTENANCE

Tune-up Specifications

Model

Power product description code

Length

Width

Height

Dry weight

Model

Engine type

Displacement

BorexStroke

Compression ratio

Engine speed

Cooling system

Ignition system

Oil capacity

Fuel tank capacity

Spark plug

Model

Type Rated voltage

Rated frequency

AC output Rated ampere

Rated output

Maximum output

DC output

EA6

GX240K1

[2.9 2.3 in (73 58 mm)]

8.2 : 1

3,600 r.p.m.

Forced air

Transistorized magneto

BPR5ES (NGK)

W16EPR-U (DENSO)

120/240 V

60 Hz

25/12.5 A

3.0 kVA

3.5 kVA

23.8 in (605 mm)

19.5 in (495 mm)

19.1 in (485 mm)

143.3 lbs (65.0 kg)

14.8 cu-in (242 cm )

1.2 US qt (1.1 , 1.0 Imp qt)

4.49 US gal (17.0 , 3.74 Imp gal)

Spark plug gap

Valve clearance

Other specifications No other adjustments needed.

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

Refer to page: 41

See your authorized

Honda dealer

EM3500SX

Specifications may vary according to the types, and are subject to

change without notice.

0.028 0.031 in (0.70 0.80 mm)

Only for charging 12V automotive batteries.

Maximum charging output = 8.3A

4-stroke, overhead valve, single cylinder

01/07/23 12:14:23 31ZB4800_049

INSTALLATION OF OPTIONAL PARTS

Remote Control Kit

REMOTE CONTROL

CABLE

RELAY BOX

REMOTE CONTROL

BOX

Install the relay box on the right side of the generator.

Remove the blind 8 P connector from the back of the control box

and connect the relay box connector instead.

Connect the remote control cable to the remote control and relay

box.

Connect the blind connector when not using the remote control.

Engine will not start unless the blind connector is connected.

01/07/23 12:14:32 31ZB4800_050

Remote Control Box

PILOT LAMP ENGINE

SWITCH STARTER

BUTTON

RELAY BOX

Starting the engine with remote control

Turn the fuel valve to the ON position.

Turn the auto-throttle switch to the OFF position.

Turn off the engine switch at the generator and remove the key.

Turn the relay box switch to the ON position.

01/07/23 12:14:41 31ZB4800_051

Turn the engine switch at the remote control box to the ON position.

Press the starter button untill the pilot lamp comes on.

Stopping the engine

Turn the engine switch at the remote control box to the OFF position.

Turn the relay box switch to the OFF position.

Turn the fuel valve to the OFF position.

01/07/23 12:14:45 31ZB4800_052

4 Wheel Kit Installation

Inside

WHEEL STOPPER

Shorter

end

Longer

end

Install the four wheels on the axle shaft.

Install the axle assembly on the generator using two bolts and nuts.

Install the shaft with wheel stopper facing engine side.

01/07/23 12:14:58 31ZB4800_053

＋

−

BATTERY TRAY KIT

Install the battery guard on the frame.

Set the battery tray on the battery guard and tighten the bolts.

Route the starter cable under the tank and connect it to the starter

solenoid.

Connect the ground cable to the generator rear housing.

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. When disconnecting, disconnect

at the battery negative ( ) terminal first.

Install the battery guard plate on the battery guard.

01/07/23 12:15:02 31ZB4800_054

BATTERY

TRAY

BATTERY

GUARD PLATE

STARTER CABLE

(positive)

BATTERY GUARD

BATTERY

BRACKET

BATTERY

GUARD

STARTER

SOLENOID

BATTERY

Use a battery rated at

12V-18-35AH or more

GROUND CABLE

01/07/23 12:15:13 31ZB4800_055

WARRANTY SERVICE INFORMATION

Servicing 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.

If you are dissatisfied 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 Relations Office

4900 Marconi Drive

Alpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

When you write or call, please give us this information:

Model and serial number (see pages and )

Name of dealer who sold the generator to you

Name and address of dealer who services your generator

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

910

01/07/23 12:15:21 31ZB4800_056

INDEX