A Few Words About Safety: How To Use This Manual

82Z36000.
book 1 ページ２０１２年１２月１１日　火曜日　午後１２時１１分
dummyhead
How to use this manual

A few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
0-1
82Z36000.book 2 ページ２０１２年１２月１１日　火曜日　午後１２時１１分
dummyhead
CONTENTS
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
CONTROL PANEL/GENERATOR 8
IGNITION SYSTEM 9
STARTING SYSTEM 10
MUFFLER 11
ENGINE REMOVAL/INSTALLATION 12
CYLINDER HEAD 13
CYLINDER BLOCK 14
WIRING DIAGRAMS 15
INDEX
dummyhead

INTRODUCTION
This manual covers the service and repair procedures for the Honda EG1000N/EP1000N generator.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgement.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the product.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.

• Instructions – how to service these products correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda PRODUCTS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: November 2012
0-3
dummyhead

SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design
specifications may damage the unit.
• Use the special tools designed for the product.
• Install new gaskets, O-rings, etc. when reassembling.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before assembly.
• After assembly, check all parts for proper installation and operation.
• Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use marine grease (water resistant urea based grease).
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use automatic transmission fluid.
( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.
0-4
dummyhead

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated term Full term
ACG Alternator
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EVAP Evaporative
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen Sensor
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside Diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
Bl Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray
0-5
dummytext
1. SPECIFICATIONS
SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVE ····························· 1-6
TYPE VARIATION ·········································1-3 DIMENSIONAL DRAWINGS······················· 1-10
SPECIFICATIONS ·········································1-4
1-1
dummyhead
SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
The engine serial number is located on the cylinder barrel.

The frame serial number is located on the frame.
Refer to these numbers when ordering parts and when making technical inquiries.
EG1000N
ENGINE SERIAL NUMBER FRAME SERIAL NUMBER
EP1000N
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
1-2
dummyhead
SPECIFICATIONS
TYPE VARIATION
EG1000N
Type M R RA K L LB S SB LS
Rated frequency 50 Hz 60 Hz
230 230
AC rated voltage 220 V 120 V 220 V
V V
AC
RECEPTACLE
SPARK PLUG
CAP WITH
RESISTANCE
EP1000N
Type R RDN
Rated frequency 50 Hz
AC rated voltage 220 V 230 V
AC
RECEPTACLE
1-3
dummyhead
SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS AND WEIGHTS
Model EG1000N EP1000N
Type K,L,LB,LS,M,R,RA,S,SB R,RDN
Description code EEGD EEHD
Overall length 376 mm (14.8 in) 404 mm (15.9 in)
Overall width 301 mm (11.9 in) 352 mm (13.9 in)
Overall height 430 mm (16.9 in) 431 mm (17.0 in)
Dry weight 22.5 kg (49.6 lbs) 27.3 kg (60.2 lbs)
Operating weight 25.4 kg (56.0 lbs) 30.2 kg (66.6 lbs)
ENGINE
Engine model GX80D
Description code GCADD
Type 4 stroke, OHV, single cylinder, inclined by 25°
Displacement 79.7 cm3 (4.86 cu–in)
Bore x stroke 46.0 x 48.0 mm (1.81 x 1.89 in)
Compression ratio 9.0
Ignition system Transistor magneto ignition
Ignition timing B.T.D.C. 20° ± 2° /600 – 4,200 min-1 (rpm)
Spark plug LR4C-E (NGK)
Lubrication system Forced spray
Oil capacity 0.36 liter (0.38 US qt, 0.32 Imp qt)
Recommended oil SAE 10W – 30 API service classification SE or later
Cooling system Forced air
Starting system Recoil starter
Stopping system Ignition primary circuit ground
Carburetor Horizontal type, butterfly valve
Air cleaner Semi-dry type
Governor Centrifugal weight system
Fuel used Regular unleaded gasoline with a pump octane rating 86 or higher*
*LB,SB types : Unleaded gasoline; E22
GENERATOR
Type K,L,LB,LS,M,R,RA,S,SB R,RDN
Description code EEGD EEHD
Generator type 2-pole revolving magnetic field type
Generator structure Self-ventilation type
Excitation Self-excitation system
Voltage regulation system Capacitor excitation
Phase Single phase
Frequency regulation Centrifugal weight system
1-4
dummyhead
SPECIFICATIONS
CHARACTERISTICS
Model EG1000N EP1000N EG1000N
Type K RDN L LB LS
Maximum output 850 VA 1000 VA
Rated output AC 750 VA 900 VA
AC Rated voltage 230 V 120 V 230 V
Rated current 3.3 A 7.5 A 3.9 A
Power factor 1.0 Cosθ
Voltage variation Momentary 30% max.
rate Average 13% max.
Average time 5 sec. max.
Voltage stability Within ± 4%
Frequency Momentary 15% max.
variation rate Average 7% max.
Frequency stability Within ± 1.5 Hz
Insulation resistance 10 MΩ min.
Circuit protector AC 4A 9A 5A
Insulation type F
Effective fuel tank capacity 3.6 Liters (0.95 US gal, 0.79 Imp gal)
Operating hours Approx. 5.5 Approx. 5.1 Approx. 5.5
Approx. 6.4 Hr.
(at rated load without refueling) Hr. Hr. Hr.
Model EG1000N EP1000N EG1000N

