Honda EU2200IT A2 Stator Replacement

Written By: Arthur Shi

Comments: 4

Difficulty

Difficult

Steps

Time Required

No estimate

Introduction

This guide shows how to remove and replace the stator for the Honda EU2200IT generator.

This is a very involved procedure and requires major disassembly. If you encounter problems during the process, consult the official Honda service guides.

You will need a flywheel puller with a metric collar set in order to pull the rotor off. You can purchase Honda’s puller collar set (07APC-ZY1A100), or you can fashion a set yourself with some metric bolts and washers.

The rotor is heavily bolted onto a free-spinning shaft. An impact wrench may be able to loosen the bolt. You may also need a strap wrench to hold the rotor steady.

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.

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.

Tools

Parts

Step 1

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

Step 2

Lift and remove the spark plug cover.

Step 3

Grab the plastic housing at the end of the spark plug wire.
Pull firmly to disconnect the wire from the spark plug.

Step 4

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

Step 5

Swing the top of the maintenance cover out.
Remove the maintenance cover.

Step 6

Unscrew and remove the oil filler cap.

Step 7

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.

Step 8

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.

Step 9

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

Step 10

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.

Step 11

Remove the four Phillips screws securing the back cover.

Step 12

Remove the back cover.

Step 13

Remove the four screws securing the front cover:
Two Phillips screws
Two Phillips screws (one on each side)

Step 14

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 -

Step 15

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.

Step 16

Remove the fasteners securing the left (non-access) cover:
Two Phillips screws
Two 10 mm bolts

Step 17

Remove the left (non-access) cover.

Step 18

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

Step 19

Remove the Phillips screw securing the starter rope port.

Step 20

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

Step 21

Remove the right (access-side) cover.

Step 22

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.

Step 23

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

Step 24

Residual fuel may leak out of this hose. Be ready to contain any spillage.
Disconnect the fuel hose from the fuel pump.

Step 25

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

Step 26

Remove the Phillips screw securing the starter rope guide.

Step 27

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

Step 28

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.

Step 29

Disconnect the fuel line and filter from the fuel tank.

Step 30

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

Step 31

Remove the left (non-access) frame assembly.

Step 32

Lift and remove the fuel tank.

Step 33

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

Step 34

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

Step 35

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

Step 36

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.

Step 37

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

Step 38

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.

Step 39

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

Step 40

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.

Step 41

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

Step 42

Disconnect the breather tube from the air cleaner housing.

Step 43

Remove the following fasteners securing the housing:
Two 8 mm nuts
During reassembly, tighten these to 3.6 ft-lb.
One 8 mm bolt

Step 44

Remove the air filter housing.

Step 45

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

Step 46

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

Step 47

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

Step 48

Pull the breather tube straight out of its port.

Step 49

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

Step 50

Slide the carburetor off its two bolt rails.

Step 51

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

Step 52

Use an 8 mm socket to remove the two bolts securing the carburetor insulator.
During reassembly, tighten these bolts to 2.2 ft-lb.

Step 53

Remove the carburetor insulator along with the two bolt rails.

Step 54

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

Step 55

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

Step 56

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

Step 57

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 -

Step 58

Remove the right shroud from the engine assembly.

Step 59

Use an 8 mm socket to remove the bolt securing the light green ground wire to the engine assembly.

Step 60

Use an 8 mm socket to remove the bolt securing the dark green ground wire to the engine assembly.

Step 61

Disconnect the wiring harness from the rectifier socket.

Step 62

Cut the zip tie securing the coil ignition wire to the harness.

Step 63

Disconnect the coil ignition wire from the harness by pulling it apart from both ends.

Step 64

Use a 10 mm socket to remove the two bolts securing the coil ignition assembly.

Step 65

Unroute the coil ignition wire from the engine assembly.

Step 66

Remove the coil ignition assembly.

Step 67

Use a 10 mm socket to remove the three bolts securing the fan cover.

Step 68

Pull the fan cover off the engine assembly.

Step 69

During reassembly, make sure that the cable strain relief sits properly in its fan cover cutout.

Step 70

Use a 10 mm socket to remove the two bolts securing the cooling fan.

Step 71

Remove the cooling fan, fan set plate, and starter pulley.

Step 72

Use a 19 mm socket to remove the nut securing the rotor.
This nut is heavily bolted on. Use an impact wrench to loosen it, or use a breaker bar with a strap wrench to break it free.
During reassembly, tighten this nut to 66 lb-ft.