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Honda EU2200IT A2 Oil Level Switch Replacement

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  1. Honda EU2200IT A2 Oil Level Switch Replacement, Honda EU2200IT A2 Safety Precautions: Schritt 1, Bild 1 von 1
    • Before you begin, make sure the generator is switched off and the generator is cool to the touch.

  2. Honda EU2200IT A2 Oil Level Switch Replacement, Disconnect the spark plug: Schritt 2, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement, Disconnect the spark plug: Schritt 2, Bild 2 von 2
    • Lift and remove the spark plug cover.

  3. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 3, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 3, Bild 2 von 2
    • Grab the plastic housing at the end of the spark plug wire.

    • Pull firmly to disconnect the wire from the spark plug.

  4. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the maintenance cover: Schritt 4, Bild 1 von 1
    • Use a Phillips #2 screwdriver to loosen the screw holding the maintenance cover in place.

  5. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 5, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 5, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 5, Bild 3 von 3
    • Swing the top of the maintenance cover out.

    • Remove the maintenance cover.

  6. Honda EU2200IT A2 Oil Level Switch Replacement, Drain the engine oil: Schritt 6, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement, Drain the engine oil: Schritt 6, Bild 2 von 2
    • Unscrew and remove the oil filler cap.

  7. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 7, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 7, Bild 2 von 2
    • 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.

  8. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 8, Bild 1 von 1
    • 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.

  9. Honda EU2200IT A2 Oil Level Switch Replacement, Drain the carburetor fuel bowl: Schritt 9, Bild 1 von 1
    • Place a container below the drain tube to catch the excess fuel.

  10. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 10, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 10, Bild 2 von 2
    • 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.

  11. Honda EU2200IT A2 Oil Level Switch Replacement, Back Cover: Schritt 11, Bild 1 von 1
    • Remove the four Phillips screws securing the back cover.

  12. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 12, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 12, Bild 2 von 2
    • Remove the back cover.

  13. Honda EU2200IT A2 Oil Level Switch Replacement, Loosen the front cover: Schritt 13, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Loosen the front cover: Schritt 13, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Loosen the front cover: Schritt 13, Bild 3 von 3
    • Remove the four screws securing the front cover:

    • Two Phillips screws

    • Two Phillips screws (one on each side)

  14. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 14, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 14, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 14, Bild 3 von 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.

  15. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the left cover: Schritt 15, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the left cover: Schritt 15, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the left cover: Schritt 15, Bild 3 von 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.

  16. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 16, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 16, Bild 2 von 2
    • Remove the fasteners securing the left (non-access) cover:

    • Two Phillips screws

    • Two 10 mm bolts

  17. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 17, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 17, Bild 2 von 2
    • Remove the left (non-access) cover.

  18. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the right cover: Schritt 18, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the right cover: Schritt 18, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the right cover: Schritt 18, Bild 3 von 3
    • Slide the vent and drain tubes out of their cover ports along the bottom of the right cover.

  19. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 19, Bild 1 von 1
    • Remove the Phillips screw securing the starter rope port.

  20. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 20, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 20, Bild 2 von 2
    • Thread the starter rope handle through the port's cutout.

  21. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 21, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 21, Bild 2 von 2
    • Remove the right (access-side) cover.

  22. Honda EU2200IT A2 Oil Level Switch Replacement, Fuel Tank: Schritt 22, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Fuel Tank: Schritt 22, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement, Fuel Tank: Schritt 22, Bild 3 von 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.

  23. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 23, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 23, Bild 2 von 2
    • Use a pair of pliers to squeeze and slide the spring clip off the fuel pump port.

  24. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 24, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 24, Bild 2 von 2
    • Residual fuel may leak out of this hose. Be ready to contain any spillage.

    • Disconnect the fuel hose from the fuel pump.

  25. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 25, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 25, Bild 2 von 2
    • Pull and disconnect the engine stop switch connector from its socket.

  26. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 26, Bild 1 von 1
    • Remove the Phillips screw securing the starter rope guide.

  27. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 27, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 27, Bild 2 von 2
    • Feed the starter rope handle and guide through the panel cutout.

  28. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the fuel tank: Schritt 28, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the fuel tank: Schritt 28, Bild 2 von 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.

  29. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 29, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 29, Bild 2 von 2
    • Disconnect the fuel line and filter from the fuel tank.

  30. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 30, Bild 1 von 1
    • Remove the Phillips screw securing the left (non-access) frame assembly.

  31. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 31, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 31, Bild 2 von 2
    • Remove the left (non-access) frame assembly.

  32. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 32, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 32, Bild 2 von 2
    • Lift and remove the fuel tank.

  33. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the muffler: Schritt 33, Bild 1 von 1
    • 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.

  34. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 34, Bild 1 von 1
    • Remove the muffler.

  35. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 35, Bild 1 von 1
    • Use a wire brush to clean any deposits off the spark arrester.

