Thank you for purchasing a Honda generator.

We want to help you get the

best results from your new generator and to operate it safely. This manual
contains the information on how to do that; please read it carefully.
This owner’s manual describes the operation and maintenance of the
EM5000SXKl Honda Generator. All information in this publication is based
on the latest product information available at the time of printing. Honda
Motor Co., Ltd. reserves the right to make changes at any time without notice
and without incurring any obligation. No part of this publication may be
reproduced without written permission.
This manual should be considered a permanent part of the generator and
should remain with it if it is resold.
Safety Messages
Your safety and the safety of others is very important. We have provided
important safety messages in this manual and on the generator. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you or
others. Each safety message is preceded by a safety alert symbol Lfi and
one of three words: DANGER, WARNING, or CAUTION.
These mean
m! D ’ You WILL be KILLED or SERIOUSLY HURT if you don’t
follow instructions.
m! L - You CAN be KILLED or SERIOUSLY HURT if you don’t
follow instructions.

r 9. * a You CAN be HURT if you don’t follow instructions.

Each message tells you what the hazard is, what can happen, and what you
can do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
-1 Your generator or other property could be damaged if
you don’t follow instructions.
The purpose of these messages is to help prevent damage to your generator,
other property, or the environment.
1
CONTENTS
SAFETY ...................................................................................... 4
Safety Label Locations ............................................................ 4
Safety Information .................................................................. 6
COMPONENT IDENTIFICATION .............................................. 8

CONTROLS ............................................................................... 10
Engine Switch ...................................................................... 10
Recoil Starter ........................................................................ 10
Fuel Valve ............................................................................ 11
Choke Rod ............................................................................ 11
Circuit Breaker ...................................................................... 12
Grond Terminal ...................................................................... 12
Oil Alert System .................................................................... 12
Auto-throttle System .............................................................. 13
Volt Meter .............................................................................. 14
Pilot Lamp .............................................................................. 14
Voltage Selector Switch (Dual voltage System) .................... 14
DC Terminals ........................................................................ 15
DC Circuit Protector .............................................................. 15
GENERATOR USE.. .................................................................. 16
Connections to a Building’s Electrical System ...................... 16
Generator Ground Circuit ...................................................... 16
AC Applications.. .................................................................... 17
AC Operation ........................................................................ 18
AC Receptacle Selection ...................................................... 19
DC Operation ...................................................................... 20
Disconnecting the battery cables ........................................ 21
Auto-throttle System .............................................................. 22
High Altitude Operation .......................................................... 23
PREOPERATION CHECK ...................................................... 24
Engine Oil ............................................................................ 25
Fuel Recommendation ........................................................ 25
STARTING THE ENGINE.. ...................................................... 27
STOPPING THE ENGINE ...................................................... 28

2
MAINTENANCE ........................................................................ 29
Maintenance Schedule .......................................................... 29
Tool Kit .................................................................................. 30
Engine Oil Change ................................................................ 31
Air Cleaner Service ................................................................ 32
Fuel Sediment Cup ................................................................ 33
Spark Plug ............................................................................ 34
Spark Arrester Maintenance ................................................... 35
TRANSPORTING/STORAGE .................................................. 36
TROUBLESHOOTING ............................................................ 38
WIRING DIAGRAM.. .................................................................. 40
SPECIFICATIONS .................................................................. 41
INSTALLATION OF OPTIONAL PARTS ................................ 42
WARRANTY SERVICE.. .......................................................... 48
INDEX ...................................................................................... 49

3
SAFETY
SAFETY LABEL LOCATION
These labels warn you of potential hazards that can cause serious injury.
Read them carefully.

If a label comes off or becomes hard to read, contact your Honda Generator
dealer for a replacement.
lCHfCK fOR SPIlltO fllfl ORflJf1 LfAKS. l
STOPtW6INL BEDIRtRtWLlNG.
lCONlR6lfR NI’IL NY A NI Wt PI WINCE
RiPANDUfSURL’APPARtlL.
ARRhR Lt HOTtURAVANIDt RtlAlRt It PLtlN.
IINSPKiCIONARPARACOMRUSTIRlt OfRRAMADO
(@ 0 ESCAPE.
PARARYOIORANKS Ot fCHAR.
0
/

WARNING DONOT!JSEINDOORS.EXHAUSTGASCONTAINSPOISONOUS
CARBONMONOXIDE.
ATTENTION NE PAS”UTILISEROANSUN ENDROIT
FERMEA CAUSEDU
RISOUED’EMPOISONNEMENT
DUGAZ.
ATENCl()N NOLO.USE’ENLUGARESCERRADOS’POROUE
EL MONOXIDE
DE CARBON0ES VENENOSO.
II CAUTION
n BE SUR~fb?ILL
WITH RECOMMENDED
BEFORE USING~
..---
_.-----.- -.---
CRANKCASE
OIL
~‘EXPLANATI~~U.
FOR DETAILEO -___ -_ _______-..I
II
ITOR CO.. LTD.

