Introduction
This guide demonstrates how to remove or replace the rotor and stator assembly on your Honda EB3000CK2A 3000 Watt Generator. The rotor and stator are removed as one unit. If you need to replace the rotor or stator individually, consult the generator’s service manual.
This is a very involved procedure and requires major disassembly. If you encounter problems during the process, consult the official Honda service guides.
You will need a universal puller with a metric collar set in order to pull the rotor off. If the bolts included do not fit correctly in the threaded holes of the rotor, you can use the 61 mm-long bolts removed in Step 41 of this guide.
The rotor is heavily bolted onto a free-spinning shaft. An impact wrench may be able to loosen the bolt. You may also need a strap wrench to hold the rotor steady.
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.
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.
Drain all fuel from the device before beginning this guide.
Some photos may show minor visual inconsistencies relative to this guide. These inconsistencies do not affect the repair procedure.
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Use a 10 mm socket to remove the nut securing the top of the cyclo converter cover.
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Use a 10 mm socket to remove the bolt securing the bottom of the cyclo converter cover.
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Un-slot the two black rubber cable grommets from the top and right edge of the plastic cover.
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Remove the cyclo converter cover.
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Pull the cyclo converter panel off of its posts on the generator body so the screw terminals are easily accessible.
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Use a Phillips #2 screwdriver to remove the seven 10 mm screws from the terminals on the cyclo converter panel. The wire that corresponds with each terminal is listed below:
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Red cable
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Double Black cable
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No cable
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White Cable
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Double Red cable
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Double White cable
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Double Blue cable
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Remove the terminal connecting bar from the panel once the corresponding terminals are unscrewed.
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Use a 10 mm socket to remove the three 12 mm-long bolts securing the recoil starter assembly.
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Remove the recoil starter assembly.
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Use a 10 mm socket to remove the two 20 mm-long bolts securing the recoil starter pulley.
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Remove the recoil starter pulley.
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Use a 10 mm socket to remove the two 20 mm-long bolts securing the sides of the control box case.
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Use a 10 mm socket to remove the five bolts securing the muffler protector and the fuel tank to the frame:
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Two 25 mm-long bolts
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Three 15 mm-long bolts
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Use a pair of pliers to remove the lock pin and clutch joint securing the fuel tank to the frame.
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Use a 10 mm socket to remove the two 20 mm-long bolts securing the fuel tank bar to the rest of the frame.
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Remove the fuel tank bar.
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Identify these two tubes and their tube clamps:
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The tube connected to the bottom of the fuel tank
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The tube connected to the petcock assembly
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Use a pair of pliers to squeeze and shift the second tube clamp left and away from the petcock assembly.
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Gently lift one side of the tank and slip it out of the generator frame.
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Remove the fuel tank.
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Unclip the two clips on top of the air cleaner housing.
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Tilt the air cleaner cover down slightly.
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Use a flathead screwdriver or a pick to remove the air cleaner element from the air cleaner housing.
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Use a 10 mm socket to remove the two nuts from the inside of the air cleaner housing.
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Use a 10 mm socket to remove the 20 mm-long bolt from the inside of the air cleaner housing.
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Lift up the canister assembly from its mounting rails to release it from the generator frame.
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Use a 12 mm socket to remove the four nuts securing the motor assembly to the generator frame.
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Use a 10 mm socket to remove the two 15 mm-long bolts securing the canister bracket.
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Remove the canister bracket.
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Use a 10 mm socket to remove the four bolts securing the fan housing:
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Two 40 mm-long bolts
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Two 30 mm-long bolts
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Use a 10 mm socket to remove the 12 mm-long bolt securing the ground cable to the fan housing.
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Use a 19 mm socket with an impact driver to remove the rotor nut from the generator assembly.
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Use a 5 mm hex driver to remove the four 61 mm-long bolts from the generator assembly.
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Ensure the proper pointed tip is fastened to the center of your universal puller.
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Affix the universal puller to the face of the rotor.
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Use an impact driver to pull the rotor and stator assembly from the crankshaft.
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Use a pair of pliers to squeeze and release the wire harness clip from the rotor side plate.
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Before you install the new rotor and stator assembly, ensure the axle key is properly installed.
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To reassemble your device, follow these instructions in reverse order.
