Generac GP6500E Generator Set

Tools: feeler gauge, crow foot wrench

1. Adjust valve clearance with engine at room temperature
2. Position piston at TDC of compression stroke (both valves closed), or set intake/exhaust valve fully open method
3. Loosen rocker arm jam nut; turn pivot ball stud while checking clearance with a feeler gauge
4. When clearance is correct, hold pivot ball stud and tighten rocker arm jam nut to specified torque with a crow foot wrench
5. Recheck valve clearance to make sure it did not change
6. Install rocker arm cover with a new gasket

Tools: AC frequency meter

1. Loosen governor clamp bolt
2. Hold governor lever at wide open throttle position
3. Rotate governor shaft counterclockwise (389/208/196cc) or clockwise (410cc) as far as it will go
4. Tighten governor lever clamp bolt to 110 in-lbs (389/208/196cc) or 70 in-lbs (410cc)
5. Turn speed adjustment screw counterclockwise three full turns to avoid overspeed
6. Start engine and let warm up under no-load
7. Connect AC frequency meter; no-load frequency should be 62.0-62.5 hertz
8. Turn speed adjust screw until frequency/RPM is within limits
9. Apply removable Loctite (Loctite 241) to speed adjust screw threads

⚠ Do NOT insert the drill bit into the LED holes; damage to the LEDs will occur

Tools: 3/64 inch drill bit

1. Do not install CO badging (decal) prior to performing this test
2. Run generator under normal operation with no CO module notifications for a minimum of 65 seconds
3. With generator running, insert blunt end of a 3/64 inch drill bit into test switch hole
4. Hold the drill bit against the mounting panel until notification LEDs appear and generator shuts off
5. Successful pin test shows both LEDs on solid (not blinking)

⚠ Disconnect negative cable first, connect it last

1. Disconnect negative (-) battery terminal first.
2. Disconnect positive (+) battery terminal second.
3. Install new battery; install hold down strap on both hooks.
4. Connect positive (+) battery terminal first, slide rubber boot over hardware.
5. Connect negative (-) battery terminal second, slide rubber boot over hardware.

⚠ Allow engine to cool before draining oil

⚠ Disconnect spark plug wire to avoid accidental start-up

1. Place generator on a level surface.
2. Disconnect the spark plug wire and place it where it cannot contact spark plug.
3. Clean area around oil fill and oil drain plug.
4. Remove oil fill cap/dipstick.
5. Remove oil drain plug and drain oil completely into a suitable container.
6. Install oil drain plug and tighten securely.
7. Add recommended engine oil as necessary.
8. Install oil fill cap/dipstick and hand-tighten.
9. Wipe up any spilled oil.
10. Properly dispose of oil per applicable regulations.

1. Loosen clamp and remove screw.
2. Inspect screen and replace if torn, perforated or damaged; if not damaged, clean with commercial solvent.
3. Replace spark arrestor cone and screen; secure with clamp and screw.

⚠ Run engine 10-15 minutes to circulate stabilizer before storage; fuel stored over 30 days can go bad

1. Change engine oil.
2. Remove spark plug.
3. Pour a tablespoon (5-10cc) of clean engine oil or fogging agent into cylinder.
4. Pull starter recoil several times to distribute oil in cylinder.
5. Install spark plug.
6. Pull recoil slowly until resistance is felt to close valves; gently release recoil.

1. Turn knob and remove air filter cover.
2. Wash in soapy water.
3. Squeeze filter dry in clean cloth (do not twist).
4. Clean air filter cover before re-installing.

⚠ Replace if electrodes pitted/burned or porcelain cracked

Tools: feeler gauge, spark plug wrench

1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Inspect electrode gap with feeler gauge and reset gap to 0.028-0.031 in (0.70-0.80 mm).
4. Install spark plug finger tight, then tighten an additional 3/8 to 1/2 turn.

1. Choose which devices you want to power at the same time.
2. Record and add the running watts listed for each device that you need to power.
3. Record the starting watt requirements for each device.
4. Add the starting watts for the highest starting watt device plus the total running watts to determine the total watts requirements.
5. Consult the specifications to find the correct generator for your needs.