~-- ~-~
11 VOLTAGE
FREQUENCY
I/RATED
AC
OUTPUT
MAX. OUTPUT
60Hz
4.5kVA
II
MADE IN JAPAN @i

5.OkVA II -..-.
DC
CURRENT
120/24OV 11VOLTAGE 12v
ARA

-_--_ ___-
SEE THE OWNER’S MANUAL 10/[ FUEL “;=J&~;j
PHAsE

5
 SAFETY INFORMATION
Honda generators are designed to give safe and dependable service if
operated according to instructions. Read and understand this owner’s
manual before operating your generator. You can help prevent accidents by
being familiar with your generator’s controls, and by observing safe operating
procedures
Operator Responsibility
. Know how to stop the generator quickly in case of emergency.
l Understand the use of all generator controls, output receptacles, and
connections.
l Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without parental
supervision.
Carbon Monoxide Hazards
l Exhaust contains poisonous carbon monoxide, a colorless and odorless
gas. Breathing exhaust can cause loss of consciousness and may lead
to death.
l 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 building up, provide adequate
ventilation.
Electric Shock Hazards
l The generator produces enough electric power to cause a serious shock
or electrocution if misused.
l 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.
l 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.
l Do not connect to a building’s electrical system unless an isolation switch
has been installed by a qualified electrician.

6
Fire and Burn Hazards
l The exhaust system gets hot enough to ignite some materials.
- Keep the generator at least 1 meter (3 feet) away from buildings and
other equipment during operation.
- Do not enclose the generator in any structure.
- Keep flammable materials away from the generator.
l 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.
l 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.
l 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.

7
 COMPONENT IDENTIFICATION

VOLT METER

ENGINE SWITCH

CHOKE ROD
RCUlT BREAKER

UN0 TERMINAL

ENGINE SERIAL NUMBER

8
 FUEL TANK CAP FUEL METER

-SPARK PLUG
CAP

SERIAL NUMBER

MUFFLER

l 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 47)
Frame serial number:
Engine serial number:

9
CONTROLS
Engine Switch
To start and stop the engine.
Key position:
OFF: To Stop the engine. Key can be removed/inserted.
ON: To run the engine after starting.
START: To start the engine by turning the starter motor.

ENGINE

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.

Recoil Starter
To start the engine, pull the starter grip lightly until resistance is felt, then pull
briskly.
[I Do not allow the starter to snap back against the engine.
Return it gently to prevent damage to the starter.

IO
Fuel Valve
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 lever to OFF after stopping the engine.

Choke Rod
The choke is used to provide proper starting mixture when the engine is cold.
It can be opened and closed by operating the choke rod manually. Pull the
rod out toward CLOSED to enrich the mixture.

11
Circuit Breaker
The circuit breaker will automatically switch OFF if there is a short circuit or
a significant overload of the generator at the receptacle. If the circuit breaker
is switched OFF automatically, check that the applicance is working properly
and does not exceed the rated load capacity of the circuit before switching
the circuit breaker ON again.
The circuit breaker may be used to switch the generator power on or off.

Ground Terminal
The gernerator ground terminal is connected to the frame of the generater,
the metal non-current carrying parts of the generator, and the ground
terminals of each receptacle.

AC CIRCUIT BREAKER

GROUND TERMINAL
Oil Alert System
The Oil Alert system is designed to prevent engine damage caused by an
insufficient amount of oil in the crankcase. Before the oil level in the
crankcase can fall below a safe limit, the Oil Alert system will automatically
shut down the engine (the engine switch will remain in the ON position). If the
Oil Alert system shuts down the engine, the Oil Alert lamp will flash when you
operate the starter, and the engine will not start. If this occurs, add engine oil
(P-24).

12
Auto-throttle System
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.
AUTO: Recommended to minimize fuel consumption and
further reduce noise levels when no load is applied to
the generator.
OFF: The auto-throttle system does not operate.

