Generac Portable Products 6500XL User manual

Owner’s Manual
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Obey all safety messages that follow this symbol to avoid possible injury or death.
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 9779-4 (6,500 Watt AC Generator) Manual No. 189417GS Revision 0 (09/04/2001)
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator
• Wheel kit
• Storage Cover
• Battery charge cables
• Spare Spark Plug,Air Filter, and Oil Filter
• Spark Plug Wrench
• (2) Locking 30 Amp plugs
• Engine oil
• Owner's manual
• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.
Parts Included*Table of Contents

2
6500XL Extended Life Generator
EQUIPMENT
DESCRIPTION
This generator is an engine–driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 Volt, single phase, 60 Hz devices
that require up to 6,500 watts (6.5 kW) of power that pull
up to 54.2 Amps at 120 Volts or 27.1 Amps at 240 Volts.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity.Add up the rated watts of all
devices you are connecting to generator receptacles at one
time.This total should not be greater than 6,500 watts. See
“Don’t Overload the Generator” on page 11.
The generator’s revolving field is driven at about 3,600 rpm
by a single-cylinder engine.
Every effort has been made to ensure that information in
this manual is accurate and current. However, Generac
reserves the right to change, alter or otherwise improve the
product and this document at any time without prior
notice.
CAUTION! Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipment.The generator supplies
correct rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load.When adequate
engine power is not available engine life may be
shortened.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner’s manual.
SAFETY RULES
This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit or
use it for any application it was not designed for. If you have
any questions about your generator’s application, ask your
dealer or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all–inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
WARNING! You must isolate the generator
from the electric utility using approved transfer
equipment if this unit is used for backup power.
Failure to isolate the generator from the
power utility may result in injury or death to
electric utility workers and damage to the
generator due to a backfeed of electrical energy.
Whenever the unit is providing backup power, the
electric utility must be notified.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
is available.
The engine exhaust from this product contains
chemicals known to the State of California
to cause cancer, birth defects,
or other reproductive harm.
WARNING:

6500XL Extended Life Generator
3
• The generator produces a very powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child or
any unqualified person to operate the generator.
•Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
•Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.
•Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine. Comply
with all laws regulating storage and handling of gasoline.
•Do Not overfill the fuel tank.Always allow room for fuel
expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.
•Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.
•Do Not insert any object through cooling slots of the
engine.You could damage the unit or injure yourself.
•Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 1).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
Figure 1 — Grounding Wing Nut
Grounding
Wing Nut

4
6500XL Extended Life Generator
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
REMOVE GENERATOR
FROM CARTON
• Set the carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
• Carefully open the top flaps of the shipping carton.
Review “Cold Weather Operation” on page 9.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping carton.
INSTALL WHEEL KIT
The wheel kit is designed to greatly improve the portability
of your generator.
NOTE: Wheel kit is not intended for over-the-road use.
You will need a socket wrench with 1/2" or 13mm sockets
and a needle-nose plier to install this kit.
Refer to Figure 2 and install the wheel kit as follows:
• Place the generator on a hard flat surface.
• Stand at the engine end of the generator and gently tilt
the generator forward, high enough to place wooden
blocks beneath the cradle.This will allow you to add the
wheels.
• Slide the axle through the holes in the brackets provided
on the generator cradle.
• Slide one wheel and flat washer on each end of the axle.
Make sure the air inflation valve is outward. Insert both
retaining pins using the needle-nose plier. Remove the
wooden blocks.
• Attach the vibration mounts to the support leg with
30mm capscrews, washers and lock nuts.
Lock
Nut
Support Leg
Vibration Mount
Flat Washer
30mm Capscrew
20mm
Capscrew
Lock Nut
Retaining Pin
Washer
Wheel
Axle
Figure 2 — Install Wheel Kit

