Honda Automobiles EP2500CX manual

31Z 1 560 1 o 200 8 Honda Motor Co., Ltd. -All Rights Reserved 2eY1 2000.2007.12 Printed in Japan Owner’ s Manual GENERA TOR EP2500CX 00X31-Z25-6100 EU6500is See page 61 for initial use instructions.  Black DIC F101[...]

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death. Never run the generator in a closed, or even partly closed area wher e people may be present. The information and specifications included in this publication were in effect at the time o[...]

1 INTRODUCT ION 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 all the information on how to do that; please read it carefully. [...]

− − − − − − 2 A FEW WORDS ABOUT SAFETY Safety Labels Safety Messages Safety Headings Safety Section Instructio ns Your safety and the safety of others are very important. And using t his generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other info[...]

3 CON TENTS ................................................................................ GENERATOR SAFETY .6 ........................................................................ CONTROLS & FEATURES .10 ............................................................................... BEFORE OPERATION .16 ...................................[...]

4 CONTENTS .............................................................................................. OPERATION .18 ............................................................. SERVICING YOUR GENERATOR .27 .................................................................................................. STORAGE .43 ............................[...]

5 CONTENTS ....................................... TAKING CARE OF UNEXPECTED PROBLEMS .49 .......................................... TECHNICAL & CONSUMER INFORMATION .52 .................................................................. INITIAL USE INSTRUCTIONS .61 ................................................................................[...]

6 GENERATO R SAFETY Operator Responsibility Carbon Monoxide Hazards IMPORTANT SAFETY INFORMATION Honda generators are designed for use with electri cal equipment that has suitable power requirements. Other uses can result in injury to the operator or damage to the generator and other property. Most accidents can be prevented if you follow all instr[...]

− − − 7 GENERATOR SAFETY Electric Shock Hazar ds Fire and Burn Hazards The generator produces enough electric power to cause a ser ious 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 electr ocu[...]

8 GENERATOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Allow the engine to cool if the generator has been in operation. Refuel only outdoors in a well-ventilated area with the engine OFF. Do not overfill the fuel tank. Never smoke near gasoline, and keep other flames and sparks away. Always store gasoli[...]

9 GENERATOR SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda servicing dealer for a replacement. 07/11/08 18:00:10 31Z15600_010[...]

10 CONTROLS & FEA TURES COMPONENT & CONTROL LOCATIONS AC RECEPTACLES AC CIRCUIT BREAKER CONTROL PANEL ENGINE SWITCH GROUND TERMINAL Use the two illustrations on these pages to locate and identify the most frequently used controls. 07/11/08 18:00:15 31Z15600_011[...]

11 CONTROL & FEATURES FUEL TANK CAP FUEL GAUGE FUEL VALVE LEVER CHOKE LEVER AIR CLEANER SEDIMENT CUP STARTER GRIP SPARK PLUG OIL DRAIN PLUG OIL FILLER CAP/ DIPSTICK MUFFLER/SPARK ARRESTER 07/11/08 18:00:21 31Z15600_012[...]

12 CONTROL & FEATURES CONTROLS Fuel Valve Lever Choke Lever FUEL VALVE LEVER O O F F F F O O N N O O P P E E N N C C L L O O S S E E D D CHOKE LEVER The fuel valve lever is located between the fuel tank and carburetor. The choke lever opens and closes the choke valve in the carburetor. The CLOSED position enriches the fuel mixture for starting [...]

− − 13 CONTROL & FEATURES Engine Switch Starter Grip AC Circuit Breaker O O F F F F STARTER GRIP O O N N ENGINE SWITCH O O F F F F O O N N AC CIRCUIT BREAKER The engine switch controls the ignition system. ON Running position, and for starting. OFF Stops the engine. Do not allow the starter grip to snap back against the engine. Return it ge[...]

14 CONTROL & FEATURES FEATURES Oil Alert System Ground Terminal GROUND TERMINAL The Oil Alert system is designed to pr event 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 Aler t system will automatically stop the engine (the engine switch will r[...]

15 CONTROL & FEATURES Fuel Gauge FUEL GAUGE FUEL TANK CAP EMPTY FUEL GAUGE FULL The fuel gauge is a mechanical device that measur es the fuel level in the tank. The red indicator in t he window will reference the level in relation to full or empty. To provide incr eased operating time, start with a full tank before b eginning operation. Check t[...]

16 BEFORE OPERAT ION ARE YOU READY TO GET STARTED? Knowledge IS YOUR GENERATOR READY TO GO? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Read and understand this manual. Know what the controls do and how to operate them. Familiarize yourself with the generator and its operatio[...]