SWITCH

13
Pilot Lamp
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.

Volt Meter
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 “120/240 V” position, the volt meter will display 240 volts. If the voltage
selector switch is in the “120 V ONLY” position, the volt meter will display 120
volts.

Voltage Selector Switch (Dual voltage System)

The voltage selector switches the main power carrying windings of the
generator to produce “12OV ONLY” or “120/24OV”. If a 240V appliance is
connected to the 4-prong receptacle, the switch must be in the “120/24OV”
position. If a 120V appliance ONLY is being connected to any of the 120V
3-prong receptacles, select the “120V ONLY” position.
120/24OV: The 12OV and 120/24OV receptacles can be used
simultaneously.
12OV ONLY: ONLY the 12OV receptacles can be used. Do not use
the 120/24OV receptacle in this position. Rated power
will be available at the 12OV twist lock receptacle.
PILOT VOLTAGE SELECTOR
LAF(P
SWIT/CH

VOLT METER

14
DC Terminals
The DC terminals may ONLY be used for charging 12 volt automotive type
batteries.
The terminals are colored red to identify the positive (+) terminal and black
to identify the negative (-) terminal. The battery must be connected to the
generator DC terminals with the proper polarity (battery positive to generator
red terminal and battery negative to the generator black terminal).

DC Circuit Protector
The DC circuit protector automatically shuts off the DC battery charging
circuit when the generator is overloaded, when there is a problem with the
battery or the connections between the battery and the generator are
improper.

DC CIR
PROTE

NEGATliE TiRMINAL POSlilVE TERMINAL

(BLACK) (RED)

15
GENERATOR USE
Connections to a Building’s Electrical System
Connections for standby power to a building’s electrical system must be
made by a qualified electrician. The connection must isolate the generator
power from utility power, and must comply with all applicable laws and
electrical codes.
m! Improper connections to a building’s electrical system
can ailbw 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. Consult the
utility company or a qualified electrician
CAUTION: Improper connections to a building’s electrical system can
allow electrical current from the utility company to backfeed into the
generator. When utility power is restored, the generator may explode,
burn, or cause fires in the building’s electrical system.

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

utility companies. Check local regulations for proper registration and use
procedures.

Generator Ground Circuits

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.

Local regulations, codes or laws may require that the ground system be
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 local regulations, codes, or laws require the system ground to be connected

to the AC neutral wire, consult a qualified electrician or electrical inspector.
Provide him with the electrical wiring diagram in this manual.

The ground terminal can be used to earth the generator or bond the frame
of the generator to the frame of a vehicle, but only if it is required by local law
or electrical code. Before using the ground terminal consult a qualified
electrician or electrical inspector for regulations in your area.

16
AC Applications
Before connecting an appliance or power cord to the generator:
l Make sure that it is in good working order. Faulty appliances or power
cords can create a potential for electrical shock.
l If an appliance begins to operate abnormally, becomes sluggish or stops
suddenly, turn it off immediately. Disconnect the applicance, and determine
whether the problem is the appliance, or if the rated load capacity of the
generator has been exceeded.
l 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.

1-1 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.
Limit operation requiring maximum power to 30 minutes.
Maximum power is:
5.0 KVA
For continuous operation, do not exceed the rated power.
Rated power is:
4.5 KVA
In either case, the totafpower 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.

17
 AC Operation
1. Start the engine (refer to page 27).
2. Turn the voltage selector switch to either position.
With the voltage selector switch in the “120/240V”position, you can use the
120V and 120/24OV receptacles simultaneously. If you are NOT using the
120/24OV receptacle, but require more power from the 12OV twist lock
receptacle, then select the “12OV
ONLY” position.
3. Switch ON the AC circuit
breaker.
4. 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 or circuit protector to switch
OFF, reduce the electrical load on the circuit, wait a few minutes and then
reset the circuit breaker.

18
AC Receptacle Selection

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 120/240 V 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 37.5 A.

Main power circuit Receptacles Powered Power Distribution

by each main circuit
Main Circuit I 1 and 5 1 +5=18.8A
maximum
Main Circuit II 2,3 and 4 2+3+4=18.8A
maximum

* The table shows the specifications when the 120/24OV Twist Lock
Receptacle is used for 12OV.

