Difficulty

Difficult

Steps

77

Time Required

                          1 - 2 hours

Sections

13

  • Honda 3000 Watt Inverter Generator EU3000IS1AWK Safety Precautions
  • 4 steps
  • Honda 3000 Watt Inverter Generator EU3000IS1AWK Lower Bushing Nuts Removal
  • 1 step
  • Air Cleaner Filter
  • 2 steps
  • Air Cleaner Housing
  • 6 steps
  • Front Cover
  • 1 step
  • Handle
  • 2 steps
  • Battery
  • 3 steps
  • How to Loosen the Control Panel for the Honda 3000 Watt Inverter Generator EU3000IS1AWK
  • 7 steps
  • Inverter
  • 5 steps
  • How to Loosen the Main Cover for the Honda 3000 Watt Inverter Generator EU3000IS1AWK
  • 9 steps
  • Honda 3000 Watt Inverter Generator EU3000IS1AWK Front Frame Disassembly
  • 10 steps
  • Fan Cover
  • 23 steps
  • Rotor
  • 4 steps

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Introduction

You will need the following specialty tools in order to complete this guide:

  • Flywheel puller kit with metric bolts (in order to remove the rotor)Long shaft (at least 5 inches) Phillips #1 screwdriver

Be sure to drain the fuel tank before you begin this guide, and have containers at hand to catch any fuel spillage.

Some images in this guide may show minor discontinuities. They should not affect the overall guide procedure.

What you need

Step 1

              Disconnect the spark plug
  • Before you begin, make sure the generator is off and cool to the touch.
  • Use a large flathead screwdriver to unlock the maintenance cover.
  • Open the maintenance cover.

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

Use a large flathead screwdriver to unlock the maintenance cover.

Open the maintenance cover.

1024

Step 2

  • Use a Phillips screwdriver to remove the screw securing the spark plug cover.
  • Remove the spark plug cover.

Use a Phillips screwdriver to remove the screw securing the spark plug cover.

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.

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

Pull firmly to disconnect the wire from the spark plug.

Step 4

              Engage the fuel cutoff
  • Turn the fuel valve to the cutoff position.

Turn the fuel valve to the cutoff position.

Step 5

              Remove the bushing nuts
  • Carefully tilt the generator to its side or back.
  • Use a 10 mm socket to remove the two nuts securing the front bushing mounts to the bottom of the generator.
  • Carefully tilt the generator back to an upright position.

Carefully tilt the generator to its side or back.

Use a 10 mm socket to remove the two nuts securing the front bushing mounts to the bottom of the generator.

Carefully tilt the generator back to an upright position.

Step 6

              Remove the air cleaner filter
  • Unlatch the four clips securing the air cleaner cover.
  • Remove the air cleaner cover.

Unlatch the four clips securing the air cleaner cover.

Remove the air cleaner cover.

Step 7

  • Remove the air cleaner filter from the housing.

Remove the air cleaner filter from the housing.

Step 8

              Remove the air cleaner housing
  • Pull and disconnect the breather tube from the top corner of the air cleaner housing.

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

Step 9

  • Pull and disconnect the lower tube from the bottom corner of the air cleaner housing.

Pull and disconnect the lower tube from the bottom corner of the air cleaner housing.

Step 10

  • Use a 10 mm socket to remove the three fasteners securing the air cleaner housing:
  • Two 10 mm nuts
  • During reassembly, tighten these nuts to 6.3 ft-lb (8.5 N-m).
  • One 10 mm bolt

Use a 10 mm socket to remove the three fasteners securing the air cleaner housing:

Two 10 mm nuts

During reassembly, tighten these nuts to 6.3 ft-lb (8.5 N-m).

One 10 mm bolt

Step 11

  • Pull the housing out slightly from its recess.
  • The housing still has tubes clipped to it.

Pull the housing out slightly from its recess.

The housing still has tubes clipped to it.

Step 12

  • Use a flathead screwdriver to pry and unclip the tube from the air cleaner housing.

Use a flathead screwdriver to pry and unclip the tube from the air cleaner housing.

Step 13

  • Remove the air cleaner housing.

Remove the air cleaner housing.

