It was unclear exactly how many people had been injured and detained, amid growing protests from international rights groups.
Pro-Zelaya supporters took to the streets of Tegucigalpa once again on Saturday, including some who said they had traveled five days to reach the capital.
Hundreds gathered briefly around the international airport in Tegucigalpa in anticipation of Mr Zelaya's arrival, vowing to return.
The Honduran leader earlier told a television news station in Venezuela that he would return on Sunday, and do so with 'several presidents' of allied countries.
'I am planning my return to Honduras... We will arrive at the international airport in Tegucigalpa, Honduras with several presidents (and) members of international organizations,' he told Caracas-based station Telesur.
However, the Honduran interim leaders warned they would arrest him on his return.
The emergency OAS meeting was also attended by Argentine President Cristina Kirchner and Paraguayan President Fernando Lugo.
President Rafael Correa of Ecuador was expected in the US capital early Sunday.
Meanwhile, Catholic leaders in Honduras warned of a potential bloodbath if Zelaya returned to the country.
'We think that a return to the country at the moment could provoke a bloodbath,' Cardinal Oscar Rodriguez - the capital's archbishop - said on national radio and television, reading a message from the country's Bishops' Conference.
'To this day no Honduran has died. Please think, because afterwards it will be too late,' Mr Rodriguez added.
Mr Insulza also agreed that Mr Zelaya's planned return to Honduras was dangerous and risky and that the ousted leader had 'to make up his mind' on whether to undertake such a step.
'I think there are risks, of course,' the OAS secretary general told reporters. 'If you ask if it is a safe return, of course not.' -- AFP