Honda EU2200IT A2 Oil Level Switch Replacement

Written By: Arthur Shi
  • Comments: 2
Honda EU2200IT A2 Oil Level Switch Replacement

Difficulty

Difficult

Steps

73

Time Required

No estimate

Introduction

This guide shows how to remove and replace the oil level switch for the Honda EU2200IT generator. The switch is attached from within the crankcase and requires major disassembly.
If you encounter problems during the process, consult the official Honda service guides.

Drain the fuel from the fuel tank before you begin this procedure. Any fuel remaining in the tank will spill out. Be ready to contain any spillage.

The crankcase must be resealed with liquid sealant. Be sure to have Threebond 1207B or equivalent liquid sealant at hand before you begin the procedure.

You will need to refill the engine oil for this procedure. The generator requires up to 0.46 liters of SAE 10W-30 oil.

You may find it helpful to loosely replace the bolts after you removed a part, in order to keep track of the bolts and to keep the screw holes clean.

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    • Before you begin, make sure the generator is switched off and the generator is cool to the touch.

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    • Lift and remove the spark plug cover.

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    • Grab the plastic housing at the end of the spark plug wire.

    • Pull firmly to disconnect the wire from the spark plug.

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    • Use a Phillips #2 screwdriver to loosen the screw holding the maintenance cover in place.

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    • Swing the top of the maintenance cover out.

    • Remove the maintenance cover.

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    • Unscrew and remove the oil filler cap.

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    • Place an oil pan below the fill port to catch the engine oil.

    • Carefully tilt the generator towards the oil pan to drain the oil.

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    • During reassembly, be sure to refill the engine oil:

    • If you recently resealed the crankcase cover with liquid sealant, wait at least 20 minutes before adding oil.

    • Use SAE 10W-30 oil, up to 0.46 US quarts.

    • Add oil until the dipstick is almost completely submerged.

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    • Place a container below the drain tube to catch the excess fuel.

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    • The carburetor drain screw is located at the bottom of the carburetor.

    • Use a flathead screwdriver to loosen the fuel drain screw until fuel begins to drain out of the carburetor.

    • Once you drain the fuel bowl, re-tighten the fuel drain screw.

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    • Remove the four Phillips screws securing the back cover.

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    • Remove the back cover.

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    • Remove the four screws securing the front cover:

    • Two Phillips screws

    • Two Phillips screws (one on each side)

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    • Swing the top edge of the front cover away from the generator.

    • Pull the front cover away slightly away.

    • The front cover still has many wires connected to it. Be careful not to strain any wires.

    This cover was damaged upon arrival. How do I take it off completely to replace it.

    janeenerider -

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    • Remove the lower gray plates from both sides of the generator.

    • During reassembly, be sure to reinstall the gray plate with the air vent cutout onto the right (access-side) cover.

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    • Remove the fasteners securing the left (non-access) cover:

    • Two Phillips screws

    • Two 10 mm bolts

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    • Remove the left (non-access) cover.

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    • Slide the vent and drain tubes out of their cover ports along the bottom of the right cover.

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    • Remove the Phillips screw securing the starter rope port.

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    • Thread the starter rope handle through the port's cutout.

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    • Remove the right (access-side) cover.

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    • If you are replacing only the fuel tank, you can skip the next six steps.

    • Use a screwdriver to pry and loosen the diaphragm tube from the fuel pump.

    • Disconnect the diaphragm tube from the fuel pump.

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    • Use a pair of pliers to squeeze and slide the spring clip off the fuel pump port.

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    • Residual fuel may leak out of this hose. Be ready to contain any spillage.

    • Disconnect the fuel hose from the fuel pump.

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    • Pull and disconnect the engine stop switch connector from its socket.

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    • Remove the Phillips screw securing the starter rope guide.

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    • Feed the starter rope handle and guide through the panel cutout.

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    • Any residual fuel in the tank will leak. Be ready to contain any spillage.

    • Use a pair of pliers to squeeze and slide the spring clip off the fuel tank port.

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    • Disconnect the fuel line and filter from the fuel tank.

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    • Remove the Phillips screw securing the left (non-access) frame assembly.

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    • Remove the left (non-access) frame assembly.

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    • Lift and remove the fuel tank.

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    • Use a 10 mm socket to remove the three bolts securing the muffler:

    • Two 50 mm-long bolts

    • One 75 mm-long bolt

    • During reassembly, these bolts should be tightened to 8.7 lb-ft.

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    • Remove the muffler.