Type M,R,RA R S SB
Maximum output 850 VA 1000 VA
Rated output AC 750 VA 900 VA
AC Rated voltage 220 V
Rated current 3.4 A 4.1 A
Power factor 1.0 Cosθ
Voltage variation Momentary 30% max.
rate Average 13% max.
Voltage stability Within ± 4%
Frequency Momentary 15% max.
variation rate Average 7% max.
Frequency stability Within ± 1.5 Hz
Insulation resistance 10 MΩ min.
Circuit protector AC 4A 5A
Insulation type F
Effective fuel tank capacity 3.6 Liters (0.95 US gal, 0.79 Imp gal)
Operating hours
Approx. 6.4 Hr. Approx. 5.5 Hr. Approx. 5.1 Hr.
(at rated load without refueling)
1-5
dummyhead
SPECIFICATIONS
PERFORMANCE CURVE
The curves show performance of the generator under average condition.
Performance may vary to some degree depending on ambient temperature and humidity.
The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts.
EG1000N K type
RATING 3.3A
AC240
220
OUTPUT
200
(V(
180
160
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
EG1000N L,LB types
RATING 7.5A
AC140
130
OUTPUT
120
(V(
110
100
~
~
0 2 4 6 8 10
LOAD CURRENT ( A (
1-6
dummyhead
SPECIFICATIONS
EG1000N LS type
RATING 3.9A
AC260
240
OUTPUT
220
(V(
200
180
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
EG1000N M,R,RA types
RATING 3.4A
AC240
220
OUTPUT
200
(V(
180
160
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
1-7
dummyhead
SPECIFICATIONS
EG1000N S,SB types
RATING 4.1A
AC240
220
OUTPUT
200
(V(
180
160
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
EP1000N R type
RATING 3.4A
AC240
220
OUTPUT
200
(V(
180
160
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
1-8
dummyhead
SPECIFICATIONS
EP1000N RDN type
RATING 3.3A
AC240
220
OUTPUT
200
(V(
180
160
~
~
0 1 2 3 4 5
LOAD CURRENT ( A (
1-9
dummyhead
SPECIFICATIONS
DIMENSIONAL DRAWINGS
EG1000N
Unit: mm (in)
430 (16.9)
376 (14.8) 301 (11.9)
EP1000N
Unit: mm (in)
431 (17.0)
404 (15.9) 352 (13.9)
1-10
dummytext
2. SERVICE INFORMATION
MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-5
TORQUE VALUES ········································2-4 CABLE/HARNESS ROUTING ······················ 2-6
LUBRICATION & SEAL POINTS··················2-5
2-1
dummyhead
SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
ENGINE
Unit: mm (in)
Part Item Standard Service limit
Engine Engine speed 50 Hz 3,150 ± 50 min-1 (rpm) –
(no load) 60 Hz 3,750 ± 50 min-1 (rpm)
Cylinder compression 0.50 MPa (5.1 kgf/cm2, 73 psi)/600
–
min-1 (rpm)
Cylinder Sleeve I.D. 46.000 – 46.015 (1.8110 – 1.8116) 46.15 (1.8169)
Cylinder head Warpage – 0.10 (0.004)
Piston Skirt O.D. 45.965 – 45.985 (1.8096 – 1.8104) 45.87 (1.806)
Piston-to-cylinder clearance 0.015 – 0.050 (0.0006 – 0.0020) 0.12 (0.005)
Piston pin bore I.D. 12.002 – 12.008 (0.4725 – 0.4728) 12.04 (0.474)
Piston pin Pin O.D. 11.994 – 12.000 (0.4722 – 0.4724) 11.97 (0.471)
Piston pin-to-piston pin bore clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.07 (0.003)
Piston rings Ring side Top 0.035 – 0.070 (0.0014 – 0.0028) 0.20 (0.008)
clearance Second 0.045 – 0.080 (0.0018 – 0.0032) 0.20 (0.008)
Ring end gap Top 0.15 – 0.35 (0.006 – 0.014) 1.0 (0.04)
Second 0.15 – 0.35 (0.006 – 0.014) 1.0 (0.04)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 2.0 (0.08)
Ring width Top 0.950 – 0.970 (0.0374 – 0.0382) 0.968 (0.0381)
Second 0.940 – 0.960 (0.0370 – 0.0378) 0.938 (0.0369)
Connecting rod Small end I.D. 12.005 – 12.020 (0.4726 – 0.4732) 12.03 (0.474)
Big end I.D. 20.016 – 20.027 (0.7880 – 0.7885) 20.07 (0.790)
Big end oil clearance 0.036 – 0.057 (0.0014 – 0.0022) 0.10 (0.004)
Big end side clearance 0.10 – 0.40 (0.004 – 0.016) 0.60 (0.024)
Crankshaft Crankpin O.D. 19.970 – 19.980 (0.7862 – 0.7866) 19.93 (0.785)
Valves Valve clearance IN 0.10 ± 0.02 (0.004 ± 0.001) –
EX 0.15 ± 0.02 (0.006 ± 0.001) –
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.97 (0.196)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.95 (0.195)
Guide-to-stem IN 0.010 – 0.037 (0.0004 – 0.0015) 0.060 (0.0024)
clearance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.080 (0.0031)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Valve guide IN 5.8 – 6.2 (0.23 – 0.24) –
installation height EX 3.3 – 3.7 (0.13 – 0.15) –
Valve seat width IN/EX 0.7 – 0.9 (0.03 – 0.04) 2.0 (0.08)
Valve spring free length 29.5 (1.16) 28.3 (1.11)
Valve spring perpendicularity – 2° max.
Camshaft Journal O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.95 (0.392)
Cam height IN 19.599 – 19.999 (0.7716 – 0.7874) 19.40 (0.764)
EX 19.641 – 20.041 (0.7733 – 0.7890) 19.44 (0.765)
Cylinder barrel Camshaft holder I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.05 (0.396)
Crankcase cover Camshaft holder I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.05 (0.396)
Rocker arm Rocker arm I.D. 6.000 - 6.030 (0.2362 - 0.2374) 6.04 (0.238)
Rocker shaft Rocker arm shaft O.D. 5.952 - 6.000 (0.2343 - 0.2362) 5.94 (0.234)
Rocker arm shaft holder I.D. 6.010 - 6.022 (0.2366 - 0.2371) 6.04 (0.238)
Spark plug Air gap 0.6 – 0.7 (0.02 – 0.03) –
Spark plug cap Resistance M type only 7.5 – 12.5 kΩ –
Ignition coil Resistance Primary side 0.8 – 1.2 Ω –
Secondary side 5.6 – 11.8 kΩ –
Air gap (at rotor) 0.2 – 0.6 (0.01 – 0.02) –
Carburetor Main jet LB,SB types # 57.5 –
Except LB,SB # 55 –
types
Float height 20.2 (0.80) –
Pilot screw opening 7/8 turn out –
2-2
dummyhead
SERVICE INFORMATION
GENERATOR
Part Item Standard
Stator Main winding L,LB type 126 V min.
voltage EG1000N/
M,R,RA,S,SB type 231 V min.
EP1000N
K, LS,RDN type 241 V min.
Main winding K type 6.84 – 7.56 Ω
resistance L,LB type 1.13 – 1.25 Ω
EG1000N LS type 4.24 – 4.68 Ω
M,R,RA type 6.78 – 7.50 Ω
S,SB type 4.11 – 4.55 Ω
R type 5.66 – 6.26 Ω
EP1000N
RDN type 5.83 – 6.45 Ω
Condenser LS,S,SB type 2.76 – 3.06 Ω
winding EG1000N L,LB type 2.60 – 2.88 Ω
resistance K,M,R,RA type 4.28 – 4.73 Ω
EP1000N R,RDN type 4.28 – 4.73 Ω
2-3
dummyhead
SERVICE INFORMATION
TORQUE VALUES
ENGINE TORQUE VALUES
Thread Dia. Torque values
Item Remarks
(mm) N·m kgf·m lbf·ft
Crankcase cover bolt M6 x 1.0 12 1.2 9
Cylinder head bolt M6 x 1.0 9.5 1.0 7.0 Apply engine oil to the bolt
threads and seating surface.
Connecting rod bolt M5 x 0.8 5 0.5 3.7 Apply engine oil to the bolt
Spark plug M10 x 1.0 12 1.2 9
Flywheel nut M12 x 1.25 60 6.1 44 Apply engine oil to the nut
Tappet adjusting nut M5 x 0.5 7 0.7 5.2
Cylinder head cover bolt M6 x 1.0 10 1.0 7
Carburetor nut M10 x 1.25 8.5 0.9 6.3
Drain plug bolt M10 x 1.25 18 1.8 13
FRAME TORQUE VALUES

Item Remarks
Rubber mount nut M6 x 1.0 8.3 0.8 6.1
(EP1000N only)
Bottom rubber bolt M6 x 1.0 10 1.0 7
(EG1000N only)
Fuel valve bolt M5 x 0.8 5.2 0.5 3.8
Rotor bolt M8 x 1.25 24 2.4 18 Apply engine oil to the bolt
Front cover insulator screw 5 mm screw 1.4 0.1 1.0
(EP1000N only)
Rear housing ground screw 5 mm screw 1.3 0.1 1.0
Recoil starter reel cover bolt 6 mm screw 10 1.0 7
STANDARD TORQUE VALUES

Item Remarks
Screw 5 mm 2.3 0.2 1.7
6 mm 2.8 0.3 2.0
Bolt and nut 5 mm 5.2 0.5 3.8
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.5 0.6 4.1
6 mm 11 1.1 8
8 mm 22 2.2 16
10 mm 39 4.0 29
SH (Small head) flange bolt 6 mm 9 0.9 6.6
CT (Cutting threads) flange bolt 5 mm 5.4 0.6 4.0
(Retightening) 6 mm 12 1.2 9
2-4
dummyhead
SERVICE INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
Location Material Remarks
Crankshaft pin and gear Engine oil
Piston outer surface and piston ring
Piston pin outer surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft bearing, profile, weight sliding portion and
gear
Valve lifter stem, stem end and slipper surface
Valve stem and stem end
Rocker arm sphere surface and rocker arm shaft hole
Governor weight holder sliding portion and gear
Governor holder shaft journal
Governor arm shaft journal
Flywheel nut threads and seating surface
Cylinder head bolt threads and seating surface
Oil seal lips Multi-purpose grease
O-ring
Recoil starter case sliding surface
Side plate return spring sliding surface
Starter reel return spring sliding surface
Recoil starter ratchet shaft sliding surface
Recoil starter ratchet whole surface
Starter reel cover sliding surface and projection
Recoil starter friction spring sliding surface
TOOLS
Seat cutter, 20.5 mm (45° IN/EX) Flat cutter, 20 mm (32° IN/EX) Interior cutter, 20.5 mm (60° IN/EX)
07780-0011000 07780-0013200 07780-0014300
Cutter holder, 5.0 mm Valve guide driver, 5 mm Valve guide reamer 5.010 mm
07781-0010400 07942-MA60000 07984-MA60001
2-5
dummyhead
SERVICE INFORMATION
CABLE/HARNESS ROUTING
CONTROL PANEL CASE
EG1000N, EP1000N
CONTROL PANEL WIRE HARNESS

CONDENSER
White tape is put together on
STATOR
grommet at the center. CONTROL PANEL
HARNESS
WHITE TAPE WIRE HARNESS
(Bu)
(EP1000N only)
STATOR
HARNESS
Engine earth terminal of the

control panel wire harness CONTROL PANEL
contact to boss. HARNESS CASE GUIDE
TUBE
BOSS
OIL LEVEL
SWITCH HARNESS
CORD GUIDE
CONTROL
PANEL WIRE HARNESS CORD CLIP OIL ALERT UNIT CORD
HARNESS
TUBE Bl Bl OIL
CONTROL
Bl Y ALERT
PANEL WIRE Y Y
HARNESS UNIT
Y/G Y/G
Bl Y
OIL LEVEL
SWITCH
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
G Green Lg Light green
R Red P Pink
W White Gr Gray
2-6
dummyhead
SERVICE INFORMATION
CONTROL PANEL
EG1000N K,L,LS,M,R,S types, EP1000N R type
STATOR HARNESS TERMINAL CORD
Except L type (Br) Except L type (Br)
CONTROL PANEL L type only (R) L type only (R)
WIRE HARNESS Do not interchange with Do not interchange with CONTROL PANEL
(Y/G) the terminal cord. the stator harness. WIRE HARNESS
(Y/G) OIL ALERT UNIT
CONTROL PANEL
STATOR
WIRE HARNESS
HARNESS
(Bl)
ENGINE
SWITCH
AC CIRCUIT
PROTECTOR STATOR
Bl Black Br Brown TERMINAL CORD HARNESS
Y Yellow O Orange AC RECEPTACLE (W)
Except L type (Br)
G Green Lg Light green L type only (R)
R Red P Pink
W White Gr Gray
EP1000N RDN type
STATOR HARNESS (Br) TERMINAL CORD (Br)

