Difficulty

Difficult

Steps

80

Time Required

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Sections

10

  • 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
  • Honda EU2200IT A2 Intermediate Disassembly
  • 26 steps
  • Rotor
  • 16 steps
  • Stator
  • 6 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 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.

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.

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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 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 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.

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.

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.

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

              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 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.

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.

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

Remove the shroud.

Step 40

              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 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

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.

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

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.

Remove the air filter housing.

Step 45

  • 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 46

  • 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 47

  • 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 48

  • Pull the breather tube straight out of its port.

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.

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.

Slide the carburetor off its two bolt rails.

Step 51

  • 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 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.

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.

Remove the carburetor insulator along with the two bolt rails.

Step 54

  • 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 55

  • 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 56

  • 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 57

  • 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 58

  • Remove the right shroud from the engine assembly.

Remove the right shroud from the engine assembly.

Step 59

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

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.

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.

Disconnect the wiring harness from the rectifier socket.

Step 62

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

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.

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

Step 64

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

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.

Unroute the coil ignition wire from the engine assembly.

Step 66

  • Remove the coil ignition assembly.

Remove the coil ignition assembly.

Step 67

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

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

Step 68

  • Pull the fan cover off the engine assembly.

Pull the fan cover off the engine assembly.

Step 69

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

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

Step 70

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

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.

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

Step 72

              Remove the rotor
  • 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.

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.

Step 73

  • Attach a flywheel puller to the rotor and attach the collar bolts to the marked holes.
  • Use the flywheel puller to loosen the rotor from the axle.

Attach a flywheel puller to the rotor and attach the collar bolts to the marked holes.

Use the flywheel puller to loosen the rotor from the axle.

Step 74

  • Remove the rotor.
  • Reassembly tip: When you replace the rotor, make sure the rotor aligns to the key on the shaft.

Remove the rotor.

Reassembly tip: When you replace the rotor, make sure the rotor aligns to the key on the shaft.

Step 75

              Remove the pulse sensor
  • Use an 8 mm socket to remove the two bolts securing the pulse sensor.

Use an 8 mm socket to remove the two bolts securing the pulse sensor.

Step 76

  • Remove the pulse sensor from the engine assembly.
  • Reassembly tip: Be sure to route the stator wiring harness underneath the pulse sensor.

Remove the pulse sensor from the engine assembly.

Reassembly tip: Be sure to route the stator wiring harness underneath the pulse sensor.

Step 77

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

Use an 8 mm socket to remove the two bolts securing the stator.

Step 78

  • Pull and remove the stator away from the engine assembly.
  • Be careful not to lose the key on the drive shaft.

Pull and remove the stator away from the engine assembly.

Be careful not to lose the key on the drive shaft.

Step 79

  • Pull up and disconnect the two stator plugs from their sockets.

Pull up and disconnect the two stator plugs from their sockets.

Step 80

  • Only the stator remains.

Only the stator remains.

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

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                    Arthur Shi

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Randall Iwanaga - Apr 20, 2022

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Great video, with good clear pictures.