6500XL Extended Life Generator
5
• With the wheels on, you can now lift up the handle end
and attach the support leg with 20mm cap screws and
lock nuts.
• Check each fastener to ensure it is secure and the tires
are inflated between 15-40 PSI.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
NOTE: The generator’s revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot.Allow
unit to cool for two minutes before refueling. Do
Not light a cigarette or smoke when filling the fuel
tank.
WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
• Use regular UNLEADED gasoline with the generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1/2" of tank space for
fuel expansion (Figure 3).
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts, such as the
carburetor, fuel filter, fuel hose or tank during storage.Also,
experience indicates that alcohol–blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leads to separation and formation of acids during storage.
Acidic fuel can damage the fuel system of an engine while
in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
Figure 3 — Typical Fuel Expansion Space
Fuel
Tank
1/2” Air
Space

6
6500XL Extended Life Generator
KNOWYOUR GENERATOR
Read this owner’s manual and safety rules before operating your generator.
Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
120 Volt AC, 20 Amp
Duplex Receptacle
Fuel Tank
Idle Control Switch
Choke Lever
Recoil Starter
12 Volt DC, 10 Amp
Receptacle
Run/Stop Switch
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
120/240 Volt AC,
30 Amp Receptacle
Spark Arrester Muffler
Air Cleaner
Grounding Wing Nut
Oil Fill Cap
12 Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120 Volt AC, 20 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle — May
be used to supply electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Wing Nut — Used for proper grounding of
unit.
Idle Control Switch — With this switch set to ON,
printed circuit board in control panel automatically reduces
engine speed when no load is connected and increases
engine to proper speed when load is applied. However, be
sure switch is OFF when starting engine.
Oil Fill Cap — Add oil to engine here.
Recoil starter — Used to start the engine.
Run/Stop Switch — Set this switch to "Run" before
using recoil starter. Set switch to "Stop" to switch OFF
engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.

6500XL Extended Life Generator
7
OPERATING THE
GENERATOR
CAUTION! Never start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1. Turn the fuel valve to the “On” position (Figure 4).
2. Make sure the Idle Control switch is in “Off” position
(Figure 5).
3. Set the Run/Stop switch to “Run” position (Figure 6).
4. Place the choke lever in the “Full” choke position
(Figure 7).
5. Grasp the recoil handle and pull slowly until slight
resistance is felt.Then pull rapidly one time only to
start engine.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move the choke lever to “Half” choke position, and
pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
7. Move choke lever to “Run” position. If engine falters,
move choke lever to “Half” choke position until the
engine runs smoothly and then to “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Refer to the engine owner’s manual for complete
starting instructions.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.
•Do Not connect 240 Volt loads to the 120 Volt
receptacles.
•Do Not connect 3–phase loads to the generator.
•Do Not connect 50 Hz loads to the generator.
•DO NOT OVERLOAD THE GENERATOR. See
“Don’t Overload the Generator” on page 11.
Figure 4 — Fuel Shut-offValve
Figure 5 — Idle Control Switch
Figure 6 — Run/Stop Switch
Figure 7 — Choke Lever

8
6500XL Extended Life Generator
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
• Put the idle control switch in the “Off” position.
• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and alternator.
• Move run/stop switch to “Stop”.
• Close the fuel shut–off valve.
Operating Automatic Idle Control
This switch is designed to greatly improve fuel economy.
When this switch is turned ON, the engine will only
run at its normal high governed engine speed when an
electrical load is connected.When an electrical load is
removed, the engine will run at a reduced speed. With the
switch off, the engine will run at the normal high engine
speed. Always have the switch off when starting and
stopping the engine.
Charging a Battery
WARNING! Storage batteries give off explosive
hydrogen gas while recharging.An explosive mixture
will remain around the battery for a long time after
it has been charged.The slightest spark can ignite
the hydrogen and cause an explosion, resulting in
blindness or other serious injury.
WARNING! Do Not permit smoking, open
flame, sparks or any other source of heat around a
battery.Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns. If
spill occurs flush area with clear water immediately.
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not
use the unit to charge any 6Volt batteries. Do Not use the
unit to crank an engine having a discharged battery.
To recharge 12Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery cells.
Do Not use tap water.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 8).
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).
• Start engine. Let the engine run while battery recharges.
• When battery has charged, shut down engine
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific
gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
Figure 8 — Battery Connections