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    • Use a wire brush to clean any deposits off the spark arrester.

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    • During reassembly, replace the muffler gasket if it shows signs of wear.

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    • Use a flathead screwdriver to pry up the blue wire harness from the under-cover.

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    • Use a mallet and punch to tap out the front collar (closest to the electrical panel) securing the motor assembly to the under-cover.

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    • Use a 10 mm socket to remove the two bolts securing the motor rear to the under-cover.

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    • The motor assembly is heavy. Follow safe lifting practices when you lift the assembly.

    • Lift the motor assembly off the under-cover and set it aside.

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    • Use a 10 mm socket to remove the two bolts securing the left shroud.

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    • Begin separating the left shroud from the engine assembly by pulling it away from the assembly.

    • The shroud sits in a groove on the engine assembly and may take some force to pull out.

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    • Pull along the edge of the shroud until you separate the shroud from the engine assembly.

    • Remove the shroud.

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    • Remove the Phillips screw securing the filter cover.

    • During reassembly, be sure to tighten the screw to at least 1.7 ft-lb to prevent it from loosening during operation.

    • Remove the filter cover.

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    • Remove the air filters from the filter box.

    • To clean the filters:

    • Clean the filters in warm soapy water

    • Allow the filters to dry thoroughly

    • Dip the filters in clean engine oil, and squeeze out excess oil

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    • Disconnect the breather tube from the air cleaner housing.

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    • Remove the following fasteners securing the housing:

    • Two 8 mm nuts

    • During reassembly, tighten these to 3.6 ft-lb.

    • One 8 mm bolt

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    • Remove the air filter housing.

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    • During reassembly, replace the air intake gasket if it shows signs of wear.

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    • During reassembly, use this photo as a reference for how to route the hoses.

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    • Unclip the fuel and air hoses from the side of the motor assembly.

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    • Pull the breather tube straight out of its port.

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    • Use a flathead screwdriver to unclip the carburetor wires from the side of the motor assembly.

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    • Slide the carburetor off its two bolt rails.

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    • During reassembly, replace the carburetor seal if it shows signs of wear.

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    • Use an 8 mm socket to remove the two bolts securing the carburetor insulator.

    • During reassembly, tighten these bolts to 2.2 ft-lb.

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    • Remove the carburetor insulator along with the two bolt rails.

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    • During reassembly, replace the insulator gasket if it shows signs of wear.

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    • Use a 10 mm socket to remove the bolts securing the right shroud.

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    • Begin separating the right shroud from the engine assembly by pulling it away from the assembly.

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    • Pull the shroud away along the edge. Use a flathead screwdriver to pry it out of the engine assembly groove.

    Here you should remove the aluminum bell housing first, that way you don’t need to force the plastic part off the housing.

    cgonzalez19835 -

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    • Remove the right shroud from the engine assembly.

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    • Use a 10 mm socket to remove the two bolts securing the exhaust pipe.

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    • Remove the exhaust pipe from the engine assembly.

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    • Loosen the cable tie securing the engine oil sensor.

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    • Disconnect the yellow engine oil sensor wire by pulling the connector apart.

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    • Use a 10 mm socket to remove the bolt securing the engine oil sensor ground.

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    • Use a 10 mm socket to remove the eight bolts securing the crankcase cover.

    • During reassembly, hand-tighten the crankcase cover bolts in the pattern indicated in the second image.

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    • The crankcase cover is sealed with liquid sealant and must be pried apart.

    • Be ready to contain any residual engine oil that may spill from the crankcase.

    • Insert a large flathead screwdriver or pry bar into the crankcase seam and pry to loosen the crankcase cover.

    • Do not use too much force, or you may gouge the mating surface.

    • Pry along the entire crankcase perimeter until you fully loosen the crankcase cover.

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    • Separate and remove the crankcase cover.

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    • To reseal the crankcase during reassembly:

    • Clean all adhesive and oil residue off of the cover and crankcase mating surfaces.

    • Apply a bead of liquid sealant to the crankcase.

    • Fit the crankcase cover to the crankcase.

    • Do not fill the crankcase with engine oil for at least 20 minutes after sealing the crankcase.

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    • Use a 10 mm socket to remove the bolt securing the oil level sensor.

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    • Thread the sensor cable through the port and remove the sensor.

    • Be sure to check if your replacement sensor has an O-ring pre-installed on the sensor's mating surface. If it doesn't, transfer the O-ring over.

Conclusion

To reassemble your device, follow these instructions in reverse order.

Author

Arthur Shi

Member since: 03/01/18

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