Step 14

              Remove the front cover
  • Use a 10 mm socket to remove the four capped nuts securing the front cover.
  • Remove the front cover.

Use a 10 mm socket to remove the four capped nuts securing the front cover.

Remove the front cover.

Step 15

              Remove the handle
  • Use a 10 mm socket to remove the four bolts securing the handle to the frame.

Use a 10 mm socket to remove the four bolts securing the handle to the frame.

Step 16

  • Remove the handle.

Remove the handle.

Step 17

              Remove the battery
  • Use an 8 mm socket to disconnect the battery wires from the battery terminals.
  • Disconnect the black negative cable first to prevent the risk of shorting the battery.
  • During reassembly, connect the black negative cable first. Make sure you reconnect the wires in the correct polarity.

Use an 8 mm socket to disconnect the battery wires from the battery terminals.

Disconnect the black negative cable first to prevent the risk of shorting the battery.

During reassembly, connect the black negative cable first. Make sure you reconnect the wires in the correct polarity.

Step 18

  • Unclip the battery strap from the lower plate.

Unclip the battery strap from the lower plate.

Step 19

  • Remove the battery.

Remove the battery.

Step 20

              Remove the lower plate
  • Use a 10 mm socket to remove the four capped nuts securing the lower plate.
  • Set these capped nuts apart. They look similar, but are smaller than the front cover nuts.
  • Remove the lower plate.

Use a 10 mm socket to remove the four capped nuts securing the lower plate.

Set these capped nuts apart. They look similar, but are smaller than the front cover nuts.

Remove the lower plate.

Step 21

              Unclip the fuse holder
  • Insert a flathead screwdriver into the top of the brown fuse clip in order to release the fuse holder.
  • Detach the fuse holder from the brown clip.

Insert a flathead screwdriver into the top of the brown fuse clip in order to release the fuse holder.

Detach the fuse holder from the brown clip.

Step 22

              Disconnect the choke cable
  • Use pliers to lift and disconnect the choke cable from the choke stay.
  • During reassembly, be sure to test the choke to ensure that it is properly connected.

Use pliers to lift and disconnect the choke cable from the choke stay.

During reassembly, be sure to test the choke to ensure that it is properly connected.

Step 23

              Remove the fuel cutoff switch
  • Use a long shaft Phillips screwdriver to remove the deeply recessed screw securing the fuel cutoff switch.
  • Be careful not to turn the fuel cutoff switch while you remove the screw.

Use a long shaft Phillips screwdriver to remove the deeply recessed screw securing the fuel cutoff switch.

Be careful not to turn the fuel cutoff switch while you remove the screw.

Step 24

  • Remove the fuel cutoff switch.
  • During reassembly, be sure to test the switch to ensure that it is properly installed.

Remove the fuel cutoff switch.

During reassembly, be sure to test the switch to ensure that it is properly installed.

Step 25

              Loosen the control panel
  • Use a 10 mm socket to remove the four bolts securing the control panel.

Use a 10 mm socket to remove the four bolts securing the control panel.

Step 26

  • Carefully tilt the control panel downwards.
  • The control panel will still be connected to many wires and cables. Be careful not to strain any of the connected wires.

Carefully tilt the control panel downwards.

The control panel will still be connected to many wires and cables. Be careful not to strain any of the connected wires.

Step 27

              Remove the inverter
  • Remove the following bolts securing the inverter:
  • One 8 mm ground bolt
  • Three 10 mm bolts (one behind the control panel)

Remove the following bolts securing the inverter:

One 8 mm ground bolt

Three 10 mm bolts (one behind the control panel)

Step 28

  • Reach behind the inverter along the edges and disconnect the six connectors from the back of the inverter.
  • All the connectors use locking tabs, so you will have to squeeze them in order to release them.
  • The third image shows the locations of all six sockets on the inverter.
  • Reassembly tip: Every socket on the inverter is different, so you can’t plug something into the wrong place. Do not force the connectors into their sockets.

Reach behind the inverter along the edges and disconnect the six connectors from the back of the inverter.

All the connectors use locking tabs, so you will have to squeeze them in order to release them.

The third image shows the locations of all six sockets on the inverter.

