The D-AVR is a generator-set controller. It is used on generator sets from Honda, including the EM4000SX, EM5000SXK3 and EM6500SXK2.
| Symptom | Cause | Remedy |
|---|---|---|
| Engine does not start or is hard to start | Engine oil level low | Inspection: (page 3-3) |
| Engine does not stop when combination switch is turned off | Combination switch faulty | Check the combination switch (page 7-7); Replace the combination switch |
| Engine does not stop when engine oil level is low | Oil level switch faulty | Start the engine; Disconnect the oil level switch wire connector (Yellow) terminal, and short the wire harness side to engine ground using a jumper wire; Replace the oil level switch (page 13-4) |
| Engine lacks power | Engine oil level low | Inspection: (page 3-3) |
| Engine speed does not stabilize | Restricted parts | Disassemble and inspect for restricted parts |
| Engine will not rev sufficiently | Engine oil level low | Inspection: (page 3-3) |
| Hard starting — Compression is too high | Carbon deposits in the combustion chamber | Check the valve clearance (page 3-9), and then perform the cylinder compression test; If the cylinder compression is too high, remove carbon deposits in the combustion chamber (page 3-10) |
| Hard starting — Compression is too low | Air leakage from the engine | Check the valve clearance (page 3-9), and then perform the cylinder compression test (page 11-5); If the cylinder compression is too low, perform a leak-down test; If there is air leakage from the engine, check the following: –Valve spring free length (page 11-7) –Valve seat width (page 11-6) –Valve face irregularly worn (page 11-7) –Decompressor operation (page 13-12) –Piston ring side clearance (page 13-8) –Piston ring width (page 13-8) –Piston ring end gap (page 13-8) –Piston skirt O.D. (page 13-6) –Cylinder sleeve I.D. (page 13-6) |
| Hard starting — Does not crank | Recoil starter hard to pull when installed on the engine | If the recoil starter operates correctly when removed but is hard to pull when installed on the engine, check the decompressor operation of the camshaft (page 13-12); If the recoil starter operates correctly when removed but cannot be pulled when installed on the engine, disassemble the engine and repair or replace the faulty part(s) (page 13-2) |
| Hard starting — Engine hard to start | Clogged carburetor ports, jets, and nozzles; choke valve not closing; control gear box fault | Disassemble the carburetor to check for clogged ports, jets, and nozzles (page 5-10); Restart the engine; Check the control gear box (page 5-7); Remove the carburetor spacer (page 5-4) and check whether the choke valve is closed when pulling the recoil starter |
| Hard starting — No fuel | Clogged fuel tube, fuel filter, or fuel valve; frozen obstruction in the breather tube in cold weather | Check for clogged fuel tube, fuel filter, and fuel valve; If the engine is stalled in a cold weather application, check for a frozen obstruction in the breather tube |
| Hard starting — No spark | Ignition system fault | Perform the IGNITION SYSTEM TROUBLESHOOTING (page 2-15) |
| Hard starting — Wet spark plug | Carburetor float valve | If spark plug gap is correct, clean and dry the electrodes, and then restart the engine; If the engine does not start and the electrodes are wet again, check the carburetor float valve (page 5-12) |
| Ignition system troubleshooting — no spark | Oil level switch faulty | Check the engine oil level before troubleshooting; Check the oil level switch (page 13-5); Replace the oil level switch (page 13-4) |
| Starter motor does not operate | Battery discharged | Check the battery condition (page 15-3); Replace with a known-good battery; If the battery runs down again, perform the CHARGING SYSTEM TROUBLESHOOTING (page 2-38) |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.