6500XL Extended Life Generator
9
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
In an emergency, use the original shipping box as a
temporary shelter:
• Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.
• Cut appropriate slots to access receptacles of unit.
• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 9.
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent problems.
CAUTION!Neverrun unit indoors. Do Not
enclose generator any more than shown.
RECEPTACLES
120 Volt AC, 20 Amp, Duplex
Receptacle
Each receptacle (Figure 10) is protected against overload
by a 20 Amp push–to–reset circuit breaker.
Use each receptacle to operate 120Volt AC, single–phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).
Figure 10 — 120Volt AC, 20 Amp Duplex Receptacle
Figure 9 — Temporary Cold Weather Shelter
Wind

10
6500XL Extended Life Generator
120/240 Volt AC, 30 Amp, Locking
Receptacle
Use a NEMA L14–30 plug with this receptacle. Connect a
4–wire cord set rated for 250 Volt AC loads at 30 Amps
(or greater) (Figure 11).You can use the same 4–wire cord
if you plan to run a 120Volt load.
This receptacle powers 120/240Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power at
30 Amps for 120 Volts; 6,500 watts of power (6.5 kW) at
30 Amps for 240Volts.The outlet is protected by a 30 Amp
push–to–reset circuit breaker.
CAUTION! Although this outlet is rated for
120/240 Volt 30 Amp (up to 7,200 watts), the
generator is only rated for 6,500 watts. Powering
loads that exceed the wattage/amperage capacity of
the generator can damage it or cause serious
injuries. 240 Volt loads powered through this outlet
should not exceed 27.1 Amps of current draw.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125 Volts AC at 30 Amps to the
plug (Figure 12).
Use this receptacle to operate 120Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps.The outlet is protected by a 30 Amp
push-to-reset circuit breaker.
12 Volt DC, 10 Amp Receptacle
This connector (identified by the legend “12-VOLT D.C.”)
supplies 12 Volts DC at 10 Amps through battery charging
cables for recharging 12 Volt batteries (Figure 13). See
“Charging a Battery” on page 8.
Figure 11 — 120/240 Volt AC, 30 Amp Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30 Ground (Green)
Figure 12 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 13 — 12Volt DC, 10 Amp Receptacle

6500XL Extended Life Generator
11
DON'T OVERLOADYOUR
GENERATOR
Capacity
You must make sure your generator can supply enough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 14.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
Never add more loads than the generator capacity.Take
special care to consider surge loads in generator capacity,
as described above.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance Rated (Running)
Watts Additional Surge (Starting) Watts
Window Air
Conditioner 1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts 1800 Highest Surge Watts
Tool or Appliance Rated* (Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb - 75 watt 75 -
Deep Freezer 500 500
Sump Pump 800 1200
Refrigerator/Freezer - 18 Cu. Ft. 800 1600
Water Well Pump - 1/3 HP 1000 2000
Heating/Cooling
Window AC - 10,000 BTU 1200 1800
Window Fan 300 600
Furnace Fan Blower - 1/2 HP 800 1300
Kitchen
Microwave Oven - 1000 Watt 1000 -
Coffee Maker 1500 -
Electric Stove - Single Element 1500 -
Hot Plate 2500 -
Family Room
DVD/CD Player 100 -
VCR 100 -
Stereo Receiver 450 -
Color Television - 27” 500 -
Personal Computer w/17” monitor 800 -
Other
Security System 180 -
AM/FM Clock Radio 300 -
Garage Door Opener - 1/2 HP 480 520
Electric Water Heater - 40 Gallon 4000 -
DIY/Job Site
Quartz Halogen Work Light 1000 -
Airless Sprayer - 1/3 HP 600 1200
Reciprocating Saw 960 960
Electric Drill - 1/2 HP 1000 1000
Circular Saw - 7 1/4” 1500 1500
Miter Saw - 10” 1800 1800
Planer/Jointer - 6” 1800 1800
Table Saw/Radial Arm Saw - 10” 2000 2000
Air Compressor - 1-1/2 HP 2500 2500
Figure 14 - Wattage Reference Chart

