Difficulty

Difficult

Steps

46

Time Required

                          1 - 2 hours

Sections

6

  • Spark Plug Disconnection
  • 1 step
  • Cyclo Converter
  • 8 steps
  • Recoil Starter Assembly
  • 2 steps
  • Fuel Tank and Muffler Protector
  • 11 steps
  • Air Cleaner and Canister Assembly
  • 9 steps
  • Rotor and Stator Assembly
  • 15 steps

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Introduction

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 universal puller with a metric collar set in order to pull the rotor off. If the bolts included do not fit correctly in the threaded holes of the rotor, you can use the 61 mm-long bolts removed in Step 41 of this guide.

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.

There are a large number of fasteners on the generator that must be removed for this repair. In order to keep them all organized and accessible, replace them in/on the same bolt hole or stud they were removed from as you work through the guide.

Drain all fuel from the device before beginning this guide.

Some photos may show minor visual inconsistencies relative to this guide. These inconsistencies do not affect the repair procedure.

What you need

Step 1

              Disconnect the spark plug
  • Before you begin, disconnect the spark plug connector from the spark plug.

Before you begin, disconnect the spark plug connector from the spark plug.

1024

Step 2

              Unfasten the cyclo converter cover
  • Use a 10 mm socket to remove the nut securing the top of the cyclo converter cover.
  • Use a 10 mm socket to remove the bolt securing the bottom of the cyclo converter cover.

Use a 10 mm socket to remove the nut securing the top of the cyclo converter cover.

Use a 10 mm socket to remove the bolt securing the bottom of the cyclo converter cover.

Step 3

  • Un-slot the two black rubber cable grommets from the top and right edge of the plastic cover.
  • Remove the cyclo converter cover.

Un-slot the two black rubber cable grommets from the top and right edge of the plastic cover.

Remove the cyclo converter cover.

Step 4

              Disconnect the cyclo converter
  • Pull the cyclo converter panel off of its posts on the generator body so the screw terminals are easily accessible.

Pull the cyclo converter panel off of its posts on the generator body so the screw terminals are easily accessible.

Step 5

  • Disconnect the two 2-pin and one 3-pin connectors from the panel.
  • Take note of which connector corresponds with each header for reassembly.
  • Reassembly tip: The connectors are keyed so they can not be plugged in with the wrong orientation.

Disconnect the two 2-pin and one 3-pin connectors from the panel.

Take note of which connector corresponds with each header for reassembly.

Reassembly tip: The connectors are keyed so they can not be plugged in with the wrong orientation.

Step 6

              Disassembly tip
  • If you are replacing the cyclo converter panel, it can be helpful to transfer a cable from the old panel to the corresponding screw terminal on the replacement panel one at a time. This prevents potentially mixing up cables and screws and maintains OEM cable management.
  • The top three screws are M4 screws while the bottom four are M5 screws. Ensure you are using the correct screw for each terminal during reassembly.

If you are replacing the cyclo converter panel, it can be helpful to transfer a cable from the old panel to the corresponding screw terminal on the replacement panel one at a time. This prevents potentially mixing up cables and screws and maintains OEM cable management.

The top three screws are M4 screws while the bottom four are M5 screws. Ensure you are using the correct screw for each terminal during reassembly.

Step 7

  • Use a Phillips #2 screwdriver to remove the seven 10 mm screws from the terminals on the cyclo converter panel. The wire that corresponds with each terminal is listed below:
  • Red cable
  • Double Black cable
  • No cable
  • White Cable
  • Double Red cable
  • Double White cable
  • Double Blue cable

Use a Phillips #2 screwdriver to remove the seven 10 mm screws from the terminals on the cyclo converter panel. The wire that corresponds with each terminal is listed below:

Red cable

Double Black cable

No cable

White Cable

Double Red cable

Double White cable

Double Blue cable

Step 8

  • Remove the terminal connecting bar from the panel once the corresponding terminals are unscrewed.
  • During reassembly, ensure the bar is in the correct orientation and lies under the crimp connector on the double black cable.

Remove the terminal connecting bar from the panel once the corresponding terminals are unscrewed.

During reassembly, ensure the bar is in the correct orientation and lies under the crimp connector on the double black cable.

Step 9

              Remove the cyclo converter unit
  • Remove the cyclo converter unit.

Remove the cyclo converter unit.

Step 10

              Remove the recoil starter assembly
  • Use a 10 mm socket to remove the three 12 mm-long bolts securing the recoil starter assembly.
  • Remove the recoil starter assembly.

Use a 10 mm socket to remove the three 12 mm-long bolts securing the recoil starter assembly.

Remove the recoil starter assembly.

Step 11

              Remove the recoil starter pulley
  • Use a 10 mm socket to remove the two 20 mm-long bolts securing the recoil starter pulley.
  • Remove the recoil starter pulley.

Use a 10 mm socket to remove the two 20 mm-long bolts securing the recoil starter pulley.

