Difficulty

Difficult

Steps

73

Time Required

Suggest a time??

Sections

11

  • Honda EU2200IT A2 Safety Precautions
  • 3 steps
  • Maintenance Cover
  • 2 steps
  • How to Change the Oil for the Honda EU2200IT A2
  • 3 steps
  • How to Drain the Carburetor for the Honda EU2200IT A2
  • 2 steps
  • Back Cover
  • 2 steps
  • Honda EU2200IT A2 Outer Cover Removal
  • 9 steps
  • Fuel Tank
  • 11 steps
  • Muffler
  • 4 steps
  • Honda EU2200IT A2 Intermediate Disassembly
  • 26 steps
  • Honda EU2200IT A2 Crankcase Removal
  • 9 steps
  • Oil Level Switch
  • 2 steps

Flags

0

  • BackHonda EU2200IT A2

  • Full Screen

  • Options

  • History

  • Save to Favorites

  • Download PDF

  • Edit

  • Translate

  • Get Shareable Link

  • Embed This Guide

  • Notify Me of Changes

  • Stop Notifications

Introduction

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.

What you need

Step 1

              Honda EU2200IT A2 Safety Precautions
  • Before you begin, make sure the generator is switched off and the generator is cool to the touch.

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

1024

Step 2

              Disconnect the spark plug
  • Lift and remove the spark plug cover.

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.

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

Pull firmly to disconnect the wire from the spark plug.

Step 4

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

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.

Swing the top of the maintenance cover out.

Remove the maintenance cover.

Step 6

              Drain the engine oil
  • Unscrew and remove the oil filler cap.

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.

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.

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

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

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.

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

              Back Cover
  • Remove the four Phillips screws securing the back cover.

Remove the four Phillips screws securing the back cover.

Step 12

  • Remove the back cover.

Remove the back cover.

Step 13

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

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.

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.

Step 15

              Remove the left cover
  • 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.

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

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

Two 10 mm bolts

Step 17

  • Remove the left (non-access) cover.

Remove the left (non-access) cover.

Step 18

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

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.

Remove the Phillips screw securing the starter rope port.

Step 20

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

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

Step 21

  • Remove the right (access-side) cover.

Remove the right (access-side) cover.

Step 22

              Fuel Tank
  • 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.

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.

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.

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.

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

Step 26

  • Remove the Phillips screw securing the starter rope guide.

Remove the Phillips screw securing the starter rope guide.

Step 27

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

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

Step 28

              Remove the fuel tank
  • 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.

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.

Disconnect the fuel line and filter from the fuel tank.

Step 30

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

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

Step 31

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

Remove the left (non-access) frame assembly.

Step 32

  • Lift and remove the fuel tank.

Lift and remove the fuel tank.

Step 33

              Remove the muffler
  • 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.

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.

Step 34

  • Remove the muffler.

Remove the muffler.

Step 35

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

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

Step 36

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

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

Step 37

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

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

Step 38

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

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 39

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

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

Step 40

  • 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.

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 41

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

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

Step 42

  • 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.

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 43

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

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

Remove the shroud.

Step 44

              Remove the air filter housing
  • 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.

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 45

  • 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

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 46

  • Disconnect the breather tube from the air cleaner housing.

Disconnect the breather tube from the air cleaner housing.

Step 47

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

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 48

  • Remove the air filter housing.

Remove the air filter housing.

Step 49

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

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

Step 50

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

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

Step 51

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

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

Step 52

  • Pull the breather tube straight out of its port.

Pull the breather tube straight out of its port.

Step 53

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

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

Step 54

  • Slide the carburetor off its two bolt rails.

Slide the carburetor off its two bolt rails.

Step 55

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

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

Step 56

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

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 57

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

Remove the carburetor insulator along with the two bolt rails.

Step 58

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

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

Step 59

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

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

Step 60

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

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

Step 61

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

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

Step 62

  • Remove the right shroud from the engine assembly.

Remove the right shroud from the engine assembly.

Step 63

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

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

Step 64

  • Remove the exhaust pipe from the engine assembly.

Remove the exhaust pipe from the engine assembly.

Step 65

              Disconnect the engine oil sensor
  • Loosen the cable tie securing the engine oil sensor.

Loosen the cable tie securing the engine oil sensor.

Step 66

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

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

Step 67

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

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

Step 68

              Remove the crankcase cover
  • 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.

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.

Step 69

  • 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.

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.

Step 70

  • Separate and remove the crankcase cover.

Separate and remove the crankcase cover.

Step 71

              Reseal the crankcase
  • 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.

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.

Step 72

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

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

Step 73

  • 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.

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.

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

Cancel: I did not complete this guide.

Author

                    Arthur Shi

Member since: 01/03/2018

211,874 Reputation

                                      442 Guides authored                  



                       Badges:
                       46







                                                        +43 more badges

Team

                       iFixit                        

                                                  Member of iFixit 



                    Community                     


                                            141 Members                     


                                            15,769 Guides authored