Example:
Receptacle 3 has a 15A load connected to it. Receptacle 2 has a 1OA load
connected to it. Both receptacles are powered by main power circuit II. The
equation tells us that the total power draw on Circuit II is 25A. This is a
substantial overload of this circuit. To eliminate the excess power draw on
circuit II, the load from receptacle 2 should be switched to receptacle 1.
Now circuit I is powering the 10A load (less than 18.8A) and circuit II is
powering the 15A load (less than 18.8A).
@ 120 V DUPLEX RECEPTACLE (20A)
@ 120 V 3-PRONG @ 1201240 V 4-PRONG
TWIST LOCK TWIST LOCK

@I 120v
(204
19
DC Operation
The DC terminals may ONLY be used for charging 12 volt automotive-type
batteries .
Connecting the battery cables:
1. Before connecting charging cables to a battery that is installed in avehicle,
disconnect the vehicle’s grounded battery cable.
m! 1 - The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate ventilation when charging
or using batteries.
2. Connect the positive (+) battery cable to the battery positive (+) terminal.
3. Connect the other end of the positive (+) battery cable to the generator
positive (+) terminal.
DC CIRCUIT

IE TERMINAL
(BLACK) (RED)

4. Connect the negative (-) battery cable to the battery negative (-) terminal.
5. Connect the other end of the negative (-) battery cable to the generator
negative (-) terminal.
6. Start the generator.

-1 Do not start the vehicle while the battery charging cables

are connected and the generator is running. The vehicle or the
generator may be damaged.
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.

20
Disconnecting the battery cables:
1. Stop the engine,
2. Disconnect the negative (-) battery cable from the generator negative (-)
terminal.
3. Disconnect the other end of the negative (-) battery cablefrom the battery
negative (-) terminal.
4. Disconnect the positive (+) battery cable from the generator positive (+)
terminal.
5. Disconnect the other end of the positive (+) battery cable to the battery
positive (+) terminal.
6. Connect the vehicle ground cable to the battery negative (-) terminal.
7. Reconnect the vehicle grounded battery cable.

DC CIRCUIT
PROTEC

NEGATIVE TERMINAL POSITIVE TERMINAL

(BLACK) (RED)

21
Auto-throttle system
With the switch in the AUTO position, engine speed is automatically reduced
when ALL loads are turned OFF or disconnected. When appliances are
turned ON or reconnected, the engine returns to rated speed. In the OFF
position, the auto-throttle system does not operate.

The auto-throttle system will not respond to electrical loads of less than 1
ampere. 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.

THROlTLE
H

22
High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will be excessively
rich. Performance will decrease, and fuel consumption will increase.
High altitude performance can be improved by installing a smaller diameter
main fuel jet in the carburetor and readjusting the pilot screw. If you always
operate the engine at altitudes higher than 6,000 feet above sea level, have
an authorized Honda generator dealer perform this carburetor modification.
Even with suitable carburetor jetting, engine horsepower will decrease
approximately 3.5% for each 1,000 foot increase in altitude. The effect of
altitude on horsepower will be greater than this if no carburetor modification
is made.

riGmq If a generator jetted for high altitude is used at a lower

altitude the air fuel mixture will reduce performance and may overheat
or seriously damage the engine.

23
PRE-OPERATION CHECK
Engine oil
1 NOTICE 1 Engine oil is a major factor affecting engine performance
and setvice life. Non-detergent and 2-stroke engine oils will damage
the engine and are not recommended.
Check the oil level BEFORE EACH
USE with the generator on a level
surface with the engine stopped.
Use Honda 4-stroke oil, or an
equivalent high detergent, premium
quality motor oil certified to meet or
exceed U.S. automobile
manufacturer’s requirements for
Service Classification SG, SF/CC, CD.
Motor oils classified SG, SF/CC, CD
will show this designation on the container.
SAE low-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.
1. Remove the oil filler cap and wipe the dipstick clean.
2. Check the oil level by inserting the dipstick into the filler neck without
screwing it in.
3. If the level is low, add the recommended oil to the upper mark on the
dipstick. Over filling with oil can cause the engine to smoke after start-up.

OIL
UPPER
LEVEL

OIL

24
Fuel Recommendation
1. Check the fuel level gauge.
2. Refill the tank if the fuel level is low. Do not fill above the shoulder of the
fuel strainer.

l Gasoline is extremely flammable and is explosive under certain

conditions.
l Refuel in a well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
l Do not overfill the fuel tank (there should be no fuel in the filler neck).
After refueling, make sure the tank cap is closed properly and
securely. 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.
l Avoid repeated or prolonged contact with skin or breathing of vapor.
. KEEP OUT OF REACH OF CHILDREN.
Fuel tank capacity: 17.0 Q (4.50 US gal, 3.74 Imp gal)

FUEL STRAINER

FUEL LEiEL GAUGE

Use gasoline with a pump octane rating of 86 or higher

We recommend unleaded gasoline because it produces fewer engine and
spark plug deposits and extends exhaust system life.
Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid
getting dirt or water in the fuel tank.