12
6500XL Extended Life Generator
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . .10,500 watts
Continuous Wattage Capacity . . . . . . . . . . .6,500 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC Load Current:
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .54.2 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .27.1 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 7 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 200 lbs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine Maintenance
See engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with
snow, leaves or any other foreign material.
NOTE: Do Not use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air
slots, some of the water will be retained in voids and
cracks of the rotor and stator winding insulation.Water
and dirt buildup on the generator internal windings will
eventually decrease the insulation resistance of these
windings.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
STORAGE
The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than
30 days, use the following guidelines to prepare it for
storage.
Generator Storage
• Clean the generator as outlined in “To Clean the
Generator.”
• Check that cooling air slots and openings on generator
are open and unobstructed.
CAUTION! Storage covers can be flammable.
Do Not place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
•Do Not store gasoline from one season to another.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.

6500XL Extended Life Generator
13
TROUBLESHOOTING
Problem Cause Solution
Engine is running, but
no AC output is
available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good
condition.
4. Contact Generac service facility.
Engine runs good but
bogs down when loads
are connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator”
on page 11.
3. Contact Generac Power Systems
service facility.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop switch set to “Stop”.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to spark
plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Set switch to “Run”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank and fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Put choke lever to “Run” position.
9. Fill crankcase to proper level.
10. Contact Generac Power Systems
service facility.
11. Contact Generac Power Systems
service facility.
12. Contact Generac Power Systems
service facility.
Engine shuts down
during operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac Power Systems
service facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the Generator”
on page 11.
2. Replace air filter.
3. Contact Generac Power Systems
service facility.
Engine “hunts” or
falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
1. Move choke to halfway position till
engine runs smoothly.
2. Contact Generac Power Systems
service facility.