CONTROL PANEL
WIRE HARNESS Do not interchange with Do not interchange with
(Y/G) the terminal cord. the stator harness. CONTROL PANEL
WIRE HARNESS
(Y/G) OIL ALERT UNIT
CONTROL PANEL
STATOR
WIRE HARNESS
HARNESS
(Bl)
ENGINE
SWITCH
AC CIRCUIT
TERMINAL CORD
PROTECTOR
(Br)
Bl Black Br Brown STATOR
Y Yellow O Orange HARNESS AC RECEPTACLE
Bu Blue Lb Light blue (W)
R Red P Pink
W White Gr Gray
2-7
dummyhead
SERVICE INFORMATION
EG1000N RA type
CONTROL PANEL
WIRE HARNESS STATOR HARNESS (Br)
TERMINAL CORD (Br)
(Y/G) Do not interchange with Do not interchange with
the terminal cord. the stator harness.
CONTROL PANEL STATOR
WIRE HARNESS OIL ALERT UNIT
HARNESS
(Bl) (W)
STATOR
HARNESS
ENGINE
SWITCH
Bl Black Br Brown TERMINAL

Y Yellow O Orange CORD
AC RECEPTACLE
AC CIRCUIT (Br)
PROTECTOR CONTROL PANEL
R Red P Pink WIRE HARNESS
W White Gr Gray (Y/G)
EG1000N LB,SB types
STATOR HARNESS
TERMINAL CORD
CONTROL PANEL LB type (R) LB type (R)
WIRE HARNESS SB type (Br)
SB type (Br)
(Y/G) Do not interchange with
Do not interchange with
the terminal cord.
the stator harness.
OIL ALERT UNIT
CONTROL PANEL
CONTROL PANEL WIRE HARNESS
WIRE HARNESS (Y/G) STATOR
(Bl) HARNESS
ENGINE
SWITCH
Bl Black Br Brown TERMINAL

Y Yellow O Orange
CORD
STATOR LB type (R)
R Red P Pink AC CIRCUIT HARNESS SB type (Br)
W White Gr Gray PROTECTOR (W) AC RECEPTACLE
2-8
dummyhead
SERVICE INFORMATION
IGNITION COIL/OIL LEVEL SWITCH
EG1000N, EP1000N
GROMMET HIGH TENSION CORD
UPPER SHROUD
BREATHER TUBE
GROMMET
INSTALLATION:
Grommet is certainly
attach to fan cover
as shown.
GROMMET
FAN COVER
IGNITION COIL
VIEWED FROM LOWER SIDE:

GUIDE
OIL LEVEL SWITCH

ENGINE EARTH
OIL LEVEL SWITCH CORD (Bl)
GUIDE
Bl Black Br Brown
Y Yellow O Orange
GUIDE OIL LEVEL SWITCH CORD
Bu Blue Lb Light blue (TO CONTROL PANEL HARNESS)
G Green Lg Light green OIL LEVEL SWITCH
R Red P Pink
GROMMET
W White Gr Gray
2-9
dummyhead
SERVICE INFORMATION
FUEL LINE
EG1000N:
FUEL TANK
TUBE
FUEL VALVE FUEL TANK

TUBE TUBE
EP1000N:
FUEL VALVE
TUBE
5m
m(
0.2
in)
FUEL VALVE
TUBE
3 mm (0.1 in) – 6 mm (0.2 in) 8m
m(
0.3
in)
– 11
TUBE CLIP (C9) m m(
0.4
in)
3 mm (0.1 in) – 6 mm (0.2 in)
TUBE CLIP (C11)
FUEL TANK
TUBE
TUBE CLIP (B8)
3 mm (0.1 in) – 6 mm (0.2 in)

5 mm (0.2 in) – 10 mm (0.4 in)
TUBE CLIP (B8)

3 mm (0.1 in)
DRAIN TUBE CLIP
DRAIN TUBE
2-10
dummyhead
SERVICE INFORMATION
EG1000N:
BREATHER TUBE
10 mm (0.4 in) – 15 mm (0.6 in)

DRAIN TUBE
GUIDE
EP1000N:
BREATHER TUBE
DRAIN TUBE
GUIDE
n)
8i
(0.
m
2 0m
in )–
6
(0.
m m
15
2-11
dummyhead
MEMO
dummytext
3. MAINTENANCE
MAINTENANCE SCHEDULE························3-2 SPARK PLUG

CHECK/ADJUSTMENT/REPLACEMENT ···· 3-5
ENGINE OIL LEVEL CHECK/CHANGE ·······3-3
VALVE CLEARANCE
AIR CLEANER CHECK/CLEANING ·············3-4 CHECK/ADJUSTMENT ································ 3-6
COMBUSTION CHAMBER CLEANING ·······3-4 FUEL TANK AND FILTER CLEANING ········ 3-7
FUEL TUBE CHECK ····································· 3-7
3-1
dummyhead
MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE
ITEM Perform at every REGULAR SERVICE PERIOD (2)

Refer
indicated month or First Every Every Every to
operating hour interval, Each use month 3 months 6 months year or page
whichever comes first. or 20 hrs. or 50 hrs. or 100 hrs. 300 hrs.
Engine oil Check level
3-3
Change
Air cleaner Check
3-4
Clean (1)
Combustion
Clean After every 500 hrs. 3-4
chamber
Spark plug Check–adjust
3-5
Replace
Valve
Check–adjust 3-6
clearance
Fuel tank and
Clean 3-7
filter
Fuel tube Check Every 2 years (Replace if necessary) 3-7
(1) Service more frequently when used in dusty areas.
(2) For commercial use, log hours of operation to determine proper maintenance intervals.
3-2
dummyhead
MAINTENANCE
ENGINE OIL LEVEL CHECK/CHANGE
CHECK
Place the generator on a level surface.
[1]
Remove the oil filler cap [1].
Check the oil level.
If it is the below the upper limit [2] fill with the
recommended oil to the upper limit.
RECOMMEND OIL:
SAE 10W-30 API service classification SE or later
Oil is a major factor affecting performance and service [2]

life. Use 4-stroke automotive detergent oil.
10W-30 is recommended for general use. Other
viscosities shown in the chart may be used when the [3]
average temperature in your area is within the
recommended range. SAE VISCOSITY GRADES
Check that the oil filler packing [3] is in good condition;
replace it if necessary.
Install the oil filler cap securely.
AMBIENT TEMPERATURE
CHANGE
Drain the engine oil while the engine is warm. Warm oil
drains quickly and completely.
Place the generator on a level surface.
Place a suitable container [1] under the oil drain plug. [2]
Remove the oil filler cap [2] and the oil drain plug [3]
and sealing washer [4].
Please dispose of used engine oil in a manner that is
compatible with the environment. We suggest you take [1]
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it into the ground, or pour it down a
drain.
[4]
[3]
Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly
with soap and water as soon as possible after
contact with used engine oil.
Install the oil drain plug with a new sealing washer, and
tighten the oil drain plug to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Fill with the recommended oil to the upper level.
Engine oil capacity:
0.36 Liter (0.38 US qt, 0.32 Imp qt)
Check that the oil filler packing [4] is in good condition;

replace it if necessary.
Install the oil filler cap securely.
3-3
dummyhead
MAINTENANCE
AIR CLEANER CHECK/CLEANING
A dirty air cleaner will restrict airflow to the carburetor,
reducing engine performance. If the engine is operated [1]
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
• Operating the engine without an air cleaner element

or with a damaged air cleaner element will allow dirt
to enter the engine, causing rapid engine wear.
Pull the clips to unlock [1] and remove the air cleaner
element case [2].
Remove the air cleaner element [3] from the air cleaner [3]
element case.
[2]
Clean the air cleaner element in warm soapy water [1],

rinse, and allow to dry thoroughly, or clean with a high
flash point solvent and allow to dry. [2]
Dip the air cleaner element in clean engine oil [2] and
squeeze out all the excess oil. Clean
• Excess oil will restrict air flow through the air cleaner Squeeze and
element and may cause the engine to smoke at dry Squeeze
startup. firmly
• Do not twist to squeeze oil from the air cleaner [1]

element. Twisting the element can damage it. Do not twist
Wipe dirt from the inside of the air cleaner element case
using a moist clean rag. Be careful to prevent dirt from
entering the air duct that leads the carburetor.
Install the air cleaner element in the air cleaner element
case.
Install the air cleaner case, then push the clips to the
lock position.
COMBUSTION CHAMBER CLEANING