25
Occasionally you may hear light “spark knock’ or “pinging” (metallic rapping
noise) while operating under heavy loads. This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal
load, change brands of gasoline. If spark knock or pinging persists, see an
authorized Honda generator dealer.

(1 Running 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.
Oxygenated Fuels
Some gasolines are being blended with alcohol or an ether compound to
increase the octane. These gasolines are collectively referred to as oxygenated
fuels. Some areas of the United States use oxygenated fuels to help meet
clean air standards.
If you use an oxygenated fuel, be sure its pump octane rating is 86 or higher.
Ethanol (ethyl or grain alcohol)
Gasoline containing more than 10% ethanol by volume may cause starting
and/or performance problems. Gasoline containing ethanol may be
marketed under the name “Gasohol”.
Methanol (methyl or wood alcohol)
Gasoline containing methanol must contain cosolvents and corrosion
inhibitors to protect the fuel system. Gasoline containing more than 5%
methanol by volume may cause starting and/or performance problems and
may damage metal, rubber and plastic parts of your fuel system.
MTBE (methyl tertiary butyl ether)
You may use gasoline containing up to 15% MTBE by volume.
Before using an oxygenated fuel, try to confirm the fuel’s contents. Some
states (provinces in Canada) require this information to be posted on the
pump. If you notice any undesirable operating symptoms, switch to a
conventional unleaded gasoline. Fuel system damage or performance
problems resulting from the use of an oxygenated fuel are not the
responsibility of Honda and are not covered under warranty.

-1 Oxygenated fuels can damage paint and plastic. Be

careful not to spill fuel when filling your fuel tank. Damage caused by
spilled fuel is not covered under warranty.

26
 STARTING THE ENGINE

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

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

2. Turn the fuel valve to the ON position.

3. 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.

4. Make sure the auto-throttle switch is in the OFF position, or more time will
be required for warm up.

5. Start the engine

l With recoil starter:
Turn the engine switch to the ON position.

Pull the starter grip lightly until resistance is felt, then pull briskly.
1-1 Do not allow the starter grip to snap back against the
engine.
Return it gently to prevent damage to the starter or housing.

l With electric starter: (Optional kit)

Turn the engine switch to the START position and hold it there for 5
seconds or until. the engine starts.
/-3imEq
l 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.
l If the speed of the starter motor drops after a period of time, it is an
indication that the battery should be recharged.

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

6. If you have manually closed the choke, push it to the OPEN position as the
engine warms up.

7. 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.
27
STOPPING THE ENGINE

In an emergency:
1. To stop the engine in an emergency, turn the engine switch to the OFF
position.
In normal use:
1. Turn the AC circuit breaker to the OFF position.
Disconnect DC battery charging cables.

2. Turn the engine switch to the OFF position.

3. Turn the fuel valve to the OFF position.

28
 MAINTENANCE
Periodic maintenance and adjustment is necessary to keep the generator in
good operating condition. Perform the service and inspection at the intervals
shown in the Maintenance schedule below.

m! Exhaust gas contains poisonous carbon monoxide.

Shut off the engine before performing any maintenance. if the engine
must be run, make sure the area is well ventilated.
1 NOTICE 1 Use only genuine HONDA parts or their equivalent for
maintenance or repair. Replacement parts which are not of equivalent
quality may damage the generator.
MAINTENANCE SCHEDULE

Performed at every indicated month

Air cleaner

Valve clearance Check-Adjust 0 (2)

Fuel tank and strainer Clean 0 (2)
Check
Fuel line (Replace if Every 2 years (2)
necessary)

(1) Service more frequently when used in dusty areas.

(2) 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.
(3) For professional commercial use, log hours of operation to determine proper maintenance
intervals.

29
Tool kit
The tools supplied with the generator will help you to perform the owner
maintenance procedures listed on the following page. Always keep this tool
kit with the generator.