14
6500XL Extended Life Generator
SCHEMATIC

6500XL Extended Life Generator
15
WIRING DIAGRAM

16
6500XL Extended Life Generator
EXPLODED VIEW – MAIN UNIT

6500XL Extended Life Generator
17
PARTS LIST – MAIN UNIT
Item Part # Qty Description
1 NSP 1 ENGINE
2 A92531GS 1 SUPPORT, Support
3 A92731GS 1 SUPPORT, Engine & Muffler
4 92247GS 1 HOUSING, Engine Adapter
5 92679GGS 1 ASSEMBLY, Rotor (Inclds Item 7)
6 92681AGS 1 ASSEMBLY, Stator
7 65791GS 1 BEARING
8 96796GS 1 WASHER, 22.2 O.D. x 3 Thk
9 22129GS 2 WASHER, M8 Lock
10 86307GS 4 HHMS, 5/16 - 24 x 3/4 SEMS
11 25254GS 1 HHCS, 5/16 - 24 x 9-7/8"
12 92609GS 2 MOUNT,Vibration
13 82857GS 4 MOUNT,Vibration
14 40976GS 2 SCREW, M8 - 1.25 x 20
15 66476GS 2 CAPSCREW, M6 - 1.0 x 12mm
16 92532GS 1 BRACKET, Muffler
17 22142GS 2 SCREW, 5/16 - 18 x 3/4"
18 A7433GS 1 MUFFLER
19 90239GS 1 GASKET, Muffler
20 81917GS 1 PIN, 4 mm x 10 Roll
21 B4986GS 1 DECAL, Ground
22 83083GS 1 SCREEN, Spark Arrester
23 22531GS 2 HHCS, 5/16-18 x 1-3/4"
24 189160GS 12 NUT, 5/16-18 Serrated Flange
25 66825CGS 1 CARRIER, Rear Bearing
26 74908GS 4 TAPTITE, M5-0.8 x 10
27 86308BGS 4 BOLT, M6 -1 x 165 mm Stator
28 65795GS 1 RECTIFIER, Battery Charge
29 66849AGS 1 TAPTITE, M5-0.8 x 20
30 67022GS 1 GROMMET, Rubber
31 84132GS 1 ASSEMBLY, Power Regulator
32 66386GS 1 ASSEMBLY, Brush Holder
33 66849GS 2 TAPTITE, M5 - 0.8 x 16
34 B4871GS 1 COVER, Bearing Carrier
35 22769GS 1 WASHER, #10 Int. Shakeproof
36 86494GS 1 SCREW, M6 -1.0 x 16 Wing
37 86292GS 1 HHCS, #10 Self Driller
38 77395GS 4 NUT, M6 Flange Lock
39 83465GS 4 GROMMET,Tank
40 78831BGS 4 HHCS, M6-1.0 x 60, SEMS
41 80270GS 1 VALVE,Tank
42 78299GS 1 BUSHING, Plastic Tank
Item Part # Qty Description
43 B4363GS 1 CAP, Fuel Gauge
44 B1998GS 1 TANK,ASM, 7- Gal (Includes
Items 41 & 42)
45 J92039GS 1 SHIELD, Heat
46 92665GS 1 INSULATION #2-1/4" Thick
47 85000GS 1 CLIP, Insulation
48 14353621GS 1 WIRE, Ground
49 26850GS 2 WASHER, M6 Shakeproof
50 39287GS 2 HHCS, M8 - 1.25 x 45
51 92982GS 1 DECAL, Danger
52 189407GS 2 DECAL, Heat Shield
53 49820GS 2 NUT, M8 Nylok
54 22145GS 4 WASHER, Flat, 5/16 - M8
55 187104GS 4 WASHER, Nylon
56 BB5586GS 2 HANDLE
57 B4605GS 2 GRIP
58 B4135GS 2 PIN, with Lanyard
59 A187024GS 1 CRADLE
60 92630GS 1 ASSEMBLY, Control Panel
61 189406GS 1 DECAL, Control Panel
62 93826GS 1 DECAL, Start Instructions
63 J96068GS 1 SHIELD, Heat
64 56893GS 5 CRIMPTITE, 10-24 x 1/2"
65 A8927GS 1 MANUAL, Engine
66 189417GS 1 MANUAL, Owners
67 43438GS 1 PLUG, 240V, 30A 4-Prong
68 37806GS 1 PLUG, 125V, 30A 3-Prong
69 70185GS 1 OIL FILTER
70 73111GS 1 ELEMENT,Air Cleaner
71 65787GS 1 CABLE, Battery Charge
72 84882GS 1 WRENCH, Spark Plug
73 72347GS 1 SPARK PLUG
74 B4767GS 1 COVER, Storage
75 B2153GS 6 SCREW, Self Driller, 12-14 x 7/8"
76 73054GS 1 DECAL, Fuel Shut Off
77 77816GS 2 DECAL, Caution Hot Muffler
78 20566GS 1 DECAL, 1-800
79 AB3061GS 2 OIL BOTTLES, 28 oz.
Optional Accessories Not Included:
84883GS Cord Wrap

18
6500XL Extended Life Generator
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part # Qty Description
1 A92070GS 1 PANEL, Control
2 23897GS 4 FLAT WASHER, #10 M5
3 49226GS 4 LOCK WASHER, M5
4 91526GS 4 SCREW, M5-0.8 x 12mm
5 82538GS 1 SWITCH, Idle Control
6 82881GS 4 LOCK WASHER, 7/16"
7 43181GS 4 SCREW, M3 - 0.5 x 10mm
8 43182GS 4 LOCK WASHER, M3
9 90418GS 1 OUTLET, 12V
10 75207AGS 2 CIRCUIT BREAKER, 30A
11 75207GS 2 CIRCUIT BREAKER, 20A
12 23365GS 6 WASHER, #8 Shakeproof
13 68868GS 1 OUTLET, 120 Volt, 30 Amp
Locking
Item Part # Qty Description
14 43437GS 1 OUTLET, 120V/240V, 30A
Locking
15 68759GS 1 OUTLET, 120V, 20A Duplex
16 43180GS 6 FLAT WASHER, M4
17 22264GS 6 LOCK WASHER, #8 M4
18 51715GS 6 NUT, M4-0.7 Hex
19 64526GS 8 SCREW, #6-32 x 3/8"
20 83970GS 1 BOARD, System Control
21 64525GS 4 STAND-OFF, 3/4" Hex
22 87962GS 1 CIRCUIT BREAKER. 12V, 10A
23 84335GS 1 ASSEMBLY,Wire Harness
24 84134GS 1 GROMMET, Rubber Conn.
25 B92069GS 1 BOX, Control Panel
26 84028GS 1 TRANSFORMER, Idle Control