Remove the cylinder head (page 13-3).
[1]
Clean any carbon deposits from the combustion
chamber [1].
3-4
dummyhead
MAINTENANCE
SPARK PLUG CHECK/ADJUSTMENT/
REPLACEMENT
If the engine has been running, the engine will be

very hot. Allow it to cool before proceeding.
Remove the rear cover (EP1000N only) (page 5-2). [2]

Clean any dirt from around the spark plug.
Disconnect the spark plug cap [1], and use a spark plug
wrench to remove the spark plug [2].
[1]
Visually inspect the spark plug. Replace the plug if the

[1]
insulator [1] is cracked, chipped, or heavily fouled.
Check the sealing washer [2] for damage. Replace the
spark plug if the sealing washer is damaged.
SPARK PLUG: LR4C-E (NGK)
Measure the plug gap with a wire-type feeler gauge. If
the measurement is out of the specification, adjust by
bending the side electrode.
PLUG GAP: 0.6 – 0.7 mm (0.02 – 0.03 in)
Install the spark plug finger tight to seat the washer, and
then tighten it to the specified torque.
0.6 – 0.7 mm
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) [2] (0.02 – 0.03 in)
• A loose spark plug can become very hot and can

damage the engine. Overtightening can damage the
threads in the cylinder head.
Install the spark plug cap securely.
3-5
dummyhead
MAINTENANCE
VALVE CLEARANCE CHECK/
ADJUSTMENT
• Valve clearance inspection and adjustment must be

performed with the engine cold. [1]
Remove the rear cover (EP1000N only) (page 5-2). [2]

[3]
Disconnect the spark plug cap [1].
Remove the cylinder head cover bolt [2] and rubber
mount [3] from the cylinder head cover [4].
Remove the breather tube [5] from the cylinder head
cover.
Remove the cylinder head cover and packing [6].
[4]
[6] [5]
Remove the recoil starter (page 10-2).
ALIGN
Turn the crankshaft until the piston is at top dead center [3]
on its compression stroke (both valves fully closed) by
turning the starter pulley [1].
[2]
Align the alignment mark [2] of the starter pulley and
projection [3] on the fan cover.
[1]
Insert a feeler gauge [1] between the tappet adjusting

screw [2] and valve stem end [3] to measure the valve [2]
clearance. [4]
VALVE CLEARANCE:
[3]
IN: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
EX: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
If adjustment is necessary, proceed as follows:
Hold the tappet adjusting screw and loosen the tappet
adjusting nut [4].
Turn the tappet adjusting screw to obtain the specified
clearance.
Hold the tappet adjusting screw and retighten the
tappet adjusting nut to the specified torque.
TORQUE: 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
[1]
Recheck the valve clearance, and if necessary, readjust
the clearance.
Replace the head cover packing with a new one and
install the removed parts in the reverse order of removal
(page 13-3).
[2]
3-6
dummyhead
MAINTENANCE
FUEL TANK AND FILTER CLEANING
Gasoline is highly flammable and explosive. You [3]

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors. [2]
• Wipe up spills immediately.
[1]
Remove the fuel tank (page 6-2).
Remove the fuel tank tube [1], and fuel strainer [2] from
the fuel tank [3].
Clean the fuel strainer and fuel tank with non-flammable
solvent, and allow it to dry thoroughly.
Check the screen of the fuel strainer for clogs or
damage.
Replace if necessary.
Install the fuel strainer, and fuel tank tube to the fuel
tank.
Install the fuel tank (page 6-2).
After installation, check for any signs of fuel leakage.
FUEL TUBE CHECK

[1]
Gasoline is highly flammable and explosive. You

fuel.
• Handle fuel only outdoors.
Check the fuel tubes [1] for deterioration, cracks, or

signs of leakage.
3-7
dummyhead
MEMO
dummytext
4. TROUBLESHOOTING
HARD STARTING OR ENGINE STARTS BUT ENGINE DOES NOT START WHEN ENGINE
THEN STALLS ··············································4-2 OIL LEVEL IS SUFFICIENT·························· 4-4
ENGINE SPEED DOES NOT INCREASE OR ENGINE DOES NOT STOP WHEN ENGINE OIL
STABILIZE·····················································4-3 LEVEL IS LOW ············································· 4-5
4-1
dummyhead
TROUBLESHOOTING
HARD STARTING OR ENGINE STARTS BUT THEN STALLS
TROUBLESHOOTING
Is the fuel valve ON position? OFF Set the fuel valve ON position.
ON
Check the fuel level in the tank. No fuel Add fuel and restart the engine.
Sufficient fuel
Check the engine oil level (page 3-3). Low oil level Add oil and restart the engine.
Sufficient oil
Fuel not reaching
Loosen the drain screw and check whether fuel the carburetor Check for blockage of the fuel tube or fuel strainer
reached the carburetor (page 6-6). (page 6-2, 6-3).
Fuel reached the carburetor

Loose nuts or
Inspect the carburetor mounting nuts and insulator damaged insulator Retighten the carburetor mounting nuts.
packing (page 6-5). Verify insulator is correctly installed.
Replace damaged insulator packing (page 6-5).
Normal
Remove the spark plug and check for wet or fouled Dry Check for blockage of the carburetor main jet port
electrode. passages, ports or main nozzle (page 6-7).
Dry the electrode and restart, taking care that the

Wet choke is not closed too much.
If flooding is severe, check the carburetor float valve
Normal
(page 6-7).
No spark or
Perform the spark test (page 9-6). weak spark Perform "ENGINE DOES NOT START WHEN
ENGINE OIL LEVEL IS SUFFICIENT" (page 4-4).
Good spark
High
Measure the cylinder compression (page 13-5). compression Check for carbon deposits in the combustion
chamber (page 3-4).
Low Check that the valve clearance is correct (page 3-6).

compression Check for worn or damaged valves, or valve seats
Normal compression (page 13-6).
Check that the cylinder head bolt is correctly
tightened (page 13-3).
Check for worn piston, piston rings, or cylinder
(page 14-5).
Reinstall the spark plug securely and restart the

engine according to the starting procedure.
4-2
dummyhead
TROUBLESHOOTING
ENGINE SPEED DOES NOT INCREASE OR STABILIZE
Check the air cleaner (page 3-4). Contaminated Clean or replace the filter element if necessary
(page 3-4).
Not contaminated
Check the spark plug (page 3-5). Abnormal Clean the spark plug and adjust the plug gap, and
replace if necessary (page 3-5).
Normal
Check the cylinder compression (page 13-5). Abnormal Check that the valve timing is correct (page 14-3).
Check for worn or damaged valves, or valve seats
(page 13-6).
Check for worn piston rings, piston, or cylinder
(page 14-5).
Normal Check to see whether excessive carbon has
accumulated in the combustion chamber
(page 3-4).
Check the valve clearance (page 3-6). Incorrect Adjust the valve clearance (page 3-6).
Correct
Loose nuts or
Inspect the carburetor mounting nuts and insulator damaged insulator Retighten the carburetor mounting nuts.
packing (page 6-5). Verify insulator is correctly installed.
Replace damaged insulator packing (page 6-5).
Normal
Check for blockage in the main jet or nozzle of the Clogged Disassemble and clean; replace if necessary
carburetor (page 6-6). (page 6-7).
Not clogged
Adjust the engine speed (page 7-3).

50 Hz : 3,150 ± 50 min-1 (rpm)
60 Hz : 3,750 ± 50 min-1 (rpm)
4-3
dummyhead
TROUBLESHOOTING
ENGINE DOES NOT START
WHEN ENGINE OIL LEVEL IS SUFFICIENT
Check the engine switch (page 8-9). Abnormal Replace the engine switch (page 8-7, 8-8).
Normal
Disconnect the oil alert unit wire (Black). No spark Check for short circuit in the black wire between the
Perform the spark test (page 9-6). engine switch, oil alert unit and ignition coil.
OIL ALERT UNIT Abnormal
Normal Repair or replace the wire harness.
Perform "IGNITION SYSTEM TROUBLESHOOTING"

(page 9-2).
OIL ALERT UNIT WIRE

(Black)
Spark
Connect the oil alert unit wire (Black). Spark Replace the oil level switch (page 9-5).
Disconnect the oil level switch wire (Yellow).
Perform the spark test (page 9-6).
OIL ALERT UNIT WIRE
(Black)
OIL LEVEL SWITCH WIRE

(Yellow)
No spark
Replace the oil alert unit (page 8-7). If the yellow wire
short between the oil alert unit and oil level switch.
4-4
dummyhead
TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW
Normal
Spark Disconnect the oil alert unit wire (Black).