10 x 12 mm WRENCH SCREW DRIVER

PLUG WRENCH DRIVER HANDLE

HANDLE BAR

TOOL BAG

30
Engine oil change
Drain the oil while the engine is warm to assure rapid and complete draining.
1. Remove the drain plug and sealing washer, oil filler cap, and drain the oil.
2. Install the drain plug and sealing washer. Tighten the plug securely.
3. Refill with the recommended oil (see page 24) and check the level.
Oil capacity: 1 .l Q (1.16 US qt, 0.97 Imp qt)

OIL DRAIN PLUG UPPERLEVEL

I 0
m! Used motor oil may cause skin cancer if repeatedly left
in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to
thoroughly wash your hands with soap and water as soon as possible
after handling used oil.
Please dispose of used motor oil 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
or pour it on the ground.

31
Air cleaner service
A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor
malfunction, service the air cleaner regularly. Service more frequently when
operating the generator in extremely dusty areas.
I-
w! Using gasoline or flammable solvent to clean the filter
element can cause a fire or explosion. Use only soapy water or
nonflammable solvent.
1 NOTICE 1 Never run the generator without the air cleaner. Rapid
engine wear will result.
1. Unsnap the air cleaner cover clips,
remove the air cleaner cover, and
remove the element.

2. Wash the element in a solution of

household detergent and warm
water, then rinse thoroughly, or wash
in nonflammable or high flash point
solvent. Allow the element to dry
thoroughly.

3. Soak the element in clean engine cLlp AIR CLEANER ELEMENT

oil and squeeze out the excess oil.
The engine will smoke during initial
start-up it too much oil is left in the
element.

4. Reinstall the air cleaner element

and the cover.

ELEMENT -

32
 Fuel Sediment Cup Cleaning
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.

1. Turn the fuel valve to the OFF position. Remove the sediment cup, O-ring,
and filter.
, 2. Clean the sediment cup, O-ring, and filter in nonflammable or high flash
point solvent.
3. Reinstall the filter, O-ring, and sediment cup.

FUEL VALVE
\ SEDIMENT CUP

FUEL FILTER -

a -O-RING

P
SEDIMENT CUP

33
Spark Plug Service

Recommended spark plugs: BPR5ES (NGK)

Wl GEPR-U (NIPPONDENSO)

To ensure proper engine operation, the spark plug must be properly gapped
and free of deposits.

If the engine has been running, the muffler will be very hot. Be careful not to
touch the muffler.

1. Remove the spark plug cap.

2. Clean and dirt from around the spark plug base.
3. Use the wrench supplied in the tool kit to remove the spark plug.

PLUG CAP

5. 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.
6. Measure the plug gap with a feeler gauge.
correct as necessary by carefully bending the side electrode.
The gap should be: 0.70-0.80 mm (0.028-0.031 in)
0.70-0.80 mm (0.02W.031 in)

34
7. Check that the spark plug washer is in good condition, and thread the
spark plug in by hand to prevent cross-threading.
8. After the spark plug is seated, tighten with a spark plug wrench to
compress the washer.
- If installing a new spark plug, tighten l/2 turn after the spark plug seats
to compress the washer. If reinstalling a used spark plug, tighten
l/8 - l/4 turn after the spark plug seats to compress the washer.

-1 The spark plug must be securely tightened. An

improperly tightened spark plug can become very hot and could
damage the engine.
Never use spark plugs which have an improper heat range. Use only
the recommended spark plugs or equivalent.

Spark Arrester Maintenance

If the generator has been running,the muffler will be very hot. Allow it to
cool before proceeding.

pi6iG-j The spark arrester must be serviced every 100 hours to

maintain its efficiency.

Clean the spark arrester as follows:

1. Loosen the screw by the exhaust port of the muffler and remove
the spark arrester.
2. Use a brush to remove carbon deposits from the spark arrester
screen. Inspect the screen for breaks or tears and replace it if
necessary.
3. Install the spark arrester in the reverse order of removal.
SPARK ARRESTER

35
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.

m. A- Contact with a hot engine or exhaust system can cause

serious burns or fires. Let the engine cool before transporting or
storing the generator.

Take care not to drop 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:

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING
Less than 1 month No preparation required
Fill with fresh gasoline and add gasoline
1 to 2 months conditioner*.
Fill with fresh gasoline and add gasoline
conditioner*.
2 months to 1 year
Drain the carburetor float bowl.
Drain the fuel sediment cup.
Fill with fresh gasoline and add gasoline
conditioner*.
Drain the carburetor float bowl.
1 year or more Drain the fuel sediment cup.
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.
After removal from storage, drain the stored gasoline
into a suitable container, and fill with fresh gasoline
before starting.
*Use gasoline conditioners that are formulated to extend storage life.
Contact your authorized Honda generator dealer for conditioner
recommendations.