17 BEFORE OPERATION Check the Engine Check the fuel level (see page ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling. Check the air filter (see page ). A dirty air filter will restrict air flow to the carburetor, reducing engine and gener ator performance. Check the oil level (see page ). A low oil[...]

18 SAFE OPERATING PRECAUTIONS OPERA TION Before operating the generator for the first time, please review the GENERATOR SAFETY section and the chapter titled BEFORE OPERATION . For your safety, do not operate the gener ator in an enclosed area such as a garage. Your gener ator’s exhaust contains poisonous carbon monoxide gas that can collect rapi[...]

19 OPERATION Use grounded 3-prong extension cords, tools, and appliances, or double-insulated tools and appliances. Inspect cords and plugs, and replace if damaged. Make sure that the appliance is in good working or der. Faulty appliances or power cords can create a potential for electric shock. Operate the generator at l east 3 feet (1 meter) away[...]

20 OPERATION STARTING THE ENGINE O O N N O O F F F F C C L L O O S S E E D D FUEL VALVE LEVER CHOKE LEVER O O P P E E N N AC CIRCUIT BREAKER Turn the fuel valve lever to the ON position. Move the choke lever to the CLOSED position to start a cold engine. Leave the choke lever in the OPEN position to restart a warm engine. Refer to SAFE OPERATING PR[...]

21 OPERATION O O P P E E N N CHOKE LEVER ON D D i i r r e e c c t t i i o o n n t t o o p p u u l l l l STARTER GRIP ENGINE SWITCH Turn the engine switch to the ON position. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown. Do not allow the starter grip to snap back against the engine[...]

22 OPERATION STOPPING THE ENGINE ENGINE SWITCH FUEL VALVE LEVER AC CIRCUIT BREAKER OFF O O F F F F OFF To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Move the AC circuit breaker to the OFF position. Turn the engine switch to the OFF position. Turn the fuel[...]

23 OPERATION AC OPERATION AC CIRCUIT BREAKER PLUG O O N N 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 in the appliance or the rated load capacity of the generator has been exceeded. Substantial overloading may damage the ge[...]

24 OPERATION 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, an[...]

25 OPERATION STANDBY POWER System Ground Connections to a Building’s Electr ical System Honda portable generators have a system ground that connects the generator frame components to the gr ound terminals in the AC output receptacles. The system ground is not connected to the AC neutr al wire. If the generator is tested with a receptacle tester, [...]

26 OPERATION 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. In some areas, generators ar e required t[...]

27 SERVICING YOUR GE NERAT OR THE IMPORTANCE OF MAINTENANCE Maintenance, replacement , or repair of the emission contr ol devices and systems may be perform ed by any engine repair establishment or individual, using parts that are ‘‘certified’’ t o EPA standards. Good maintenance is essential for safe, economical, and trouble-free operation[...]

− − − 28 SERVICING YOUR GENERATOR MAINTENANCE SAFETY Safety Precautions Carbon monoxide poisoning from engine exhaust . Burns from h ot parts . Injury from moving parts. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can ari se in performing maintenance. Only you can decide w[...]

29 SERVICING YOUR GENERATOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) Each use (1) ITEM Perform at every indic ated month or operating hour interval, whic hever comes first. Engine oil Air cleaner Canister (California type) Purge tube (California type) Charge tube (California type) Sediment cup Spark plug Spark arrester (equipped type only) V[...]

30 SERVICING YOUR GENERATOR REFUELING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage[...]

31 SERVICING YOUR GENERATOR FUEL RECOMMENDATIONS FULL FUEL TANK CAP FUEL GAUGE UPPER LIMIT MARK UPPER LIMIT EMPTY FUEL GAUGE TETHER (CALIFORNIA TYPE) You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Never use stale or con[...]

32 SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK UPPER LIMIT OIL FILLER HOLE OIL FILLER CAP/DIPST ICK Check the engine oil level with the generator on a level surface and the engine stopped. The Oil Alert system will autom atically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected s[...]

33 SERVICING YOUR GENERATOR ENGINE OIL CHANGE UPPER LIMIT OIL DRAIN PLUG SEALING WASHER OIL FILLER CAP/DIPST ICK Drain the oil while the engine is warm to assur e rapid and complete draining. Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap/dipstick , drain plug, and sealing washer. Wash your han[...]

34 SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS AMBIEN T TEMPERATUR E Oil is a major factor affecting engine performance and service life. SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the aver age temperature in your area is within the indicated range. Use 4-stroke motor oil that meets or e[...]

35 SERVICING YOUR GENERATOR AIR CLEANER SERVICE AIR CLEANER COVER AIR CLEANER CASE HOOK SETTING PIN FORM AIR FILTER LATCH TAB Push the latch tabs and open the air cleaner cover. Free the hooks from the setting pins on the air cleaner case and remove the air cleaner cover to the right side of the frame pipe, taking care not to damage the air cleaner[...]