  36. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 36, Bild 1 von 1
    • During reassembly, replace the muffler gasket if it shows signs of wear.

  37. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the under-cover: Schritt 37, Bild 1 von 1
    • Use a flathead screwdriver to pry up the blue wire harness from the under-cover.

  38. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 38, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 38, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 38, Bild 3 von 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.

  39. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 39, Bild 1 von 1
    • Use a 10 mm socket to remove the two bolts securing the motor rear to the under-cover.

  40. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 40, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 40, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 40, Bild 3 von 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.

  41. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the left shroud: Schritt 41, Bild 1 von 1
    • Use a 10 mm socket to remove the two bolts securing the left shroud.

  42. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 42, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 42, Bild 2 von 2
    • 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.

  43. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 43, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 43, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 43, Bild 3 von 3
    • Pull along the edge of the shroud until you separate the shroud from the engine assembly.

    • Remove the shroud.

  44. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the air filter housing: Schritt 44, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the air filter housing: Schritt 44, Bild 2 von 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.

  45. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 45, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 45, Bild 2 von 2
    • 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

  46. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 46, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 46, Bild 2 von 2
    • Disconnect the breather tube from the air cleaner housing.

  47. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 47, Bild 1 von 1
    • Remove the following fasteners securing the housing:

    • Two 8 mm nuts

    • During reassembly, tighten these to 3.6 ft-lb.

    • One 8 mm bolt

  48. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 48, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 48, Bild 2 von 2
    • Remove the air filter housing.

  49. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 49, Bild 1 von 1
    • During reassembly, replace the air intake gasket if it shows signs of wear.

  50. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 50, Bild 1 von 1
    • During reassembly, use this photo as a reference for how to route the hoses.

  51. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 51, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 51, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 51, Bild 3 von 3
    • Unclip the fuel and air hoses from the side of the motor assembly.

  52. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 52, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 52, Bild 2 von 2
    • Pull the breather tube straight out of its port.

  53. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 53, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 53, Bild 2 von 2
    • Use a flathead screwdriver to unclip the carburetor wires from the side of the motor assembly.

  54. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 54, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 54, Bild 2 von 2
    • Slide the carburetor off its two bolt rails.

  55. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 55, Bild 1 von 1
    • During reassembly, replace the carburetor seal if it shows signs of wear.

  56. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 56, Bild 1 von 1
    • Use an 8 mm socket to remove the two bolts securing the carburetor insulator.

    • During reassembly, tighten these bolts to 2.2 ft-lb.

  57. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 57, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 57, Bild 2 von 2
    • Remove the carburetor insulator along with the two bolt rails.

  58. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 58, Bild 1 von 1
    • During reassembly, replace the insulator gasket if it shows signs of wear.

  59. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 59, Bild 1 von 1
    • Use a 10 mm socket to remove the bolts securing the right shroud.

  60. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 60, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 60, Bild 2 von 2
    • Begin separating the right shroud from the engine assembly by pulling it away from the assembly.

  61. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 61, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 61, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 61, Bild 3 von 3
    • Pull the shroud away along the edge. Use a flathead screwdriver to pry it out of the engine assembly groove.

  62. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 62, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 62, Bild 2 von 2
    • Remove the right shroud from the engine assembly.

  63. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the exhaust pipe: Schritt 63, Bild 1 von 1
    • Use a 10 mm socket to remove the two bolts securing the exhaust pipe.

  64. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 64, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 64, Bild 2 von 2
    • Remove the exhaust pipe from the engine assembly.

  65. Honda EU2200IT A2 Oil Level Switch Replacement, Disconnect the engine oil sensor: Schritt 65, Bild 1 von 1
    • Loosen the cable tie securing the engine oil sensor.

  66. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 66, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 66, Bild 2 von 2
    • Disconnect the yellow engine oil sensor wire by pulling the connector apart.

  67. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 67, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 67, Bild 2 von 2
    • Use a 10 mm socket to remove the bolt securing the engine oil sensor ground.

  68. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the crankcase cover: Schritt 68, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement, Remove the crankcase cover: Schritt 68, Bild 2 von 2
    • 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.

  69. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 69, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 69, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 69, Bild 3 von 3
    • 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.

  70. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 70, Bild 1 von 2 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 70, Bild 2 von 2
    • Separate and remove the crankcase cover.

  71. Honda EU2200IT A2 Oil Level Switch Replacement, Reseal the crankcase: Schritt 71, Bild 1 von 1
    • 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.

  72. Honda EU2200IT A2 Oil Level Switch Replacement, Remove the oil level sensor: Schritt 72, Bild 1 von 1
    • Use a 10 mm socket to remove the bolt securing the oil level sensor.

  73. Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 73, Bild 1 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 73, Bild 2 von 3 Honda EU2200IT A2 Oil Level Switch Replacement: Schritt 73, Bild 3 von 3
    • 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.

Abschluss

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

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