36
1. Drain the carburetor by loosening the drain screw. Drain the gasoline
into a suitable container.

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

2. Change the engine oil.

3. 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.
4. 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.

ch on the starter pulley

with the hole at the top of recoil starter.

37
TROUBLESHOOTING
When the engine will not start:

t Refill the fuel tank.

Is there enough oil in b Add the recommend-

(The oil alert lamp flashes when ed oil.
cranking the engine.)
YES

Is there a spark from No

the spark plug?

To check:
I
.- 1) Remove the spark plug
w! Besure cap and clean any dirt from
there is no spilled fuel around the spark plug.
around the spark plug. 2) Remove the spark plug
Spilled fuel may ignite. and install the spark plug in
the plug cap.
YES 3) Set the plug side electrode
on the cylinder head.
4) Crank the engine, sparks
should jump across the
SW

YES ’
1)
1)Turn off the engine switch
and loosen the drain
screw.
Clean the fuel
sedimentcup.
DRAIN SCREW

If the engine still 2) Fuel should flow from the

does not start, take drain when the engine
the generator to an switch is turned on.
authorized Honda
1
rgenerator dealer. I

38
No electricity at the AC receptacles:

7 No -d Turn the ACcircuitbreaker ON.)

I YES
Check the electrical NO DEFECTS
appliance or equipment
for any defects.
I
I

39
 ING DIAGRAM

40
 SPECIFICATIONS
Dimensions
Model EM5000SX
Power equipment description code EA7

Length x Width x Height 655 x 510 x 490 mm (25.8 x 20.1 x 19.3 in)

Dry weight 80 kg (176.4 lb)

Engine
Model GX340Kl
Engine type 4-stroke, overhead valve, single cylinder
Displacement (Bore x Stroke) 337 cc (20.6 cu in) [82 x 64 mm (3.2 x 2.5 in)]
Compression ratio 8.0 : 1
Engine speed 3,600 r.p.m.
Cooling system Forced air
Ignition system Transistorized magneto
Oil capacity 1.1 e (1.16 USqt, 0.97 Impqt)
Fuel tank capacity 17.0 e (4.5 US gal, 3.74 Imp gal)
Spark plug BPR5ES (NGK), WlGEPR-U (NIPPONDENSO)

Generator
Model EM5000SX

Type A
Rated voltage 1201240 V
Rated frequency 60 Hz
AC output Rated ampere 37.5118.8 A
Rated output 4,500 VA
Maximum output 5,000 VA
DC output Only for charging 12 V automotive batteries.
Maximum charging output = 8.3 A

NOTE: Specifications are subject to change without notice.

41
INSTALLATION OF OPTIONAL PARTS
Remote Control Kit

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

2. Remove the blind 8-P connector from the back of the control box and
connect the relay box connector instead.

3. Connect the remote control cable to the remote control and relay box.
REMOTE CONTROL
CABL

REMOTE CONTROL BOX

NOTE: l Connect the blind connector when not using the remote control.
l Engine will not start unless the blind connector is connected.

42
Remote Control Box

ENGINE STARTER
SWITCH BUlTON
PILOT LAMP

\ I /

Starting the engine with remote control

1. Turn the fuel valve to the ON position.
2. Turn the auto-throttle switch to the OFF position.
3. Turn off the engine switch at the generator and remove the key.
4. Turn the relay box switch to the ON position.

RELAY B

43
5. Turn the engine switch at the remote control box to the ON position.

6. Press the starter button until the pilot lamp comes on.

Stopping the engine

1. Turn the engine switch at the remote control box to the OFF position.
2. Turn the relay box switch to the OFF position.
3. Turn the fuel valve to the OFF position.
4-Wheel Kit Installation

1. Install the four wheels on the axle shaft.

2. Install the axle assembly on the generator using four bolts and nuts.

Inside

WHEEL STOPPER

NOTE: Install the shaft with wheel stopper facing engine side.
45
Battery Tray Kit
1. Install the battery guard on the frame.
Set the battery tray on the battery guard and tighten the bolts.
2. Route the starter cable under the tank and connect it to the starter
solenoid.
3. Connect the ground cable to the generator rear housing.
4. Set the battery on the battery tray and secure with the battery bracket.
Connect the starter cable to the battery positive (+) terminal first, then to
the negative (-) terminal. when disconnecting, disconnect at the battery
negative (-) terminal first.
5. Install the battery guard plate on the battery guard.

