Group 1 Honda Generator-Dissection

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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	Removal movie
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

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