Disconnect the oil alert unit wires (Yellow) and
(Yellow/Green). Ground the wire (Black) to the rear housing with the
Ground the oil alert unit wires (Yellow) and (Yellow/ suitable wire.
Green) connectors to the rear housing with the Perform the spark test (page 9-6).
suitable wire. OIL ALERT UNIT
OIL ALERT UNIT
OIL ALERT UNIT WIRE

(Black)
OIL ALERT UNIT OIL ALERT UNIT WIRE
(Yellow/Green) No spark Spark
WIRE (Yellow)
No spark
Replace the oil alert unit (page 8-7, 8-8).
Disconnect the oil level switch wires from the control

panel wire harness (page 8-4).
Check the continuity between the oil level switch wire
(Yellow) and engine ground. Check the Ignition coil (page 9-7).
Normal Abnormal
Replace the Ignition coil (page 9-3).
Check that the connectors are connected securely.

Check for open wire (Black) of the wire harness.
OIL LEVEL SWITCH WIRE No continuity Replace the oil level switch (page 9-5).
(Yellow)
Continuity

Check for open wires (Yellow) and (Yellow/Green) of
the wire harness.
4-5
dummyhead
MEMO
dummytext
5. COVER
FRONT COVER/REAR COVER

REMOVAL/INSTALLATION··························5-2
5-1
dummyhead
COVER
FRONT COVER/REAR COVER
COVER
REMOVAL/INSTALLATION
EP1000N
REAR COVER
SCREW (5 x 12 mm) (3)

1.4 N·m (0.1 kgf·m, 1.0 lbf·ft)
INSULATOR CLIP (3)
INSULATOR
FRONT COVER
REMOVAL:
The front cover can be removed with the
insulator, clips and screws installation.
BOLT (6 x 18 mm) (2)
COVER WASHER (2)
5-2
dummytext
6. FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION ····6-2 CARBURETOR

DISASSEMBLY/ASSEMBLY ························ 6-6
AIR CLEANER
REMOVAL/INSTALLATION··························6-4 CARBURETOR BODY CLEANING ·············· 6-7
CARBURETOR CARBURETOR INSPECTION ······················ 6-7

CHOKE REPLACEMENT ····························· 6-8
6-1
dummyhead
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
FUEL SYSTEM
EP1000N

fuel.
Remove the control panel case (page 8-4).

Loosen the drain screw of the carburetor and drain the fuel if necessary.
When installing, route the tubes properly (page 2-10).
FUEL TANK CAP FUEL FILTER

INSTALLATION:
Clean the screen and check for damage.
CAP PACKING
FUEL FILTER HOLDER
FUEL TANK BOLT (6 x 12 mm) (4)
FUEL TANK RUBBER (2)

FUEL STRAINER
INSTALLATION:
Clean the screen and check for damage.
TUBE CLIP (C11)

BOND PART
INSTALLATION: FUEL TANK TUBE
Bond Loctite 495 [1] INSTALLATION:
or equivalent to the Check for cracks, deterioration,
inside of the fuel tank or signs of leakage.
rubber [2] as shown.
[1] TUBE CLIP (B8)
[2]
BOND PART
INSTALLATION:
Bond Loctite 495 [1]
or equivalent to the
inside of the fuel tank
rubber [2] as shown.
[1]
[2]
FUEL VALVE
BOLT (5 x 14 mm)
TUBE CLIP (B8) 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
6-2
dummyhead
FUEL SYSTEM
EG1000N

fuel.
Remove the control panel case (page 8-4).

Loosen the drain screw of the carburetor and drain the fuel if necessary.
FUEL TANK CAP HANDLE BAR

CAP PACKING
FUEL FILTER
INSTALLATION:
Clean the screen and
check for damage. BOLT
(6 x 10 mm) (4)
FUEL FILTER HOLDER
FUEL STRAINER
INSTALLATION:
Clean the screen and
check for damage.
BOLT (6 x 12 mm) (4)
FUEL TANK TUBE
INSTALLATION:
Check for cracks, deterioration,
or signs of leakage.
TUBE CLIP (C11)

TUBE CLIP (B8)
R. SIDE FRAME
FUEL TANK BOLT
REMOVAL: (6 x 16 mm) (3)
The fuel tank can be
removed with the handle
bar, R./L. side frames, and
fuel valve installed.
L. SIDE FRAME
FUEL VALVE
BOLT (5 x 14 mm)
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
BOLT (6 x 55 mm)
TUBE CLIP
(B8)
6-3
dummyhead
FUEL SYSTEM
AIR CLEANER
• If you perform the removal/installation of the air

cleaner with the carburetor installed, and turn the
choke lever fully to the CLOSED position so that
dust and dirt do not enter the engine.
AIR CLEANER CASE

RUBBER
AIR CLEANER CASE
BOLT (6 x 28 mm) (4)
CLIP
AIR CLEANER CASE

PACKING
AIR CLEANER ELEMENT
AIR CLEANER
ELEMENT CASE
REMOVAL:
Pull the clips to unlock and remove the
air cleaner element case.
INSTALLATION:
Install the air cleaner case, then push
the clips to the lock position.
6-4
dummyhead
FUEL SYSTEM
CARBURETOR

fuel.
Remove the air cleaner (page 6-4).

Remove the governor arm (page 7-2).
Loosen the drain screw of the carburetor and drain the fuel.
LOWER SHROUD
GUIDE
CARBURETOR INSULATOR
INSULATOR PACKING (2)
BREATHER TUBE
CARBURETOR
AIR CLEANER GASKET
TUBE CLIP
(C9)
DRAIN TUBE FUEL VALVE

TUBE
AIR CLEANER BASE

INSTALLATION: TUBE CLIP
Install the breather tube [1] in the (B8)
position. [1]
NUT (6 mm)
8.5 N·m (0.9 kgf·m, 6.3 lbf·ft)
6-5
dummyhead
FUEL SYSTEM
CARBURETOR
DISASSEMBLY/ASSEMBLY

fuel.
To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.
Remove the carburetor (page 6-5).

Before disassembly, clean the outside of the carburetor.
PILOT JET FUEL STRAINER SCREEN

ASSEMBLY: ASSEMBLY: PILOT SCREW
Clean thoroughly with Before installation, clean the ASSEMBLY:
the compressed air screen and check for damage. Turn the pilot screw in until it is lightly
before installation. seated, and then turn the screw out
the required number of turns.
THROTTLE LEVER PILOT SCREW Opening: 7/8 turn out
SPRING
THROTTLE STOP SCREW

CARBURETOR BODY ASSEMBLY:
Turn the throttle stop screw in
SPRING until it is touched to throttle
lever (closed position), and then
turn the clockwise two turns.
MAIN NOZZLE
FLOAT PIN MAIN JET
ASSEMBLY:
Clean thoroughly with the ASSEMBLY:
compressed air before Clean thoroughly with the and
installation. compressed air before installation.
FLOAT CLIP
FLOAT FLOAT VALVE

Check for smooth ASSEMBLY:
movement after installation. [2]
Check for worn
float valve seat [1],
float valve [2]
[1]
before installation.
O-RING OK CLEAN REPLACE
DRAIN SCREW
DRAIN SCREW
SPRING FLOAT CHAMBER
ASSEMBLY:
Install the float chamber to the
carburetor body at an angle as shown.
DRAIN TUBE
CLIP WASHER
DRAIN TUBE SCREW

ASSEMBLY: 30°
After assembly,
check for any sign
of fuel leakage. DRAIN SCREW
6-6
dummyhead
FUEL SYSTEM
CARBURETOR BODY CLEANING
ENGINE SIDE:
To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air. [3] [2]
[1]
• Some commercially available chemical cleaners are

very caustic. These cleaners may damage plastic
parts such as the O-ring, the float, and the float [5]
valve of the carburetor. Check the container for
instructions. If you are in doubt, do not use these [4] [7]
products to clean a Honda carburetor.
• High air pressure may damage the carburetor. Use
low air pressure (0.2 MPa (30 psi) or less) when
cleaning passages and ports.
Clean the carburetor body [1] with high flash point
solvent.
Clean thoroughly the following passages and ports with
low pressure compressed air. [8]
– Pilot screw hole [2]
– Pilot jet hole [3]
– Pilot air jet [4] [6]
– Main air jet [5]
– Bypass hole [6]
– Main nozzle holder [7]
– External vent port [8]
INTAKE SIDE:
CARBURETOR INSPECTION
FLOAT LEVEL HEIGHT
Place the carburetor in the position as shown, and
measure the distance between the float top [1] and
[3]
carburetor body [2] when the float just contacts the
valve seat [3].
STANDARD FLOAT HEIGHT: 20.2 mm (0.80 in) [2]

If the height is outside the specification, replace the
float and float valve and recheck the height.
[1]
6-7
dummyhead
FUEL SYSTEM
CHOKE REPLACEMENT
Remove the carburetor (page 6-5).
[2]
Pull out the choke valve plate [1].
Remove the choke shaft [2] and install a new choke
shaft. [3]
Insert a new choke valve plate into the slit [3] of the
choke shaft.
Be sure the choke shaft is in the position between the
projections [4] of the choke valve plate. [1]
[2]
[1]
[4] [4]
6-8
dummytext
7. GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE GOVERNOR 7