36 SERVICING YOUR GENERATOR HOOK AIR CLEANER COVER SETTING PIN FORM AIR FILTER GOOD NO GOOD AIR CLEANER CASE LATCH TAB Reinstall the foam air filter in the air cleaner case. Set the hooks of the air cleaner cover to the setting pins securely, then push the air cleaner cover to lock the latch tabs. Be sure that the cover is set securely. There must [...]

37 SERVICING YOUR GENERATOR FOAM AIR FILTER CLEANING A dirty foam air f ilter will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in ver y dusty areas, clean the foam air filter more frequently than specified in the Maintenance Schedule. Clean the foam air filter in warm soapy water , rinse, and allow[...]

38 SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING SEDIMENT CUP O-RING (Replace.) FILTER FUEL VALVE LEVER OFF Turn the fuel valve lever to the OFF position, then remove the sediment cup, O-ring, and filter. Discard the O-ring. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and k[...]

−− − − 39 SERVICING YOUR GENERATOR Recommended spark plugs: SPARK PLUG SERVICE SPARK PLUG WRENCH SPARK PLUG CAP SIDE ELECTRODE SEALING WASHER 0.028 0.031 in (0.7 0.8 mm) BPR6ES (NGK) W20EPR-U (DENSO) If the engine is hot, allow it to cool before servicing the spark plug. An incorrect spark plug can cause engine damage. Disconnect the spark [...]

− 40 SERVICING YOUR GENERATOR Make sure that the spark plug sealing washer i s in good condition, and thread the spark plug in by hand to prevent cross-threading. After the spark plug seats, tighten with a 13/16-inch spark plug wrench to comp ress the washer. If reinstalling a used spark plug, tighten 1/ 8 1/ 4 turn af ter the spark plug seats. I[...]

41 SERVICING YOUR GENERATOR SPARK ARRESTER SERVICE SPARK ARRESTER 4 mm SCREW If the engine has been running, the muffler will be very hot. Allow the muffler t o cool before servici ng the spark arr ester. Remove the 4 mm screw, then pull out the spark arr ester. Be careful to avoid damaging the screen. Use a brush to remove carbon deposits from the[...]

42 SERVICING YOUR GENERATOR SPARK ARRESTER 4 mm SCREW Reinsert the s park arres ter, tighten the 4 mm sc rew to reinstall it. 3. 07/11/08 18:04:51 31Z15600_043[...]

43 STORAGE PREPARATION Cleaning Fuel STORAGE Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from im pairing your generator’s function and appearance, and will make the engine easier to star t when you use the generator again. Wipe the gener[...]

44 STORAGE Adding a Gasoline Stabilizer to Extend Fuel Storage Life Stop the engine, and turn the fuel valve lever to the OFF position. After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has r eplaced the untreated gasoline in the carburetor. Add gasoline stabilizer following the manufacturer[...]

45 STORAGE Draining the Fuel Tank and Carburet or DRAIN BOLT NON-CALIFORNIA TYPE SEALING WASHER DRAIN SCREW CALIFORNIA TYPE Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Place a suita[...]

− 46 STORAGE Engine Oil Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion. Return the starter grip gently. Reinstall the spark plug. Pull the s[...]

47 STORAGE STORAGE PRECAUTIONS REMOVAL FROM STORAGE If your generator will be stored with gasoline in the fuel tank and carburetor, it is important to r educe the hazard of gasoline vapor ignition. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the generator , promoting rust and cor rosion. With the engine and[...]

48 TRANSP ORTING If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the tr ansport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the generator level when transporting to reduce the possibility of fuel leakage. Move the fuel valve lever to th[...]

49 ENGINE WILL NOT START Possible Cause Correcti on TAKING CARE OF UNEXPECTED PROBLEMS Fuel valve lever OFF. Choke OPEN. Engine switch OFF. Out of fuel. Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline. Low oil level caused Oil Alert to stop engine. Spark plug faulty, fouled, or improperly gapped. Spar[...]

50 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE LACKS POWER Possible cause Correcti on Air filter restr icted. Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Clean or replace air filter (p. 35 thru. 37). Drain fuel[...]

51 TAKING CARE OF UNEXPECTED PROBLEMS NO POWER AT THE RECEPTACLES Possible Cause Correcti on Circuit breaker left in the OFF position after starting. Faulty power tool or appliance. Faulty generator. Switch circuit breaker ON. Replace or repair power tool or appliance. Stop and restart the engine. Take the generator to an authorized Honda servicing[...]

52 TECHNICAL INFORMATION Serial Number Location TECHNICAL & CONSUMER INFORMATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER Date purchased: Frame serial number: Engine serial number: Record the engine and frame serial num bers and date purchased in the spaces below. You will need this information when ordering parts and when making technical or w[...]