Reassembly tip: Every socket on the inverter is different, so you can’t plug something into the wrong place. Do not force the connectors into their sockets.

Step 29

  • Remove the inverter.

Remove the inverter.

Step 30

              Transfer the rubber mounts
  • If you are replacing the inverter and the replacement did not come with rubber mounts, follow the next two steps to transfer them over.
  • Use a screwdriver to push the metal collar out of the center of the rubber mount.

If you are replacing the inverter and the replacement did not come with rubber mounts, follow the next two steps to transfer them over.

Use a screwdriver to push the metal collar out of the center of the rubber mount.

Step 31

  • Squeeze the mount and remove it from the inverter.
  • Repeat the procedure with the remaining mounts and transfer them to the replacement inverter.

Squeeze the mount and remove it from the inverter.

Repeat the procedure with the remaining mounts and transfer them to the replacement inverter.

Step 32

              Remove the rear cover
  • Use a 10 mm socket to remove the four capped nuts securing the rear cover.
  • Remove the rear cover.

Use a 10 mm socket to remove the four capped nuts securing the rear cover.

Remove the rear cover.

Step 33

  • Use a 10 mm socket to remove the four bolts securing the muffler protector.
  • Remove the muffler protector.

Use a 10 mm socket to remove the four bolts securing the muffler protector.

Remove the muffler protector.

Step 34

              Loosen the main cover
  • Pull the muffler shroud slightly away from the frame to access the top frame bolts.
  • Use a 10 mm socket to remove the two bolts securing the top edge of the cover.

Pull the muffler shroud slightly away from the frame to access the top frame bolts.

Use a 10 mm socket to remove the two bolts securing the top edge of the cover.

Step 35

  • Use a 10 mm socket to remove the three bolts securing the front edge of the cover.

Use a 10 mm socket to remove the three bolts securing the front edge of the cover.

Step 36

  • Use a 10 mm socket to remove the four bolts from the maintenance cover side.
  • Remove the maintenance cover.

Use a 10 mm socket to remove the four bolts from the maintenance cover side.

Remove the maintenance cover.

Step 37

  • Carefully peel the maintenance cover seal from the frame.

Carefully peel the maintenance cover seal from the frame.

Step 38

  • Use an 8 mm socket to remove the two bolts securing the non-access side of the cover.

Use an 8 mm socket to remove the two bolts securing the non-access side of the cover.

Step 39

  • Unscrew the gas cap.

Unscrew the gas cap.

Step 40

  • Lift the cover up slightly to free it from the frame and slide it back by a few inches.

Lift the cover up slightly to free it from the frame and slide it back by a few inches.

Step 41

              Disassembly tip
  • At this point, it may be helpful to temporarily re-attach the control panel back onto the front frame with some 10 mm bolts.

At this point, it may be helpful to temporarily re-attach the control panel back onto the front frame with some 10 mm bolts.

Step 42

              Release the choke cable bushing
  • Lift up and release the choke cable’s rubber bushing from the choke stay.
  • During reassembly, make sure that the choke cable’s rubber bushing is properly seated on the choke stay.

Lift up and release the choke cable’s rubber bushing from the choke stay.

During reassembly, make sure that the choke cable’s rubber bushing is properly seated on the choke stay.

Step 43

              Loosen the front frame
  • Use a 10 mm socket to remove the three frame bolts securing the bottom of the front frame.

Use a 10 mm socket to remove the three frame bolts securing the bottom of the front frame.

Step 44

  • Use a 10 mm socket to remove the four bolts securing the top of the front frame.

Use a 10 mm socket to remove the four bolts securing the top of the front frame.

Step 45

  • Pull and disconnect the starter motor’s black barrel and white barrel connectors.
  • During reassembly, the wires should be reconnected to their respective colors.

Pull and disconnect the starter motor’s black barrel and white barrel connectors.

During reassembly, the wires should be reconnected to their respective colors.

Step 46

  • Unplug the two-wire oil switch connector.

Unplug the two-wire oil switch connector.

Step 47

  • Unplug the four-wire regulator connector from the bottom edge of the control panel.

Unplug the four-wire regulator connector from the bottom edge of the control panel.

Step 48

  • Unplug the two winding connectors.
  • These connectors all have brown wiring in black sleeves.