REMOVAL/INSTALLATION··························7-2 DISASSEMBLY/ASSEMBLY ························ 7-4
ENGINE SPEED ADJUSTMENT···················7-3
7-1
dummyhead
GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE
GOVERNOR SYSTEM
Remove the fuel tank (page 6-2).
After installation, adjust the engine speed (page 7-3).
GOVERNOR ARM BOLT

GOVERNOR ROD/
THROTTLE RETURN SPRING
REMOVAL/INSTALLATION:
Take care not to bend the governor rod/throttle
return spring during removal/installation.
GOVERNOR ARM
GOVERNOR SPRING
NUT (6 mm)
INSTALLATION:
Install with the longer end side
toward the governor arm.
CONTROL ADJUSTING
SPRING
BOLT (6 x 12 mm)
SCREW (4 x 16 mm)
LONGER END CONTROL BASE
CONTROL LEVER
GOVERNOR ARM SHAFT
7-2
dummyhead
GOVERNOR SYSTEM
GOVERNOR ARM INSTALLATION
Loosen the nut (6 mm) [1] of the governor arm.
Turn the governor arm [2] counterclockwise to fully
open the carburetor throttle valve [3].
Rotate the governor arm shaft [4] as far as it will go in
the same direction the governor arm moved to open the
throttle valve.
Make sure the carburetor throttle valve is fully open.
Tighten torque shall be 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
minimum and 0.5 mm (0.02 in) minimum shall be kept
for the clearance.
[4]
0.5 mm (0.02 in)

minimum
[2]
[1]
[2]
[1]
[3] [4]
Fully open
ENGINE SPEED ADJUSTMENT

Use a tachometer with graduations of 50 min-1 (rpm) or [1]
smaller that will accurately indicate 50 min-1 (rpm)
changes.
Start the engine and allow it to warm up to normal
operating temperature.
Check the engine speed at no load.
ENGINE SPEED (no load):
50 Hz: 3,150 ± 50 min-1 (rpm)
60 Hz: 3,750 ± 50 min-1 (rpm)
Adjust the engine speed, if necessary, by turning the
adjusting screw [1] in or out from adjusting hole [2].
[2]
7-3
dummyhead
GOVERNOR SYSTEM
GOVERNOR
Remove the crankcase cover (page 14-2).
GOVERNOR HOLDER CLIP

INSTALLATION:
Set the governor holder clip [1] as shown. Push the governor slider from the above
Pull up the governor [2] and install the to press the clip into the groove [6].
thrust washer [3] and governor slider [4] Check to be sure them moves smoothly.
through the gap between the governor
weight arms [5].
[2] [5]
[3] [6]
[4]
(Journal)
GOVERNOR HOLDER SHAFT
[1]
[1]
WASHER (6 mm)
GOVERNOR WEIGHT
ARM (2) WASHER (6 mm)
LOCK PIN
INSTALLATION:
Install firmly into the groove
of the governor arm shaft.
GROOVE
GOVERNOR WEIGHT
PIN (2) THRUST WASHER
GOVERNOR WEIGHT HOLDER

(Weight holder sliding portion and gear)
GOVERNOR SLIDER
(Journal)
GOVERNOR ARM SHAFT
7-4
dummytext
8. CONTROL PANEL/GENERATOR
SYSTEM DIAGRAM ······································8-2 ENGINE SWITCH INSPECTION ··················· 8-9

8
TROUBLESHOOTING···································8-2 AC CIRCUIT PROTECTOR INSPECTION···· 8-9
CONTROL PANEL AC RECEPTACLE INSPECTION ················· 8-9

GENERATOR INSPECTION ······················· 8-10
GENERATOR
REMOVAL/INSTALLATION··························8-5 ROTOR BEARING REPLACEMENT ·········· 8-13
CONTROL PANEL
DISASSEMBLY/ASSEMBLY ························8-7
8-1
dummyhead
CONTROL PANEL/GENERATOR
SYSTEM DIAGRAM
SUB CORD
Br or R Y/G
CONDENSER AC
CIRCUIT N
PROTECTOR
AC RECEPTACLE
FIELD
WINDING Bu
CONDENSER
WINDING
Bu
Br or R
MAIN
WINDING
W
Bl Black Br Brown
Y Yellow O Orange
ENGINE
GROUND R Red P Pink
TERMINAL W White Gr Gray
TROUBLESHOOTING
High voltage and electrical current present. Shock or electrocution can be caused touching the non insulated portions of the
meter leads or generator wiring.
NO OR LOW AC OUTPUT
Is the AC circuit protector ON? Remove the appliance which causes overload. Set
OFF the AC circuit protector to ON position.
ON
Is the engine speed normal? (page 7-3) Adjust the engine speed (page 7-3).
Abnormal
50 Hz: 3,150 ± 50 min-1 (rpm)
60 Hz: 3,750 ± 50 min-1 (rpm)
Normal
Check the main winding voltage (page 8-10). Appliance does not function.
Normal
Abnormal
Check the main winding continuity (page 8-11). Replace the stator (page 8-5).
Abnormal
Normal
Go to page 8-3
8-2
dummyhead
From page 8-2
Check the AC receptacle (page 8-9). Replace the AC receptacle (page 8-7, 8-8).
Abnormal
Normal
Check the AC circuit protector (page 8-9). Replace the AC circuit protector (page 8-7, 8-8).
Abnormal
Normal
Check the condenser winding (page 8-11). Replace the stator (page 8-5).
Abnormal
Normal
Check the condenser (page 8-12). Replace the condenser (page 8-7, 8-8).
Abnormal
Normal
Check the rotor (page 8-12). Replace the rotor (page 8-5).
Abnormal
Normal
Check for open or short circuit in the sub cord

between the receptacle and the circuit protector.
If necessary, repair or replace the sub cord.
8-3
dummyhead
CONTROL PANEL
When installing, route the wire harness properly (page 2-6).
BOLT (6 x 12 mm)
STATOR
HARNESS
CONTROL PANEL CASE
INSTALLATION:
Set the tabs of the control
panel case into the frame.
TAB (2)
CONTROL PANEL
WIRE HARNESS
OIL LEVEL SWITCH
CORD
CONTROL PANEL
BOLT (6 x 18 mm) (4)
8-4
dummyhead
GENERATOR REMOVAL/INSTALLATION
• Clean the crankshaft, crankcase cover, rotor, and

stator thoroughly with degreasing agent
Remove the following:
– Engine (page 12-2)
– Recoil starter (page 10-2)
When installing the rotor, turn the starter pulley to set the piston in the TDC of the compression stroke.
(page 3-6).
STATOR
INSTALLATION:
Stator harness [1] shall not be slack
this area to avoid contact with fan [2].
[1]
ALIGN [2]
MAGNET
STOPPER RING
ALIGN
REAR HOUSING
ROTOR
INSTALLATION:
Note the direction of
the magnet and install
the rotor as shown.
BOLT
(6 x 90 mm) (4)
BEARING GROUND SCREW (5 x 12 mm)
INSTALLATION: 1.3 N·m (0.1 kgf·m, 1.0 lbf·ft)
Make sure that the projected part [1]
of the stopper ring aligns with the BOLT (8 x 130 mm)
mark [2] on the ball bearing as shown.
REMOVAL:
Hold the starter pulley [1] in a
[1] screwdriver [2] or equivalent, and
remove the rotor bolt.
INSTALLATION:
[2] Hold the starter pulley in a
screwdriver or equivalent.
Tighten the rotor bolt to the
specified torque.
24 N·m (2.4 kgf·m, 18 lbf·ft)
[1] [2]
8-5
dummyhead
ROTOR REMOVAL
• Do not strike any part of the rotor when removing it.