53 TECHNICAL & CONSUMER INFORMATION Carburetor Modificati on for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Perform ance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard star ting. Operation at an altitude that diff ers f[...]

54 TECHNICAL & CONSUMER INFORMATION Emission Control System Inform ation Source of Emissions The U.S. and California Clean Air Acts Tampering and Altering The combustion process produces car bon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, the[...]

55 TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions Replacement Parts Maintenance If you are aware of any of the following symptoms, have your engine inspected and repaired by your authorized Honda ser vicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfi[...]

− − − 56 TECHNICAL & CONSUMER INFORMATION Air Index (Models certified for sale in California) 125 hours (0 80 cc, inclusive) 250 hours (greater than 80 cc) 50 hours (0 80 cc, inclusive) 125 hours (greater than 80 cc) Applicable to Emission Durability Period Extended Intermediate Moderate Descriptive Ter m The durability description is int[...]

×× ± ± × −− 57 TECHNICAL & CONSUMER INFORMATION SPECIFICATION MA INTENANCE Tuneup Specifications ITEM Dimensions Engine Generator Specifications EP2500CX1 W20EPR-U (DENSO) BPR6ES (NGK) 3.83 US gal (14.5 ) 0.61 US qt (0.58 ) Transistoriz ed magneto ignition Forced air 3,600 rpm 8.5:1 2.68 1.77 in (68.0 45.0 mm) 9.9 cu-in (163 cm ) 4-str[...]

58 TECHNICAL & CONSUMER INFORMATION Wiring Diagra m 07/12/06 12:25:21 31Z15600_059[...]

59 TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Shop Manual Accessories Catalog Parts Catalog Dealer Locator Informati on Honda Publications To find an authorized Honda Servicing Dealer anywhere in the United States: This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Call[...]

60 TECHNICAL & CONSUMER INFORMATION Customer Service Inform ation Honda Power Equipment dealership per sonnel 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 Manag[...]

61 INITIAL USE INSTRUCT IONS ENGINE OIL WITHOUT OIL FUEL OIL FILLER HOLE UPPER LIMIT AMBIENT TEMPERATU RE OIL FILLER CAP/DIPST ICK The generator is shipped in the engine. Place the generator on a level surface. Add enough of the recommended oil to bring the oil level to the outer edge of the o il filler hole. SAE 10W-30 is recommended for general u[...]

62 INITIAL USE INSTRUCTIONS BEFORE OPERATION GENERATOR SAFETY CONTROLS & FEATURES OPERATION STARTING THE ENGINE STOPPING THE ENGINE Before using your generator, you should become familiar with information contained in the following chapters and sections: (page ) (page ) (page ) (page ) (page ) 10 6 20 22 18 07/11/08 18:07:58 31Z15600_063[...]

63 INDEX A B C E D ......................................................................... Electric Shock Hazards . 7 .............................................. Emission Control System Information . 54 ..................................................................... ENGINE LACKS POWER . 50 ................................................[...]

64 INDEX F G H I K M N .................................................................... MAINTENANCE SAFETY . 28 .............................................................. MAINTENANCE SCHEDULE . 29 .................................................. NO POWER AT THE RECEPTACLES . 51 .............................................................[...]

65 INDEX O Q R S ........................ QUICK REFERENCE INFORMATION . Inside back cover .......................................................................................... REFUELING . 30 ................................................................................... Refuel With Care . 8 .................................................[...]

66 INDEX T W ................................................................................... Wiring Diag ram . 58 ................................. TAKING CARE OF UNEXPECTED PROBLEMS . 49 .................................... TECHNICAL & CONSUMER INFORMATION . 52 ............................................................... TECHNICAL INFOR[...]

67 MEMO 07/11/08 18:08:27 31Z15600_068[...]

68 MEMO 07/11/08 18:08:29 31Z15600_069[...]

−− QUICK REFERENCE INFORMATION Fuel Spark Plug Maintenance Type Type Subsequent Regular unleaded gasoline with ap u m po c t a n er a t i n go f8 6o r higher Check engine oil level. Check air filter. Change engine oil. See Maintenance Schedule (page 29) 0.028 0.031 in (0.7 0.8 mm) NGK: DENSO: BPR6ES W20EPR-U Electr ode Gap Firs t 20 hours Befor[...]

31Z 1 56 01 o 2007 Honda Motor Co., Ltd. -All Rights Reserved 2eY1 2000.2007.12 Printed in Japan Owner’ s Manual GENERA TOR EU6500is 00X31-Z25-6100 EU6500is See page 78 for instructions on assembling your generator . Black DIC F101[...]