Remove the recoil starter pulley.

Step 12

              Unfasten the control box
  • Use a 10 mm socket to remove the two 20 mm-long bolts securing the sides of the control box case.

Use a 10 mm socket to remove the two 20 mm-long bolts securing the sides of the control box case.

Step 13

              Remove the control box
  • Remove the control box from the generator frame and tilt it downwards.
  • Do not attempt to completely remove the control box as it is still wired to the generator.

Remove the control box from the generator frame and tilt it downwards.

Do not attempt to completely remove the control box as it is still wired to the generator.

Step 14

              Unfasten the fuel tank and muffler protector
  • Use a 10 mm socket to remove the five bolts securing the muffler protector and the fuel tank to the frame:
  • Two 25 mm-long bolts
  • Three 15 mm-long bolts
  • Use a pair of pliers to remove the lock pin and clutch joint securing the fuel tank to the frame.

Use a 10 mm socket to remove the five bolts securing the muffler protector and the fuel tank to the frame:

Two 25 mm-long bolts

Three 15 mm-long bolts

Use a pair of pliers to remove the lock pin and clutch joint securing the fuel tank to the frame.

Step 15

              Remove the fuel tank bar
  • Use a 10 mm socket to remove the two 20 mm-long bolts securing the fuel tank bar to the rest of the frame.
  • Remove the fuel tank bar.

Use a 10 mm socket to remove the two 20 mm-long bolts securing the fuel tank bar to the rest of the frame.

Remove the fuel tank bar.

Step 16

              Disconnect the fuel tank tubes
  • Identify these two tubes and their tube clamps:
  • The tube connected to the bottom of the fuel tank
  • The tube connected to the petcock assembly

Identify these two tubes and their tube clamps:

The tube connected to the bottom of the fuel tank

The tube connected to the petcock assembly

Step 17

  • Use a pair of pliers to squeeze and shift the first tube clamp down the fuel tank tube.

Use a pair of pliers to squeeze and shift the first tube clamp down the fuel tank tube.

Step 18

  • Disconnect the tube from the fuel tank.
  • Residual fuel may leak when you disconnect this tube. Be ready to catch any spillage.

Disconnect the tube from the fuel tank.

Residual fuel may leak when you disconnect this tube. Be ready to catch any spillage.

Step 19

  • Use a pair of pliers to squeeze and shift the second tube clamp left and away from the petcock assembly.

Use a pair of pliers to squeeze and shift the second tube clamp left and away from the petcock assembly.

Step 20

  • Disconnect the tube from the petcock assembly.

Disconnect the tube from the petcock assembly.

Step 21

              Remove the fuel tank
  • Gently lift one side of the tank and slip it out of the generator frame.
  • Remove the fuel tank.

Gently lift one side of the tank and slip it out of the generator frame.

Remove the fuel tank.

Step 22

              Remove the muffler cover
  • Remove the muffler protector.

Remove the muffler protector.

Step 23

              Remove the choke rod
  • Lift the choke rod off of the air cleaner housing.

Lift the choke rod off of the air cleaner housing.

Step 24

  • Continue lifting the choke rod until it’s free from the generator.
  • Remove the choke rod.

Continue lifting the choke rod until it’s free from the generator.

Remove the choke rod.

Step 25

              Remove the air cleaner cover
  • Unclip the two clips on top of the air cleaner housing.
  • Tilt the air cleaner cover down slightly.

Unclip the two clips on top of the air cleaner housing.

Tilt the air cleaner cover down slightly.

Step 26

  • Remove the air cleaner cover.

Remove the air cleaner cover.

Step 27

              Remove the air cleaner element
  • Use a flathead screwdriver or a pick to remove the air cleaner element from the air cleaner housing.

Use a flathead screwdriver or a pick to remove the air cleaner element from the air cleaner housing.

Step 28

              Unfasten the air cleaner housing
  • Use a 10 mm socket to remove the two nuts from the inside of the air cleaner housing.
  • Use a 10 mm socket to remove the 20 mm-long bolt from the inside of the air cleaner housing.
  • During reassembly, tighten these fasteners to 7 lb-ft (10 N-m) of torque.

Use a 10 mm socket to remove the two nuts from the inside of the air cleaner housing.

Use a 10 mm socket to remove the 20 mm-long bolt from the inside of the air cleaner housing.

During reassembly, tighten these fasteners to 7 lb-ft (10 N-m) of torque.

Step 29

              Disconnect the breather tube
  • Pull up and disconnect the breather tube from the top of the air cleaner housing.

Pull up and disconnect the breather tube from the top of the air cleaner housing.

Step 30

              Unfasten the canister assembly
  • Lift up the canister assembly from its mounting rails to release it from the generator frame.

Lift up the canister assembly from its mounting rails to release it from the generator frame.

Step 31

              Remove the canister and air cleaner assembly
  • Remove the air cleaner and canister assembly.

