Group 1 Honda Generator-Dissection

From GICL Wiki
Jump to: navigation, search
Back to the Group 1 Homepage


Dissection Process

\'\'\'Difficulty scale definition:\'\'\'
\'\'\'1\'\'\' - Very easy, highly intuitive, trivial. Part is removed easily and quickly.
\'\'\'2\'\'\' - Somewhat easy, intuitive, some thinking. Minor difficulties encountered. (i.e. many bolts, time consuming but still easy.)
\'\'\'3\'\'\' - Average difficulty, awkward part location. (i.e. parts were hard to get to or required special tools like a ratchet extension)
\'\'\'4\'\'\' - Difficult, requires large force, not intuitive. (i.e. parts were tightly fastened, difficult to remove, required planning in order to remove)
\'\'\'5\'\'\' - Very difficult, requires maximum planning/thinking or very large forces. (i.e. very high torques required, parts needed to be broken)


\'\'\'Honeywell Generator Dissection Process\'\'\'
\'\'\'Step\'\'\' \'\'\'Part\'\'\' \'\'\'Bolts\'\'\'
\'\'Quantity-Size\'\'
\'\'\'Nuts\'\'\'
\'\'Quantity-Size\'\'
\'\'\'Washers\'\'\'
\'\'Quantity-Size\'\'
\'\'\'Tool\'\'\' \'\'\'Difficulty\'\'\' \'\'\'Meant to be taken off\'\'\' \'\'\'Picture Link\'\'\'
1 Gas tank removed 4-8mm 2-10mm 4-14mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Gas Tank
2 Bolts taken off of frame 4-14mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Frame
3 Remove control panel 4-8mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Control Panel
4 Disconnect and label wires from control panel None 1 - No difficulties No, but it can be removed for servicing
5 Disconnect and remove battery 2-10mm Socket Wrench 1 - No difficulties Yes, battery can be replaced by consumer Battery
6 Remove generator cover 2-8mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Generator Cover
7 Disconnect wires from generator 5-8mm 5-14mm-locking 5-14mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Generator Inside
8 Lift engine and generator off of frame None 3 - Large weight required several members No, but it can be removed for servicing Engine and Generator
9 Remove long brass bolts from generator housing 4-10mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Generator Housing Bolts
10 Remove sheet metal from generator Needle Nose Pliers 2 - rivets had to be broken with pliers No, had to break rivets)
11 Remove muffler bolts and muffler 2-13mm 2-12mm Socket Wrench 2 - No difficulties No,but it can be removed for servicing Muffler
12 Remove interior generator covering None 2 - No difficulties No, but it can be removed for servicing Generator Interior
13 Remove 3 bolts from pull start assembly 3-10mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Pull Starter
14 Remove 2 main bolts from killswitch solenoid assembly and arm 2-10mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Kill Switch
15 Remove 4 bolts from start fan shroud (one bolt is from killswitch solenoid assembly) 5-10mm Socket Wrench 3 - Some bolts were difficult to get to because of restrictions from other parts No, but it can be removed for servicing Fan Shroud
16 Remove 6 nuts from air cleaner housing (2 10 mm nuts attach housing to carburator) 6-8mm 2-10mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Air Filter
17 Remove Choke linkage assembly (nuts removed with air cleaner) None 1 - No difficulties No, But it can be removed for servicing Choke Linkage
18 Disconnect throttle linkage (Loosen idle adjust screw to remove link) 1-10mm screw driver 1 - No difficulties No, but it can be removed for servicing Throttle Linkage
19 Remove connection A (C.A) None 1 - No difficulties No, but it can be removed for servicing Sonnection A
20 Remove 2 10mm bolts from cylinder cover 2-10mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Cylinder Cover
21 Slide Carburetor off cylinder screw driver 1 - No difficulties No, but it can be removed for servicing Carburetor
23 Remove 2 14 mm bolts from piston head and 1 10 mm bolts from plate covering head 2-14mm 1-10mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Piston Head Bolts
24 Pull off piston head None 1 - No difficulties No, but it can be removed for servicing Piston Head
25 Remove armature nut (15/16 inch) 1-23mm Socket Wrench 4 - Nut was fastened with thread-locker. Due to lack of tools, a slightly larger socket was used, with pliers on the end of the wrench for added torque. No, it was secured with thread-locker) Aperture Nut
26 Remove 2 bolts from starter 2-12mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Starter
27 Remove Spark-cap assembly None 1 - No difficulties Yes, spark plug is intended to be serviced by consumer Spark Cap
28 Removed flywheel by wedging the gear and hitting center shaft with metal hammer Hammer and Socket Wrenches 5 - Flywheel was very tightly pressed on the crankshaft. A wedge and hammer was used to force it off No, it was pressed together tightly, and had to be broken Flywheel
29 Removed 3 10mm bolts around crank shaft 3-10mm Socket Wrench 2 - No difficulties No, but it can be removed for servicing Crank Shaft
30 Removed flywheel sensor assembly 2-10mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Flywheel Sensor
31 Removed IIDA wire connector + guard 3 - No difficulties No, but it can be removed for servicing IIDA Connector
32 Pried apart engine and engine generator interplate using wedge + wrenches Hammer and Socket Wrenches 5 - generator armature was very tightly pressed on the crankshaft. A wedge and hammer was used to force it off No, gears and gasket had to be damaged Wedge.avi
33 Remove two 10 mm bolts from interior engine oil sensor 2-10mm Socket Wrench 1 - No difficulties No, but it can be removed for servicing Engine Oil Sensor
34 Pried out gear 28 from engine Screw Driver 1 - No difficulties No, but it can be removed for servicing Gear 28
35 Tapped out connector at CA with hammer through interior Hammer and Socket Wrenches 1 - No difficulties No, but it can be removed for servicing
36 Removed two riders 1 - No difficulties No, but it can be removed for servicing Riders
37 Removed two 10mm bolts from F/P gear 2-10mm 2 - No difficulties No, but it can be removed for servicing Piston Bolts
38 Removed piston by hand 1 - No difficulties No, but it can be removed for servicing Piston
[top]