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Old 09-12-2010, 11:49 AM
Kevbo Kevbo is offline
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Join Date: Mar 2005
Location: Albuquerque
Posts: 64
Default Getting her clothes off.

Getting the case off:

This is perhaps the worst part of servicing this unit. The case has to come off to do most any sort of service. It is not simple or quick, but I have learned a few tricks that help.

The case is structural. The guts are mounted on a sheet metal frame inside, but this is flexy and you will need to take some care not to bend it when handling the unit out of the case. The frame also has sharp edges, so take care not to cut yourself. Gloves might be a good idea if you need to move the naked unit.

If this is the first time you are removing the case, drain the fuel tank. With practice, you can leave some fuel in the tank, but the first time you need to make things as easy as possible, and taking care to avoid spilling fuel complicates things. Go back and read the safety post if you skipped ahead.

It is much more pleasant to work at a table or bench rather than the
floor/ground...especially if you are getting long of tooth like me. Enough primliminarys, lets get to work!


Turn the fuel valve off and remove the knob.

Remove the "oil change" service hatch, reach inside, and take the fuel line that goes to the fuel filter loose from the fuel pump. The fuel pump is inside the lower right corner of the service hatch. Looks kind of like a small aluminum hockey puck. Remove and store the spring clips from this and any other fuel or vacuum hoses you take loose. If you leave them on the hoses, they will soon get knocked off and lost.

Remove the four screws holding the black louvred cooling outletair/exhaust panel in place.

Pad your work area with cardboard or carpet scraps. Lay the generator over with the electrical panel down. (you did drain the tank, right?) Avoid laying it over the other way, as this will allow oil to flood the aircleaner. (voice of experience) Remove the four feet and the three nut/bolt pairs holding the clamshell halves togethor. The feet bolts hold the frame to the case, so the guts are now loose inside. Gently stand the generator back upright.

Remove the three 5mm allen bolts, two at the handle and one below the fuel cap. You will need a long allen wrench for that last one due to the deep counterbore. Remove only one of the two remaining screws holding the case halves togethor. (the metal bridge between them is likely to get lost if you take both out)

Pull the rope out, and tie a big knot in about the middle. This will keep the rope from getting sucked into the engine, which will waste a lot of time if it happens. Now work the metal insert out of the tee grip, and work the rope out and untie the knot in the end, and remove the handle. Now remove the screw holding the black cover where the rope comes out of the case. Twist that cover around so it can pass into the case. I wish they had made
that hole large enough to pass the handle.


Take out all the little black screws holding the electrical panel in place. Pull it out, turn it a bit, and allow it to pass inside the case as you remove that half of the case. You can unplug the panel if you want, or just lay it on the bench. Don't try to leave the panel on the case, because it is too easy to break a wire when trying to disconnect the plugs in the tight space available. I did that the first time before I got smart.

Now remove the fuel tank. and unclip the hose from the tool storage compartment. Work the case away from the guts, reach in with a stubby screwdriver and remove the screw holding the fuel valve to the case, and then the two mounting screws for the fuel pump. Now you can remove the second half of the case. Whew!


Reverse the above to reinstall the case. Take care not to allow the fuel tank vent line to get caught between the case halves. And remember to lay the generator over only onto the electrical panel side to avoid oil spills.

The fuel tank has two studs that fit into grommets in the plate above the inverter. If you are careless, you will knock those grommets out when you set the tank back in place. One will fall into the tool compartment, but the back one will fall into the inverter guts. A bicycle spoke is the ideal tool for fishing it out of there.

Make sure the starter rope is still below all the wires before you put that side of the case back.

Last edited by Kevbo; 09-12-2010 at 12:35 PM.
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