Honda 3000 Watt Inverter Generator EU3000IS1AWK Control Wire Harness Replacement

ID: 136206

Description: This guide shows how to remove and replace the...

Steps:

1. Before you begin, make sure the generator is off and cool to the touch.
2. Use a large flathead screwdriver to unlock the maintenance cover.
3. Open the maintenance cover.

4. Use a Phillips screwdriver to remove the screw securing the spark plug cover.
5. Remove the spark plug cover.

6. Grab the plastic housing at the end of the spark plug wire.
7. Pull firmly to disconnect the wire from the spark plug.

8. Turn the fuel valve to the cutoff position.

9. Use a 10 mm socket to remove the four capped nuts securing the front cover.
10. Remove the front cover.

11. Use an 8 mm socket to disconnect the battery wires from the battery terminals.
12. Disconnect the black negative cable first to prevent the risk of shorting the battery.
13. During reassembly, connect the black negative cable first. Make sure you reconnect the wires in the correct polarity.

14. Unclip the battery strap from the lower plate.

15. Remove the battery.

16. Use a 10 mm socket to remove the four capped nuts securing the lower plate.
17. Set these capped nuts apart. They look similar, but are smaller than the front cover nuts.
18. Remove the lower plate.

19. Insert a flathead screwdriver into the top of the brown fuse clip in order to release the fuse holder.
20. Detach the fuse holder from the brown clip.

21. Use pliers to lift and disconnect the choke cable from the choke stay.
22. During reassembly, be sure to test the choke to ensure that it is properly connected.

23. Use a long shaft Phillips screwdriver to remove the deeply recessed screw securing the fuel cutoff switch.
24. Be careful not to turn the fuel cutoff switch while you remove the screw.

25. Remove the fuel cutoff switch.
26. During reassembly, be sure to test the switch to ensure that it is properly installed.

27. Use a 10 mm socket to remove the four bolts securing the control panel.

28. Carefully tilt the control panel downwards.
29. The control panel will still be connected to many wires and cables. Be careful not to strain any of the connected wires.

30. Remove the following bolts securing the inverter:
31. One 8 mm ground bolt
32. Three 10 mm bolts (one behind the control panel)

33. Reach behind the inverter along the edges and disconnect the six connectors from the back of the inverter.
34. All the connectors use locking tabs, so you will have to squeeze them in order to release them.
35. The third image shows the locations of all six sockets on the inverter.
36. Reassembly tip: Every socket on the inverter is different, so you can't plug something into the wrong place. Do not force the connectors into their sockets.

37. Remove the inverter.

38. If you are replacing the inverter and the replacement did not come with rubber mounts, follow the next two steps to transfer them over.
39. Use a screwdriver to push the metal collar out of the center of the rubber mount.

40. Squeeze the mount and remove it from the inverter.
41. Repeat the procedure with the remaining mounts and transfer them to the replacement inverter.

42. The remaining steps show all the connectors you need to disconnect in order to replace the wire harness.
43. To help keep track of the connectors, disconnect each one from the old harness and immediately connect it to the new harness.
44. Most connectors are keyed to plug in one orientation. Do not force the connectors.
45. Be sure to replace any cable ties you removed along the way.
46. During reassembly, use these images as reference for how the harness is secured to the control panel.

47. Unplug the five-wire starter relay connector.

48. Unplug the starter motor's black and white barrel connectors.
49. The wires should be connected to their respective colors.

50. Unplug the two-wire oil switch connector.

51. Unplug the four-wire rectifier connector from the bottom right corner of the control panel.

52. Unplug the four-wire regulator connector from the bottom edge of the control panel.

53. Unplug the green ground barrel connector.

54. Unplug the green and brown wires connected to the eco-throttle switch.
55. Be sure to connect these wires to their respective sockets.

56. Unplug the six-pin combination switch connector.

57. Insert a flathead screwdriver into the slot behind the DC receptacle in order to release the receptacle wires.
58. Pull and unplug the black and grey wires from the DC receptacle.
59. Be sure to connect these wires to the proper sockets.

60. Unplug the six-wire ignition control module connector.

61. Unplug the two winding connectors next to the air filter box.
62. Do not plug in the new wire harness yet.

63. Pull the existing wire harness out of the front frame.
64. Thread the replacement harness through the same cutout.
65. Route the three inverter connectors on the replacement harness through the double circular cutout in the front frame.

66. Connect the two winding connectors to the new harness.

67. The old wire harness should be completely removed.
68. Compare your harness routing with the images in step 21. Be sure that the harness is securely fastened to the generator.