Honda 3000 Watt Generator EB3000CK2A Oil Level Switch Assembly Replacement

Geschrieben von: Tarun Thiruma

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Honda 3000 Watt Generator EB3000CK2A Oil Level Switch Assembly Replacement

Schwierigkeitsgrad

Moderate

Schritte

Zeitaufwand

30 - 45 Minuten

Einleitung

This guide demonstrates how to remove or replace the oil level switch assembly on your Honda EB3000CK2A 3000 Watt Generator.

There are a large number of fasteners on the generator that must be removed for this repair. In order to keep them all organized and accessible, replace them in/on the same bolt hole or stud they were removed from as you work through the guide. If you encounter problems during the process, consult the official Honda service guides.

You will need to refill the engine oil for this procedure. The generator requires up to 0.58 liters of SAE 10W-30 oil.

Werkzeuge

Ersatzteile

Schritt 1

Before you begin, disconnect the spark plug connector from the spark plug.

Schritt 2

Elevate the generator on a set of stable risers, like wooden blocks.
Place a drain pan underneath the generator, between the blocks.

Schritt 3

Use a 12 mm socket to remove the oil drain plugs from either side of the generator.
Give the oil a few minutes to drain from the cylinder and crankcase housing.
Tip the generator back and forth towards either drain hole to allow any last bits of oil to drain.
Once the oil is finished draining, replace the drain plugs.
Tighten the drain plugs to 13 ft-lb (18 N-m) of torque.
During reassembly, be sure to refill the engine oil:
Use up to 0.58 liters of SAE 10W-30 oil, until the dipstick is almost completely submerged.

Schritt 4

Use a 12 mm socket to remove the two 20 mm-long bolts securing the shaft guard to the crankcase cover.
Remove the shaft guard.

Schritt 5

Use a 12 mm socket to remove the six 32 mm-long bolts securing the crankcase cover.
During reassembly, tighten these bolts down to 17 ft-lb (24 N-m) of torque.

Schritt 6

Use a 12 mm socket to remove the nut securing the upper cylinder shroud and air guide plate.
Use a 10 mm socket to remove the 12 mm-long bolt securing the air guide plate.
Remove the air guide plate.

Schritt 7

Use a 10 mm socket to remove the 12 mm-long bolt securing the upper cylinder shroud.
Tilt the upper shroud upward slightly so the hook on the right of the shroud is free from the bolt.
You may need to bend the hook out of shape slightly to reposition the shroud like this.
If you do bend the hook, simply use a pair of pliers to bend it back into place before refastening the nut during reassembly.

Schritt 8

When the shroud is sufficiently out of the way, remove the crankcase cover.
Residual oil may leak when you remove the cover. Be ready to catch any spillage.

Schritt 9

Use a 10 mm socket to remove the two 12 mm-long bolts securing the oil level switch assembly.
It is not necessary to remove the camshaft to access the oil level switch assembly. The camshaft is removed in the photo for illustration purposes only. If you have a universal flex joint, it is possible to work around the camshaft and timing gears.
If you do remove the camshaft, be sure to check the timing during reassembly by lining up the punch marks on the timing gears. If you need to turn the engine to do this, you can do so by gently pulling on the starter pulley.

Schritt 10

Remove the two cables to the left of the crankcase from the cable clip.

Schritt 11

Pull apart the yellow wire's bullet connector to disconnect the oil level switch.

Schritt 12

Use a 14 mm wrench to remove the retaining nut around the oil level switch cable.
During reassembly, tighten this nut to 7 ft-lb (10 N-m) of torque.

Schritt 13

Guide the oil level switch cable through its hole in the crankcase and remove the oil level switch sensor.

Schritt 14

It is best practice to replace the crankcase cover gasket and oil seal whenever opening the crankcase.
Remove the old gasket from the crankcase housing.

Schritt 15

Use a pick or a flathead screwdriver to remove the oil seal from the crankcase cover.
Reassembly tip: When installing the replacement oil seal, ensure its spring doesn't kink or fall out of its recess so it can maintain a proper seal.