Unplug the two winding connectors.

These connectors all have brown wiring in black sleeves.

Step 49

  • Insert the edge of a large flathead screwdriver under the bottom edge of the front frame.
  • Pry up and outward to release the bottom edge of the front frame.

Insert the edge of a large flathead screwdriver under the bottom edge of the front frame.

Pry up and outward to release the bottom edge of the front frame.

Step 50

  • Carefully swing the front frame to the right side of the generator.
  • While the images show the control panel unbolted from the front frame, you can keep it bolted to the frame.
  • The front frame is still connected to the generator by many wires. Be careful not to strain any wires.

Carefully swing the front frame to the right side of the generator.

While the images show the control panel unbolted from the front frame, you can keep it bolted to the frame.

The front frame is still connected to the generator by many wires. Be careful not to strain any wires.

Step 51

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

Use a 10 mm socket to remove the three bolts securing the recoil starter.

Step 52

  • Remove the recoil starter and move it out of the way.
  • Be careful not to lose the metal collar in each of the recoil starter’s bolt holes.

Remove the recoil starter and move it out of the way.

Be careful not to lose the metal collar in each of the recoil starter’s bolt holes.

Step 53

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

Use a 10 mm socket to remove the two bolts securing the starter pulley.

Remove the starter pulley.

Step 54

              Remove the air cleaner housing bracket
  • Use a 10 mm socket to remove the bolt securing the air cleaner housing bracket.
  • Remove the air cleaner housing bracket.

Use a 10 mm socket to remove the bolt securing the air cleaner housing bracket.

Remove the air cleaner housing bracket.

Step 55

              Remove the petcock assembly
  • Fuel may leak out when you disconnect this hose. Be ready to catch any spillage.
  • Use pliers to squeeze and loosen the hose clamp securing the carburetor fuel line.
  • Pull and disconnect the carburetor fuel line from the petcock assembly.

Fuel may leak out when you disconnect this hose. Be ready to catch any spillage.

Use pliers to squeeze and loosen the hose clamp securing the carburetor fuel line.

Pull and disconnect the carburetor fuel line from the petcock assembly.

Step 56

  • Be sure to drain the fuel tank before you perform this step.
  • Use a large crescent wrench to loosen the petcock assembly from the fuel tank.
  • Residual fuel will leak out as you remove the petcock assembly. Be ready to catch any spillage.
  • Remove the petcock assembly.

Be sure to drain the fuel tank before you perform this step.

Use a large crescent wrench to loosen the petcock assembly from the fuel tank.

Residual fuel will leak out as you remove the petcock assembly. Be ready to catch any spillage.

Remove the petcock assembly.

Step 57

              Drain the carburetor bowl
  • Place a container below the carburetor drain tube to catch the excess fuel.
  • The carburetor drain screw is located at the bottom of the carburetor.
  • Use a flathead screwdriver to loosen the brass fuel drain screw until fuel begins to drain out of the carburetor.
  • Once you drain the fuel bowl, re-tighten the fuel drain screw.

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

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

Use a flathead screwdriver to loosen the brass 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 58

              Remove the carburetor
  • Be sure to replace any gaskets that are torn or worn out.
  • Remove the carburetor spacer gasket.
  • Replacement part: Honda Spacer, Carburetor 16220-ZE1-020

Be sure to replace any gaskets that are torn or worn out.

Remove the carburetor spacer gasket.

Replacement part: Honda Spacer, Carburetor 16220-ZE1-020

Step 59

  • Remove the choke stay.

Remove the choke stay.

Step 60

  • Remove the air cleaner gasket.
  • Replacement part: Honda Gasket, Air Cleaner 16269-ZE1-800

Remove the air cleaner gasket.

Replacement part: Honda Gasket, Air Cleaner 16269-ZE1-800

Step 61

  • Slide the carburetor off the mounting bolts.
  • During reassembly, use the third photo as a reference for how to route the carburetor tubes.

Slide the carburetor off the mounting bolts.

During reassembly, use the third photo as a reference for how to route the carburetor tubes.

Step 62

  • Disconnect the throttle control connector from the top of the carburetor.
  • Unwrap the throttle control wires from the carburetor.

