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Einleitung

This guide shows how to remove and replace the oil level switch for the Honda EU2200IT generator. The switch is attached from within the crankcase and requires major disassembly.
If you encounter problems during the process, consult the official Honda service guides.

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.

  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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