Honda EU2200IT A2 Stator Replacement

简介

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.

你所需要的

步骤 1 Honda EU2200IT A2 Safety Precautions

Honda EU2200IT A2 Stator Replacement, Honda EU2200IT A2 Safety Precautions: 步骤 1 中的图像 1，1

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

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步骤 2 Disconnect the spark plug

Honda EU2200IT A2 Stator Replacement, Disconnect the spark plug: 步骤 2 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Disconnect the spark plug: 步骤 2 中的图像 2，2

Lift and remove the spark plug cover.

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步骤 3

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

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步骤 4 Remove the maintenance cover

Honda EU2200IT A2 Stator Replacement, Remove the maintenance cover: 步骤 4 中的图像 1，1

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

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步骤 5

Honda EU2200IT A2 Stator Replacement: 步骤 5 中的图像 3，3

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

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步骤 6 Drain the engine oil

Honda EU2200IT A2 Stator Replacement, Drain the engine oil: 步骤 6 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Drain the engine oil: 步骤 6 中的图像 2，2

Unscrew and remove the oil filler cap.

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步骤 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.

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步骤 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.

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步骤 9 Drain the carburetor fuel bowl

Honda EU2200IT A2 Stator Replacement, Drain the carburetor fuel bowl: 步骤 9 中的图像 1，1

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

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步骤 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.

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步骤 11 Back Cover

Honda EU2200IT A2 Stator Replacement, Back Cover: 步骤 11 中的图像 1，1

Remove the four Phillips screws securing the back cover.

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步骤 12

Remove the back cover.

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步骤 13 Loosen the front cover

Honda EU2200IT A2 Stator Replacement, Loosen the front cover: 步骤 13 中的图像 1，3

Honda EU2200IT A2 Stator Replacement, Loosen the front cover: 步骤 13 中的图像 2，3

Honda EU2200IT A2 Stator Replacement, Loosen the front cover: 步骤 13 中的图像 3，3

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

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步骤 14

Honda EU2200IT A2 Stator Replacement: 步骤 14 中的图像 3，3

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.

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步骤 15 Remove the left cover

Honda EU2200IT A2 Stator Replacement, Remove the left cover: 步骤 15 中的图像 1，3

Honda EU2200IT A2 Stator Replacement, Remove the left cover: 步骤 15 中的图像 2，3

Honda EU2200IT A2 Stator Replacement, Remove the left cover: 步骤 15 中的图像 3，3

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.

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步骤 16

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

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步骤 17

Remove the left (non-access) cover.

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步骤 18 Remove the right cover

Honda EU2200IT A2 Stator Replacement, Remove the right cover: 步骤 18 中的图像 1，3

Honda EU2200IT A2 Stator Replacement, Remove the right cover: 步骤 18 中的图像 2，3

Honda EU2200IT A2 Stator Replacement, Remove the right cover: 步骤 18 中的图像 3，3

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

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步骤 19

Remove the Phillips screw securing the starter rope port.

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步骤 20

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

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步骤 21

Remove the right (access-side) cover.

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步骤 22 Fuel Tank

Honda EU2200IT A2 Stator Replacement, Fuel Tank: 步骤 22 中的图像 1，3

Honda EU2200IT A2 Stator Replacement, Fuel Tank: 步骤 22 中的图像 2，3

Honda EU2200IT A2 Stator Replacement, Fuel Tank: 步骤 22 中的图像 3，3

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.

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步骤 23

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

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步骤 24

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

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步骤 25

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

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步骤 26

Remove the Phillips screw securing the starter rope guide.

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步骤 27

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

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步骤 28 Remove the fuel tank

Honda EU2200IT A2 Stator Replacement, Remove the fuel tank: 步骤 28 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Remove the fuel tank: 步骤 28 中的图像 2，2

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.

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步骤 29

Disconnect the fuel line and filter from the fuel tank.

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步骤 30

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

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步骤 31

Remove the left (non-access) frame assembly.

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步骤 32

Lift and remove the fuel tank.

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步骤 33 Remove the under-cover

Honda EU2200IT A2 Stator Replacement, Remove the under-cover: 步骤 33 中的图像 1，1

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

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步骤 34

Honda EU2200IT A2 Stator Replacement: 步骤 34 中的图像 3，3

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

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步骤 35

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

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步骤 36

Honda EU2200IT A2 Stator Replacement: 步骤 36 中的图像 3，3

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.

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步骤 37 Remove the left shroud

Honda EU2200IT A2 Stator Replacement, Remove the left shroud: 步骤 37 中的图像 1，1

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

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步骤 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.

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步骤 39

Honda EU2200IT A2 Stator Replacement: 步骤 39 中的图像 3，3

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

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步骤 40 Remove the air filter housing

Honda EU2200IT A2 Stator Replacement, Remove the air filter housing: 步骤 40 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Remove the air filter housing: 步骤 40 中的图像 2，2

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.

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步骤 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

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步骤 42

Disconnect the breather tube from the air cleaner housing.

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步骤 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

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步骤 44

Remove the air filter housing.

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步骤 45

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

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步骤 46

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

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步骤 47

Honda EU2200IT A2 Stator Replacement: 步骤 47 中的图像 3，3

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

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步骤 48

Pull the breather tube straight out of its port.

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步骤 49

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

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步骤 50

Slide the carburetor off its two bolt rails.

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步骤 51

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

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步骤 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.

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步骤 53

Remove the carburetor insulator along with the two bolt rails.

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步骤 54

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

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步骤 55

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

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步骤 56

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

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步骤 57

Honda EU2200IT A2 Stator Replacement: 步骤 57 中的图像 3，3

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

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步骤 58

Remove the right shroud from the engine assembly.

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步骤 59 Disconnect the wires

Honda EU2200IT A2 Stator Replacement, Disconnect the wires: 步骤 59 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Disconnect the wires: 步骤 59 中的图像 2，2

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

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步骤 60

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

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步骤 61

Disconnect the wiring harness from the rectifier socket.

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步骤 62

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

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步骤 63

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

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步骤 64 Remove the coil ignition assembly

Honda EU2200IT A2 Stator Replacement, Remove the coil ignition assembly: 步骤 64 中的图像 1，1

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

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步骤 65

Unroute the coil ignition wire from the engine assembly.

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步骤 66

Remove the coil ignition assembly.

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步骤 67 Remove the fan cover

Honda EU2200IT A2 Stator Replacement, Remove the fan cover: 步骤 67 中的图像 1，1

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

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步骤 68

Pull the fan cover off the engine assembly.

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步骤 69 Reassembly tip

Honda EU2200IT A2 Stator Replacement, Reassembly tip: 步骤 69 中的图像 1，2

Honda EU2200IT A2 Stator Replacement, Reassembly tip: 步骤 69 中的图像 2，2

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

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步骤 70 Remove the cooling fan

Honda EU2200IT A2 Stator Replacement, Remove the cooling fan: 步骤 70 中的图像 1，1

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

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步骤 71

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

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步骤 72 Remove the rotor

Honda EU2200IT A2 Stator Replacement, Remove the rotor: 步骤 72 中的图像 1，1

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.