Remove the air cleaner and canister assembly.

Step 32

              Unfasten the engine mounting nuts
  • Use a 12 mm socket to remove the four nuts securing the motor assembly to the generator frame.
  • During reassembly, tighten these nuts to 25 ft-lb (34 N-m) of torque.

Use a 12 mm socket to remove the four nuts securing the motor assembly to the generator frame.

During reassembly, tighten these nuts to 25 ft-lb (34 N-m) of torque.

Step 33

              Disconnect the ground lead
  • Remove the ground ring terminal from its motor mount bolt.

Remove the ground ring terminal from its motor mount bolt.

Step 34

              Remove the canister bracket
  • Use a 10 mm socket to remove the two 15 mm-long bolts securing the canister bracket.
  • Remove the canister bracket.

Use a 10 mm socket to remove the two 15 mm-long bolts securing the canister bracket.

Remove the canister bracket.

Step 35

              Remove the motor assembly
  • To prevent injury and damage to the device, we highly advise you to perform this step with another individual during reassembly.
  • Remove the motor assembly from the generator frame.
  • Try having one person lift the motor while another slides the frame out from under it.

To prevent injury and damage to the device, we highly advise you to perform this step with another individual during reassembly.

Remove the motor assembly from the generator frame.

Try having one person lift the motor while another slides the frame out from under it.

Step 36

              Unfasten the fan cover bolts
  • Use a 10 mm socket to remove the four bolts securing the fan housing:
  • Two 40 mm-long bolts
  • Two 30 mm-long bolts
  • During reassembly, tighten these bolts to 7 ft-lb (10 N-m) of torque.

Use a 10 mm socket to remove the four bolts securing the fan housing:

Two 40 mm-long bolts

Two 30 mm-long bolts

During reassembly, tighten these bolts to 7 ft-lb (10 N-m) of torque.

Step 37

              Remove the fan cover ground lead
  • Use a 10 mm socket to remove the 12 mm-long bolt securing the ground cable to the fan housing.

Use a 10 mm socket to remove the 12 mm-long bolt securing the ground cable to the fan housing.

Step 38

              Remove the fan housing
  • Lift up and remove the fan housing.

Lift up and remove the fan housing.

Step 39

              Remove the cooling fan
  • Remove the cooling fan.

Remove the cooling fan.

Step 40

              Unfasten the rotor nut and stator bolts
  • Use a 19 mm socket with an impact driver to remove the rotor nut from the generator assembly.
  • During reassembly, tighten this nut to 53 ft-lb (74 N-m) of torque.
  • If you are not able to tighten the nut without the rotor moving, use a strap wrench to hold the rotor in place while refastening the nut.
  • Use a 5 mm hex driver to remove the four 61 mm-long bolts from the generator assembly.
  • During reassembly, tighten these bolts to 8 ft-lb (11 N-m) of torque.

Use a 19 mm socket with an impact driver to remove the rotor nut from the generator assembly.

During reassembly, tighten this nut to 53 ft-lb (74 N-m) of torque.

If you are not able to tighten the nut without the rotor moving, use a strap wrench to hold the rotor in place while refastening the nut.

Use a 5 mm hex driver to remove the four 61 mm-long bolts from the generator assembly.

During reassembly, tighten these bolts to 8 ft-lb (11 N-m) of torque.

Step 41

              Pull the rotor and stator
  • Ensure the proper pointed tip is fastened to the center of your universal puller.
  • Affix the universal puller to the face of the rotor.
  • Use an impact driver to pull the rotor and stator assembly from the crankshaft.

Ensure the proper pointed tip is fastened to the center of your universal puller.

Affix the universal puller to the face of the rotor.

Use an impact driver to pull the rotor and stator assembly from the crankshaft.

Step 42

              Free the stator cables
  • Cut and remove the zip tie securing the stator wires to the rest of the harness.

Cut and remove the zip tie securing the stator wires to the rest of the harness.

Step 43

  • Unseat the stator wiring harness grommet from the rotor side plate.

Unseat the stator wiring harness grommet from the rotor side plate.

Step 44

  • Use a pair of pliers to squeeze and release the wire harness clip from the rotor side plate.

Use a pair of pliers to squeeze and release the wire harness clip from the rotor side plate.

Step 45

              Remove the rotor and stator
  • Remove the rotor and stator assembly.

Remove the rotor and stator assembly.

Step 46

              Confirm axle key and wiring harness placement
  • Before you install the new rotor and stator assembly, ensure the axle key is properly installed.
  • Be sure to route the stator wiring harness in the correct orientation, as shown in the second photo.

Before you install the new rotor and stator assembly, ensure the axle key is properly installed.

Be sure to route the stator wiring harness in the correct orientation, as shown in the second photo.

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

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                    Tarun Thiruma

Member since: 11/20/2019

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bk2571 - Jun 17, 2022

Reply

Question, The rotor is it magnetic?

The rotor flywhell is it magetic?