46
 STARTER
STARTER
SOLE,NOID \

BAlTERY
NOTE: Use a battery
rated at 12V-18-35AH G
nr mnrP c P

BATTERY
GUARD

BRACKET

BAl-rERY
TRAY
GUARD PLATE

47
WARRANTY SERVICE
Owner satisfaction
Your satisfaction and goodwill are important to your dealer and to us. All
Honda warranty details are explained in the Distributor’s Limited Warranty.
Normally, any problems concerning’ the product will be handled by your
dealer’s service department. If you have a warranty problem that has not
been handled to your satisfaction, we suggest you take the following action:
l Discuss your problem with a member of dealership management. Often
complaints can be quickly resolved at that level. If the problem has
already been reviewed with the Service Manager, contact the owner of
the dealership or the General Manager.
l If your problem still has not been resolved to your satisfaction, contact
the Power Equipment Customer Service Department of American Honda
Motor Co., Inc.
American Honda Motor Co., Inc.
Power Equipment Customer Service
4475 River Green Parkway
Duluth, Georgia 30136-9420
Telephone: (404) 497-6400
We will need the following information in order to assist you:
- Your name, address, and telephone number
- Product model and serial number
- Date of purchase
- Dealer name and address
- Nature of the problem

After reviewing all the facts involved, you will be advised of what action can
be taken. Please bear in mind that your problem will likely be resolved at the
dealership, using the dealer’s facilities, equipment, and personnel, so it is
very important that your initial contact be with the dealer.
Your purchase of a Honda product is greatly appreciated by both your dealer
and American Honda Motor Co., Inc. We want to assist you in every way
possible to assure your satisfaction with your purchase.
 INDEX
COMPONENT IDENTIFICATION .............................................. 8
CONTROLS ............................................................................ 10
Auto-throttle System .............................................................. 13
Choke Rod .......................................................................... 11
Circuit Breaker .................................................................... 12
DC Circuit Protector .............................................................. 15
DC Terminals ........................................................................ 15
Engine Switch ...................................................................... 10
Fuel Valve ............................................................................ 11
Grond Terminal ...................................................................... 12
Oil Alert System .................................................................... 12
Pilot Lamp .............................................................................. 14
Recoil Starter ...................................................................... 10
Volt Meter .............................................................................. 14
Voltage Selector Switch (Dual Voltage System) .................... 14
GENERATOR USE.. .................................................................. 16
AC Applications.. .................................................................... 17
AC Operation ........................................................................ 18
AC Receptacle Selection ...................................................... 19
Auto-throttle System .............................................................. 22
Connections to a Building’s Electrical System ...................... 16
DC Operation ...................................................................... 20
Disconnecting the battery cables ........................................ 21
Generator Ground Circuit ...................................................... 16
High Altitude Operation.. ........................................................ 23
INSTALLATION OF OPTIONAL PARTS ................................ 42
MAINTENANCE ........................................................................ 29
Air Cleaner Service ................................................................ 32
Engine Oil Change ................................................................ 31
Fuel Sediment Cup ................................................................ 33
Maintenance Schedule .......................................................... 29
Spark Arrester Maintenance ................................................ 35
Spark Plug ............................................................................ 32
Tool Kit .................................................................................. 30

49
INDEX
PREOPERATION CHECK . .. . .. . .. . ... . .. . .. . . .. . .. . .. . .. . .. . . .. . . .. . .. . .. . . .. . 24
Engine Oil .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. ... . .. . .. . . .. . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . 24
Fuel Recommendation .. . . .. . .. . .. .. .. . .. . .. . .. . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . 25
SAFETY . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. ... . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. 4
Safety Information .. . .. . . .. . . .. . .. . . .. ... . . .. . .. . . .. . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . . 6
Safety Label Locations . . .. . . .. . . .. ... . . .. . . .. . .. . . .. . .. . . .. . . .. . .._............. 4
SPECIFICATIONS .. . . .. . . .. . .. . . .. . . .. . ... . . .. . .. . . .. . . .. . .. . . .. . .._............... 41
STARTING THE ENGINE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . . 27
STOPPING THE ENGINE . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . .. . .. . . . .. 28
TRANSPORTING/STORAGE . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . . .. . . .. . . . . 36
TROUBLESHOOTING . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . . .. . . .. . . . . 38
WARRANTY SERVICE . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . . .. . . .. . . . . 48
WIRING DIAGRAM .. . . .. . . .. . . .. . . . .. . . ... . .. . . .. . . . .. . .. . . .. . . .. . . . .. . . .._........... 40

50
MEMO

51
 -

MEMO

52