Honda EM4000SX Generator Set

⚠ 10 sec start delay is used in combination with an ATS panel to prevent multiple short start-stop commands coming from the ATS panel while the mains is unstable during blackout.

1. Open the controller cover and locate the red dip switch (S-DELAY).
2. Use your finger to move the dip switch 1 to ON position.
3. Replace the cover and tighten screws.

⚠ Excess oil will restrict air flow and may cause engine to smoke at startup.

⚠ Operating without element or loose element allows dirt to enter engine.

1. Remove air cleaner case lid springs and unhook tabs.
2. Remove air cleaner cover and element.
3. Check element and replace if damaged.
4. Clean element in warm soapy water or non-flammable solvent, dry thoroughly.
5. Dip filter in clean engine oil, squeeze out excess oil.
6. Install air cleaner in reverse order of removal.

⚠ Battery gives off explosive gases; keep sparks, flames, and cigarettes away.

⚠ Battery contains sulfuric acid; contact with skin or eyes may cause severe burns.

Tools: Digital multimeter, Battery charger

1. Turn combination switch OFF.
2. Remove battery.
3. Check battery for damage.
4. Leave battery for 30 minutes.
5. Measure battery voltage with digital multimeter.
6. If below 12.4 V, charge battery.
7. Connect charger positive to positive, negative to negative.
8. Leave for 30 minutes.
9. Measure voltage; if below 12.7 V, charge.
10. If still below 12.7 V, replace battery.

⚠ Used engine oil contains substances that have been identified as carcinogenic. Wash hands thoroughly after contact.

1. Drain oil while engine is warm.
2. Place suitable container under oil drain bolt.
3. Remove oil filler cap, oil drain bolt, and washer.
4. Install new oil drain washer and tighten drain bolt to specified torque.
5. Fill with recommended oil to upper level mark.
6. Tighten oil filler cap securely.

1. Place engine on level surface.
2. Remove oil filler cap and wipe oil level gauge clean.
3. Insert oil filler cap without screwing in.
4. Remove cap and check oil level on gauge.
5. If near or below lower mark, fill to upper mark with recommended oil.
6. Tighten oil filler cap securely.

⚠ Gasoline is highly flammable and explosive. Keep heat, sparks, and flame away. Handle fuel only outdoors.

1. Drain fuel into suitable container.
2. Remove fuel tank and fuel strainer.
3. Clean fuel strainer and fuel tank with non-flammable solvent.
4. Allow to dry thoroughly.
5. Install fuel tank.
6. Check for any signs of fuel leakage.

⚠ If engine has been running, allow it to cool before proceeding.

Tools: Wire brush

1. Remove two screws and spark arrester.
2. Clean carbon deposits from spark arrester screen with wire brush.
3. Check screen for damage; replace spark arrester if damaged.
4. Install spark arrester in reverse order of removal.

⚠ If engine has been running, allow it to cool before proceeding.

Tools: Spark plug wrench, Wire-type feeler gauge

1. Remove spark plug cap, then spark plug using spark plug wrench.
2. Visually check; replace if heavily fouled or insulator cracked.
3. Measure plug gap with wire-type feeler gauge.
4. Adjust gap by bending side electrode.
5. Install spark plug finger-tight, then tighten 1/8 – 1/4 turn.
6. Install spark plug cap securely.

Tools: Thickness gauge

1. Disconnect breather hose.
2. Remove head cover bolt and head cover.
3. Set piston near top dead center of compression stroke.
4. Insert thickness gauge between rocker arm and valve stem.
5. If adjustment needed, loosen pivot adjusting nut, turn pivot to obtain specified clearance.
6. Retighten pivot adjusting nut to specified torque.
7. Recheck clearance.
8. Install head cover and breather hose.