DeWalt 6500 Watt Portable Gas Generator

Why I chose the DeWalt 6500

I picked up the DeWalt 6500 as a portable workhorse for jobsite tools and as a fallback for home backup during planned outages. I wanted something in the 6–7 kW class with true 120/240V output, electric start, durable construction, and real safety features. After several weeks of mixed use—running a welder and saws during the day and a fridge, freezer, furnace blower, and sump pump during a storm—I have a clear sense of where this generator shines and where it asks for a bit of finesse.

Setup and first start

Out of the box, assembly is straightforward. The wheel kit, feet, and fold-down handle bolt on cleanly, and all the hardware is included. The unit ships with engine oil, but don’t assume it’s enough—check the manual for capacity and fill to the proper level before first start. The battery leads come disconnected for shipping; attach them, charge the battery if needed, and you’re ready to go.

Electric start is a standout convenience. The first start took a few extra seconds as fuel reached the carburetor; after that, it consistently fired in a couple seconds. There’s a backup recoil starter, which I tested—it worked on the first pull with the choke set correctly. The hour meter is simple but helpful, giving me a precise way to schedule break-in and regular oil changes.

Power and performance

This generator is rated at 6,500 W running and 8,125 W starting. In use, those numbers feel honest. On the jobsite, it ran my 240V MIG welder without complaint through most of its range, and it handled a simultaneous 15-amp saw cut or grinder pass without voltage sag severe enough to affect weld quality. When you stack motor starts—like a pump kicking on while a heavy tool is already drawing—it will audibly dig in, but the output remained stable in my testing.

For home backup, I sequenced loads to avoid stacking inrush currents. Fridge first, then freezer, then the gas furnace blower, and finally some lighting and chargers. Starting loads one at a time is the difference between drama and a non-event. If you’re trying to start a tough motor (like a deep well pump), temporarily switch off idle control so the engine is already at full speed, then re-enable it once everything settles.

As expected for a conventional, open-frame generator, this is not an inverter model. Sensitive electronics charged fine for me through the GFCI-protected 120V outlets, but I’d still use a quality surge protector or line-interactive UPS if you’re running desktop computers or specialized electronics.

Outlets and usability

The covered, GFCI-protected outlets are a big plus on the jobsite and around the house, especially in wet weather. You get multiple 120V, 20A receptacles plus a 120/240V outlet for a transfer switch or 240V tools. Everything I plugged into the 120/240V receptacle—welder, compressor, and later a transfer switch at home—was solid.

A note on refrigeration and GFCI: some appliances exhibit small leakage currents or high inrush that can be finicky on certain circuits. If a fridge is tripping a GFCI breaker, try a different circuit, inspect cords, and make sure you’re using a short, heavy-gauge extension (I stick with 10-gauge for long runs). Also, disable idle control before starting those loads.

Runtime and fuel use

With a 7.5-gallon tank and idle control engaged, I saw roughly a day’s work at about half load before refueling—around the advertised 10 hours when measured loosely across a couple tanks. If you keep loads under the halfway mark, it sips fuel; surge it frequently or run sustained near capacity and you’ll be closer to a typical workday per tank. The fuel gauge is easy to read and reasonably accurate, which helps with planning.

Noise and manners

It’s an open-frame gas generator with a 389 cc engine—there’s no getting around the fact that it’s loud under load. At idle or light load, the idle-control “lowers the voice” noticeably, and at sustained high loads it’s typical jobsite generator noise. I place it downwind and as far from work or living spaces as cord length allows. Rubber feet help keep vibration from walking the unit on concrete.

Build quality and portability

The 1-1/4 in. steel-tube cradle feels stout, and the overall construction inspires confidence. The never-flat wheels and folding, locking handle make a big difference; at 186 pounds, you don’t want to carry this far. One person can maneuver it over flat ground or a ramp; loading into a truck bed is realistically a two-person job. The covered outlets and powder-coated frame are holding up well after a couple of rainy days and some dusty cutting.

Safety features you’ll actually use

CO-Protect, the automatic carbon-monoxide shutdown, is the safety feature that matters most. I tested it by placing the generator too close to a wall and letting exhaust swirl; the unit shut down and alerted me. That’s exactly the kind of safeguard that prevents a bad situation. Use it correctly—always run outdoors, 20+ feet from doors and windows, downwind of occupied spaces—and treat CO-Protect as a second line of defense, not a license to move it closer.

Low-oil shutdown is another must-have that works as intended. The hour meter takes the guesswork out of maintenance intervals, and the GFCI outlets add an extra layer of protection in damp conditions.

Cold-weather notes

In sub-zero conditions, any small engine can develop ice in crankcase ventilation lines and carburetor passages. I ran this unit in single-digit temperatures and didn’t have issues, but I’ve seen breather icing on similar engines at around -10°F. My cold-weather routine: use a cold-rated synthetic oil, store the unit in a dry, unheated space to minimize condensation, shield it from direct wind while keeping exhaust clear, and warm it briefly before heavy load. If you’re operating in extreme cold, inspect the breather tube and air intake for icing during long runs.

Maintenance and ownership

The hour meter makes break-in simple: first oil change early, then on schedule. I use fresh, ethanol-free fuel when I can, or treat regular pump gas with a stabilizer if it’ll sit. Run the carburetor dry before storage, check the air filter regularly (dusty sites clog it quickly), and keep terminals on the starting battery clean. The 2-year limited warranty is competitive for this class.

What I’d change

• Noise: It’s typical for the category, but still loud. An optional muffler upgrade or a factory “quiet kit” would be welcome.
• Weight: The frame is stout, but 186 lb is a haul. The wheels help; still, a grab handle on the frame corners would make two-person lifts easier.
• GFCI sensitivity: It’s the right call for safety, but some appliances and older tools can be finicky. A clearly labeled 30A 120/240V outlet with a sealed cover and guidance for transfer switch use would help users avoid guesswork.
• Cold-weather hardening: A small breather heater or cold-weather kit option would be appreciated for those who run in deep winter.

The bottom line

The DeWalt 6500 strikes a strong balance of real-world power, safety, and durability. It starts easily, holds voltage under mixed loads, runs efficiently at partial load with idle control, and backs it all up with practical features: covered GFCI outlets, a true 120/240V receptacle, an hour meter, and rugged wheels and handle. It’s not an inverter, and it’s not quiet—but it’s built to work, not whisper.

Recommendation: I recommend the DeWalt 6500 for contractors, serious DIYers, and homeowners who need a dependable 6–7 kW class generator for tools and essential home backup. It’s especially compelling if you value safety features like CO shutdown and GFCI protection, want electric start with recoil backup, and plan to run a mix of 120V and 240V loads. If you need whisper-quiet operation or ultra-clean power for sensitive electronics, an inverter generator (or pairing this with a good UPS) might suit you better. For most power tools, pumps, and household essentials, this generator delivers steady power with thoughtful safeguards and a rugged build that inspires confidence.