Disconnect the throttle control connector from the top of the carburetor.

Unwrap the throttle control wires from the carburetor.

Step 63

  • Remove the carburetor.

Remove the carburetor.

Step 64

  • Remove the carburetor gasket.
  • Replacement part: Honda Gasket, Carburetor 16221-ZH8-801

Remove the carburetor gasket.

Replacement part: Honda Gasket, Carburetor 16221-ZH8-801

Step 65

  • Remove the carburetor insulator.

Remove the carburetor insulator.

Step 66

  • If the carburetor insulator gasket is worn, remove and replace it.
  • Replacement part: Honda Gasket, Insulator 16212-ZH8-800

If the carburetor insulator gasket is worn, remove and replace it.

Replacement part: Honda Gasket, Insulator 16212-ZH8-800

Step 67

              Remove the fan cover
  • Use a 10 mm socket to remove the seven bolts securing the fan cover:
  • Four bolts on top
  • One recessed bolt in the bottom left corner
  • Two bolts in the bottom right corner
  • During reassembly, be sure to reattach the ground wire.

Use a 10 mm socket to remove the seven bolts securing the fan cover:

Four bolts on top

One recessed bolt in the bottom left corner

Two bolts in the bottom right corner

During reassembly, be sure to reattach the ground wire.

Step 68

  • Use a 12 mm socket to remove the mounting nuts securing the front bushings.

Use a 12 mm socket to remove the mounting nuts securing the front bushings.

Step 69

  • Insert a pry bar underneath the fan cover.
  • Pry upwards to lift the generator assembly slightly.

Insert a pry bar underneath the fan cover.

Pry upwards to lift the generator assembly slightly.

Step 70

  • As you lift the generator assembly with the pry bar, maneuver and remove the two generator mounts from their recess.

As you lift the generator assembly with the pry bar, maneuver and remove the two generator mounts from their recess.

Step 71

  • Use a 10 mm socket to remove the long bolt from the fan cover.

Use a 10 mm socket to remove the long bolt from the fan cover.

Step 72

  • Carefully pull the fan cover away from the generator assembly.
  • During reassembly, make sure that the cord grommet is properly slotted into the fan cover.

Carefully pull the fan cover away from the generator assembly.

During reassembly, make sure that the cord grommet is properly slotted into the fan cover.

Step 73

  • The fan cover is a tight fit. You may need to push the gas tank upwards as you maneuver the fan cover out.
  • Remove the fan cover.

The fan cover is a tight fit. You may need to push the gas tank upwards as you maneuver the fan cover out.

Remove the fan cover.

Step 74

              Remove the cooling fan
  • Remove the cooling fan.

Remove the cooling fan.

Step 75

              Remove the rotor
  • Use a 19 mm socket to remove the nut securing the rotor to the generator shaft.
  • During reassembly, tighten this nut to 55 ft-lb (74 N-m).

Use a 19 mm socket to remove the nut securing the rotor to the generator shaft.

During reassembly, tighten this nut to 55 ft-lb (74 N-m).

Step 76

  • Attach a flywheel puller to the rotor and use it to loosen the rotor.
  • To prevent the rotor from spinning, insert a flathead screwdriver into one of the rotor slots and brace it against the ignition coil bracket.
  • Be careful not to insert the screwdriver too deeply into the slot, or you will damage the stator.

Attach a flywheel puller to the rotor and use it to loosen the rotor.

To prevent the rotor from spinning, insert a flathead screwdriver into one of the rotor slots and brace it against the ignition coil bracket.

Be careful not to insert the screwdriver too deeply into the slot, or you will damage the stator.

Step 77

  • Remove the rotor.
  • Be careful not to lose the Woodruff key.
  • During reassembly, be sure to align the rotor to the Woodruff key.
  • After you install the replacement rotor, rotate it by hand to make sure that the rotor does not rub against the stator.

Remove the rotor.

Be careful not to lose the Woodruff key.

During reassembly, be sure to align the rotor to the Woodruff key.

After you install the replacement rotor, rotate it by hand to make sure that the rotor does not rub against the stator.

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

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Author

                    Arthur Shi

Member since: 01/03/2018

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