The rotor may be damaged.
• Place the stator core side down. Do not set the
stator on the coil end. The coils may be damaged.
Remove the rotor bolt (page 8-5). [6]
[4]
Lean the generator and shop towel [1] under the
bearing [2] as shown. [3]
Use an appropriate bolt [3] that matches the thread
diameter and pitch of the rotor hole [4]. Wrap the seal
tape [5] 2 - 3 times around the bolt.
Fill with the engine oil [6] from the rotor hole and set the
bolt.
[5]
[2] [1]
Hold the starter pulley [1] in a screwdriver [2] or

equivalent and tighten the bolt [3].
Remove the rotor and stator.
[3]
[1] [2]
Remove the engine oil [1] from the crankshaft hole [2]
[2]
and crankcase cover [3].
Clean the crankshaft, crankcase cover, rotor [4], and
[1]
stator [5] thoroughly with degreasing agent.
[3]
[5]
[4]
8-6
dummyhead
CONTROL PANEL
EG1000N K,L,LS,M,R,S types
EP1000N R,RDN types
Remove the control panel (page 8-4).
CONDENSER
CONTROL PANEL CASE
INSTALLATION:
Install the condenser [1] in
the condenser cushion [2] as
shown.
[1] [2]
OIL ALERT UNIT

CONDENSER CUSHION
CUSHION
OIL ALERT UNIT
AC CIRCUIT PROTECTOR
(9 A) (L type)
(5 A) (LS,S types)
(4 A) (K,M,R,RDN types)
CONTROL PANEL
WIRE HARNESS TERMINAL CORD
NUT (4 mm) (2)
WASHER (4 mm) (2)
ENGINE
CONTROL PANEL
SWITCH
AC RECEPTACLE
(240 V/6 A)
(RDN type)
SCREW (4 x 12 mm) (2) AC RECEPTACLE
(250 V/15 A)
(K,L,LS,M,R,S types)
8-7
dummyhead
EG1000N LB,RA,SB types
CONDENSER
INSTALLATION:
CONTROL PANEL CASE
Install the condenser [1] in
the condenser cushion [2] as
shown.
[1] [2]
OIL ALERT UNIT

CONDENSER CUSHION
CUSHION
OIL ALERT UNIT
AC CIRCUIT PROTECTOR
(9 A) (LB type)
(5 A) (SB type)
(4 A) (RA type)
CONTROL PANEL
WIRE HARNESS
TERMINAL CORD
CONTROL PANEL
ENGINE
SWITCH NUT (3 mm) (2)
AC RECEPTACLE LOCK WASHER (3 mm) (2)

(250 V/10 A)
(LB,SB types) WASHER (3 mm) (2)
AC RECEPTACLE
(250 V/10 A)
SCREW (3 x 12 mm) (2) (RA type)
8-8
dummyhead
ENGINE SWITCH INSPECTION
Disconnect the engine switch connectors.
Check the continuity between the terminals at each
switch position.
Switch position Continuity ON

ON No
OFF Yes
OFF
AC CIRCUIT PROTECTOR INSPECTION

Disconnect the AC circuit protector connectors.
Push the AC circuit protector button, and check that it is
on.
Check for continuity between the terminals. ON
OFF
AC RECEPTACLE INSPECTION
[2]
Disconnect the AC receptacle connectors (page 8-7).
Connect both terminals of the receptacle with a jumper
wire [1] to short. There should be continuity between
the wire terminals [2].
There should be continuity between the ground terminal
[3] of the receptacle and the wire terminal [4].
Remove the jumper wire after testing.
[1]
[3]
[4]
8-9
dummyhead
GENERATOR INSPECTION
MAIN WINDING
VOLTAGE INSPECTION
Start the engine and allow it to warm up to normal
RDN type
operating temperature.
Measure the AC voltage between the terminals [1] as
shown. [1]
M, R, K, L, S, LS types
[1]
LB, SB types
[1]
RA type [1]
Model Type Voltage (VAC)

L, LB 126 V min.
EG1000N / EP1000N M, R, RA, S, SB 231 V min.
K, LS, RDN 241 V min.
8-10
dummyhead
CONTINUITY INSPECTION
Disconnect the AC receptacle wire (White) [1] and AC [2]
circuit protector wire [2] of the stator harness [3].
EXCEPT L,LB Type: (Brown)
Measure the resistance between the terminals as L,LB Types only: (Red) [3]
shown in the table.
[1]
Model Type Terminals Resistance (Ω)

K (Brown) - (White) 6.84 – 7.56 Ω
L,LB (Red) - (White) 1.13 – 1.25 Ω
EG1000N LS (Brown) - (White) 4.24 – 4.68 Ω
M,R,RA (Brown) - (White) 6.78 – 7.50 Ω
S,SB (Brown) - (White) 4.11 – 4.55 Ω
R (Brown) - (White) 5.66 – 6.26 Ω
EP1000N
RDN (Brown) - (White) 5.83 – 6.45 Ω
CONDENSER WINDING
CONTINUITY INSPECTION
[1]
Disconnect the condenser wires (Blue) [1] of the stator [2]
harness [2].
Measure the resistance between the terminals as
shown in the table.
Model Type Terminals Resistance (Ω)

LS, S,SB 2.76 – 3.06 Ω
EG1000N L,LB 2.60 – 2.88 Ω
(Blue) - (Blue)
K,M,R,RA 4.28 – 4.73 Ω
EP1000N R,RDN 4.28 – 4.73 Ω
8-11
dummyhead
CONDENSER
[3] [4] [1]
Disconnect the condenser wires (Blue) [1] of the stator
harness [2].
[2]
Discharge the condenser [3] by shorting across the
terminals [4].
Check continuity between the terminals in the Maximum
ohm range.
Resistance (Ω)
The meter needle should deflect and return to
infinity within a few seconds.
ROTOR
DIODE (BUILT-IN)
Remove the rotor (page 8-5). LIGHT (12 V/15 W)
Remove the varnish of the rotor terminals [1] using a BRIGHT or DIMMER
sandpaper or equivalent.
Remove the rotor and attach a light (12 V/15 W) to the
rotor terminals through a known-good 12 V battery.
Depending on battery polarity, the light should go on Change
brightly and then, when you reverse polarity, go the
dimmer. polarity
12 V
BATTERY
[1]
Remove the varnish
FIELD COIL
Remove the rotor (page 8-5).
Remove the varnish of the rotor terminals [1] using a
sandpaper or equivalent.
Measure the resistance between the terminals as
shown in the table.
Resistance (Ω)
17.9 – 19.7 Ω
[1]
Remove the varnish
8-12
dummyhead
ROTOR BEARING REPLACEMENT
Remove the bearing [1] using a commercially available
bearing puller [2].
[2]
[1]
Drive a new rotor bearing [1] with the stopper ring

groove [2] facing the rotor side.
[1]
• Install by pressing the inner race squarely.
[2]
8-13
dummyhead
MEMO
dummytext
9. IGNITION SYSTEM
SYSTEM DIAGRAM ······································9-2 IGNITION COIL AIR GAP ADJUSTMENT···· 9-6
TROUBLESHOOTING···································9-2 SPARK TEST ················································ 9-6

9
IGNITION COIL SPARK PLUG CAP INSPECTION················ 9-6
IGNITION COIL INSPECTION ······················ 9-7
FLYWHEEL/STARTER PULLEY
REMOVAL/INSTALLATION··························9-4 OIL LEVEL SWITCH INSPECTION ·············· 9-7
OIL LEVEL SWITCH OIL ALERT UNIT INSPECTION ··················· 9-8

9-1
dummyhead
IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION SYSTEM
ENGINE
SWITCH
E
Y/G Y/G Y/G
Y Y Bl
IG
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT
Bl Black Br Brown
Y Yellow O Orange
ENGINE OIL IGNITION G Green Lg Light green
GROUND LEVEL SPARK COIL R Red P Pink
TERMINAL SWITCH PLUG W White Gr Gray
TROUBLESHOOTING
NO SPARK AT SPARK PLUG
Check the following before troubleshooting:
– Engine oil level (page 3-3)
– Spark plug (page 3-5)
– Perform the spark test (page 9-6)
– Loose connectors
Disconnect the ignition coil connector (page 9-3). No spark Check the spark plug cap (page 9-6).
Normal Abnormal
Replace the spark plug cap (page 9-3).
Spark
Check the ignition coil (page 9-7).
Abnormal
Replace the ignition coil (page 9-3) if abnormalities

are found, and recheck.
Check the oil level switch (page 9-7). Abnormal Replace the oil level switch (page 9-5).
Normal
Normal
Check for short circuit in the ignition line of the wire

harness.
If necessary, repair or replace the wire harness.
9-2
dummyhead
IGNITION SYSTEM
IGNITION COIL
– Engine (page 12-2)
– Carburetor (page 6-5)
After installation, check the ignition coil air gap (page 9-6).
BOLT (6 x 20 mm)
UPPER SHROUD
BOLT
(6 x 18 mm)
SPARK PLUG CAP
FAN COVER
IGNITION COIL BOLT (6 x 28 mm) (3)
LOWER SHROUD
BOLT (6 x 20 mm) (2)
BOLT (6 x 50 mm)
(EP1000N only)
BOLT (6 x 25 mm) (2)
BOTTOM RUBBER (4)

(EG1000N only)
BOLT (6 x 14 mm) (4) (EG1000N only)
10 N·m (1.0 kgf·m, 7 lbf·ft)
9-3
dummyhead
IGNITION SYSTEM
FLYWHEEL/STARTER PULLEY
Remove the ignition coil (page 9-3).
FLYWHEEL
REMOVAL:
Use the commercially available tool [1]
to remove the flywheel [2] as shown.
CUTOUT
[2]
[1]
WOODRUFF KEY
INSTALLATION:
Set the woodruff key in the
key groove securely.
KEY GROOVE
MAGNET PART NUT (12 mm)
INSTALLATION:
Be sure there are no metal parts or
other foreign material on the magnet
part.
Set the flywheel by aligning the key slot
with the woodruff key on the crankshaft.
KEY SLOT
STARTER PULLEY
INSTALLATION:
Degrease the tapered parts.
COOLING FAN
NUT (12 mm) (Threads and seating surface)