6500XL Extended Life Generator
19
EXPLODED VIEW AND PARTS LIST – WHEEL KIT
Item Part # Qty Description
1 BB5586GS 2 HANDLE
2 B4966GS 2 WHEEL
3 93693GGS 1 AXLE
4 87005AGS 2 PIN, Retaining
5 39287GS 2 HHCS, M8 - 1.25 x 45
6 B186927GS 1 LEG, Support
7 27007GS 2 MOUNT,Vibration
8 42909GS 2 CAPSCREW, Hex Hd. M8 - 1.25
x 30
Item Part # Qty Description
9 52858GS 4 NUT, Lock M8
10 22247GS 2 WASHER,Wheel
11 39253GS 2 CAPSCREW, Hex Hd. - M8 -
1.25 x 20
12 22145GS 6 WASHER, Flat, 5/16-M8
13 49820GS 2 NUT, M8 Nylok
14 187104GS 4 WASHER, Nylon
15 B4605GS 2 GRIP
16 B4135GS 2 PIN, with Lanyard

GENERAC PORTABLE PRODUCTS, LLC (hereafter referred to as the COMPANY) warrants to the original purchaser that the
components in its portable generator will be free from defects in materials or workmanship for the items and period set forth
below from the date of original purchase.This warranty does not include the gasoline engine when furnished or attached because
such engine is covered solely by the engine manufacturer’s warranty. Starting batteries are not warranted by the COMPANY.The
term “original purchaser” means the person for whom the generator is originally purchased.This warranty is not transferable and
applies only to portable generators driven by an overhead valve engine.
Warranty Schedule:
Consumer* Commercial*
Engine Warranted solely by the engine manufacturer
All other parts 2 years (2nd year parts only) 1 Year
With the exception of European Community Countries, all units bound for export shall be warranted for One (1)Year in
Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original
purchaser.This warranty does not apply to units used for prime power in place of utility. "Commercial Use" means
all other uses, including rental, construction, commercial and income producing purposes. Once a generator has
experienced commercial use, it shall thereafter be considered a commercial use generator for the purposes of this
warranty.
During the warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**.All transportation costs under warranty, including return to
the factory if necessary, are to be borne by the purchaser and prepaid by the purchaser.This warranty does not cover normal
maintenance and service and does not apply to a generator set, alternator, or parts which have been subjected to improper or
unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or
storage so as, in the COMPANY’s judgement, to adversely affect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator needs periodic parts service and replacement to
perform well.This warranty will not cover repair when normal wear has exhausted the life of a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY.THE COMPANY HEREBY DISCLAIMS ANY AND ALL IMPLIED
WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW.THE DURATION OF ANY IMPLIEDWARRANTIES
WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS
WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL
WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR THE USE OFTHE POWER EQUIPMENT, OR ANY
COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT:AND ANY IMPLIED WARRANTIES ARE
LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you.This warranty gives you specific legal rights and
you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Or look on the internet at
www.generac-portables.com.Warranty service can be performed only by a COMPANY authorized service facility.This warranty will
not apply to service at any other facility.At the time of requesting warranty service, evidence of original purchase date must be
presented.
LIMITED WARRANTY
FOR PORTABLE GENERATORS
GENERAC PORTABLE PRODUCTS, L.L.C.
Jefferson,Wisconsin U.S.A.