Introduction
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.
What you need
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Grab the plastic housing at the end of the spark plug wire.
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Pull firmly to disconnect the wire from the spark plug.
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Use a Phillips #2 screwdriver to loosen the screw holding the maintenance cover in place.
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Place an oil pan below the fill port to catch the engine oil.
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Carefully tilt the generator towards the oil pan to drain the oil.
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Place a container below the drain tube to catch the excess fuel.
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The carburetor drain screw is located at the bottom of the carburetor.
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Use a flathead screwdriver to loosen the fuel drain screw until fuel begins to drain out of the carburetor.
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Once you drain the fuel bowl, re-tighten the fuel drain screw.
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Remove the four screws securing the front cover:
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Two Phillips screws
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Two Phillips screws (one on each side)
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Swing the top edge of the front cover away from the generator.
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Pull the front cover away slightly away.
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Remove the lower gray plates from both sides of the generator.
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Remove the fasteners securing the left (non-access) cover:
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Two Phillips screws
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Two 10 mm bolts
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Slide the vent and drain tubes out of their cover ports along the bottom of the right cover.
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Use a screwdriver to pry and loosen the diaphragm tube from the fuel pump.
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Disconnect the diaphragm tube from the fuel pump.
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Use a pair of pliers to squeeze and slide the spring clip off the fuel pump port.
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Use a pair of pliers to squeeze and slide the spring clip off the fuel tank port.
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Use a flathead screwdriver to pry up the blue wire harness from the under-cover.
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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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Use a 10 mm socket to remove the two bolts securing the motor rear to the under-cover.
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Use a 10 mm socket to remove the two bolts securing the left shroud.
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Begin separating the left shroud from the engine assembly by pulling it away from the assembly.
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Pull along the edge of the shroud until you separate the shroud from the engine assembly.
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Remove the shroud.
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Remove the Phillips screw securing the filter cover.
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Remove the filter cover.
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Remove the air filters from the filter box.
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Clean the filters in warm soapy water
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Allow the filters to dry thoroughly
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Dip the filters in clean engine oil, and squeeze out excess oil
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Remove the following fasteners securing the housing:
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Two 8 mm nuts
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One 8 mm bolt
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Use a flathead screwdriver to unclip the carburetor wires from the side of the motor assembly.
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Use an 8 mm socket to remove the two bolts securing the carburetor insulator.
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Begin separating the right shroud from the engine assembly by pulling it away from the assembly.
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Pull the shroud away along the edge. Use a flathead screwdriver to pry it out of the engine assembly groove.
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Use an 8 mm socket to remove the bolt securing the light green ground wire to the engine assembly.
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Use an 8 mm socket to remove the bolt securing the dark green ground wire to the engine assembly.
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Disconnect the coil ignition wire from the harness by pulling it apart from both ends.
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Use a 10 mm socket to remove the two bolts securing the coil ignition assembly.
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Use a 10 mm socket to remove the three bolts securing the fan cover.
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Use a 10 mm socket to remove the two bolts securing the cooling fan.
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Attach a flywheel puller to the rotor and attach the collar bolts to the marked holes.
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Use the flywheel puller to loosen the rotor from the axle.
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Remove the rotor.
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Reassembly tip: When you replace the rotor, make sure the rotor aligns to the key on the shaft.
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Use an 8 mm socket to remove the two bolts securing the pulse sensor.
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Pull and remove the stator away from the engine assembly.
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Be careful not to lose the key on the drive shaft.
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Ask FixBot
To reassemble your device, follow these instructions in reverse order.
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3 other people completed this guide.
3 Guide Comments
Great video, with good clear pictures.
Well done - this also applies about 99% to the non-USA version the EU22i.
Excellent flow chart. I needed this to change my stator on my EU22i genset yesterday. I however struggled to get the flywheel off even with the puller and damaged the threads. I needed to fit nuts inside the flywheel to pull from the inside as such and it came loose