REMOVAL:
Hold the starter pulley [1] in a [3]
screwdriver [2] or equivalent,
and remove the nut [3].
INSTALLATION:
Loosely tighten the nut.
Hold the starter pulley in a
[2]
screwdriver or equivalent.
Tighten the nut to the specified
torque.
60 N·m (6.1 kgf·m, 44 lbf·ft) [1]
9-4
dummyhead
IGNITION SYSTEM
OIL LEVEL SWITCH
Drain the engine oil (page 3-3).
Remove the front cover (page 5-2) (EP1000N only).
Disconnect the oil level switch connectors from the control panel wire harness (page 8-4).
Disconnect the oil level switch connector from the ignition coil (page 9-3).
CYLINDER BARREL
LOWER SIDE
O-RING
CORD CLIP
OIL LEVEL SWITCH
BOLT (5 x 14 mm) (3)
OIL LEVEL SWITCH

BRACKET
BOLT (5 x 14 mm)
9-5
dummyhead
IGNITION SYSTEM
IGNITION COIL AIR GAP ADJUSTMENT
Remove the fan cover (page 9-3).
0.2 – 0.6 mm
Insert the thickness gauge of proper thickness between (0.01 – 0.02 in)
the ignition coil [1] and the flywheel [2]. [2]
[3]
[1]
• Avoid the magnet part [3] of the flywheel when
adjusting.
• Adjust the ignition coil air gap equally on both sides.
IGNITION COIL AIR GAP:
0.2 – 0.6 mm (0.01 – 0.02 in)
If measured clearance is out of specification, adjust the
air gap.
Loosen the two bolts [4].
Both gaps should be adjusted simultaneously.
Insert the thickness gauge of proper thickness between [4]
the ignition coil and flywheel.
Push the ignition coil firmly against the flywheel and
tighten the ignition coil bolts securely. 0.2 – 0.6 mm
Remove the thickness gauge. (0.01 – 0.02 in)
SPARK TEST
Never hold the high-tension cord with wet hands

while performing this test.
Check for the following before conducting the spark

test. [2]
– Faulty spark plug

– Loose spark plug cap
– Water in the spark plug cap (leaking ignition coil
secondary voltage)
Close the fuel valve. [3]
Disconnect the spark plug cap [1] from the spark plug
[2].
Connect a known-good spark plug [3] to the spark plug
cap and ground the spark plug to the cylinder head
cover bolt.
Turn the engine stop switch to the ON position.
[1]
Crank the engine by pulling the recoil starter and check
whether sparks jump across the electrodes.
SPARK PLUG CAP INSPECTION

Remove the spark plug cap from the high tension cord.
EXCEPT M type
Check the continuity between the terminal in the spark
plug cap and high tension cord terminal.
There should be continuity.
M type ONLY (WITH RESISTANCE)
Measure the resistance of the spark plug cap by
attaching one ohmmeter probe to the terminal in the
spark plug cap and the other to the terminal connected
to the high tension cord terminal.
RESISTANCE: 7.5 – 12.5 kΩ
9-6
dummyhead
IGNITION SYSTEM
IGNITION COIL INSPECTION
PRIMARY SIDE
Measure the resistance of the primary coil by attaching
one ohmmeter probe to the ignition coil wire terminal
and the other to the iron core.
Use a recommended analog multi-tester.
• SP-15D (SANWA) or equivalent
• TH-5H (KOWA) or equivalent
RESISTANCE: 0.8 – 1.2 Ω
If the measured resistance is out of specification,
replace the ignition coil (page 9-3).
SECONDARY SIDE
Measure the resistance of the secondary coil by
attaching one ohmmeter probe to the high tension cord
and the other to the iron core.
Use a recommended analog multi-tester.
• TH-5H (KOWA) or equivalent
RESISTANCE: 5.6 – 11.8 kΩ
If the measured resistance is out of specification,
replace the ignition coil (page 9-3).
OIL LEVEL SWITCH INSPECTION

Check the oil level (page 3-3).
[2] [1]
Disconnect the oil level switch connectors from the
control panel wire harness (page 8-4).
Check the continuity between the oil level switch
connector [1] and engine ground [2].
There should be no continuity when the engine is full of
oil.
Drain the engine oil completely (page 3-3).
connector and engine ground.
There should be continuity.
connector and engine ground while filling the engine
with oil.
The ohmmeter reading should go from continuity to no
continuity as the oil is filled.
If the correct continuity is not obtained, replace the oil
level switch (page 9-5).
Engine oil Continuity

Full No
Low Yes
9-7
dummyhead
IGNITION SYSTEM
OIL ALERT UNIT INSPECTION
High voltage and electrical current present. Shock

or electrocution can be caused touching the non
insulated portions of the meter leads or generator
wiring.
1. Remove the control panel (page 8-4).

OIL ALERT UNIT
Disconnect the oil alert unit wires (Yellow) [1] and
(Yellow/Green) [2].
Start the engine and ground the oil alert unit wires
(Yellow) and (Yellow/Green) connectors to the rear [2]
housing [3] with the suitable wire [4].
– Engine stops:
The oil alert is normal.
– Engine does not stop:
Stop the engine. Perform the inspection of step 2. [1]
[4] [3]
2. Disconnect the oil alert wire (Black) [1].

[1] OIL ALERT UNIT
Start the engine and ground the wire (Black) to the
rear housing [2] with the suitable wire [3].
[2]
– Engine stops:
The oil alert unit is faulty, replace the oil alert unit
(page 8-7).
– Engine does not stop:
The oil alert is normal. The ignition coil or wire
harness will be faulty.
[2]
9-8
dummytext
10. STARTING SYSTEM
RECOIL STARTER RECOIL STARTER

REMOVAL/INSTALLATION························10-2 DISASSEMBLY/ASSEMBLY ······················ 10-3
RECOIL STARTER INSPECTION ·············· 10-6
10
10-1
dummyhead
STARTING SYSTEM
RECOIL STARTER
STARTING SYSTEM
STARTER GRIP
REMOVAL:
Before removing the starter
grip, knot the recoil starter
rope to avoid rewinding the
rope into the recoil starter.
Remove the starter grip.
(EP1000N only)
RECOIL STARTER ROPE
RECOIL STARTER
INSTALLATION:
Remove dirt and debris, then install the recoil starter
to the original position.
BOLT (6 x 12 mm)
10-2
dummyhead
STARTING SYSTEM
RECOIL STARTER
• Wear gloves and eye protection.

• During disassembly, take care not to allow the
return spring to come out from the spring cover.
Remove the recoil starter (page 10-2).
REEL COVER BOLT

FRICTION PLATE B 10 N·m (1.0 kgf·m, 7 lbf·ft)
(Sliding surface)
(Sliding surface and projection)
FRICTION SPRING
STARTER REEL COVER
FRICTION PLATE A (Whole surface)

STARTER RATCHET
(Return spring
sliding surface)
STARTER REEL
(Sliding surface)
RATCHET SHAFT
RECOIL STARTER ROPE

ASSEMBLY:
Check for fraying, wear, or damage
RETURN SPRING and replace if necessary.
SIDE PLATE
(Return spring
sliding surface)
STARTER GRIP
(EG1000N only)
(Sliding surface)
RECOIL
STARTER CASE
10-3
dummyhead
STARTING SYSTEM
RECOIL STARTER ASSEMBLY
Pass the recoil starter rope [1] through the hole [2] on
[4] [3]
the starter reel [3] and make a figure eight knot [4] at
the end of the rope.
Wind the recoil starter rope onto the reel as shown.
[2]
[1]
Hook the recoil starter rope [1] into the notch [2] on the
recoil starter reel [3]. [1] [3]
[2]
Apply grease to the return spring sliding surface of the

starter reel [1].
Hook the outer hook [2] of the return spring [3] to the
groove [4] of the starter reel and then install the return [2]
spring by winding it.
[1] [4] [3]
Install the side plate [1] to the recoil starter case [2].
[3] [4]
Apply grease to the inside of the side plate and boss of
the starter case.
Insert the reel [3] into the recoil starter case by aligning
the return spring inner end hook [4] with the boss [5] on
the recoil starter case.
[1] [5]
[2]
10-4
dummyhead
STARTING SYSTEM
Apply grease to the sliding surface of the ratchet shaft
[1], starter ratchet [2], friction spring [3] and starter reel [8] [7]
cover [4].
Install the ratchet shaft, starter ratchet, friction plate A
[5], friction spring and starter reel cover to the starter
reel [6] as shown.
Set the friction plate B [7] and reel cover bolt [8] in the
starter reel cover.
Hold the starter reel cover and tighten the reel cover
bolt to the specified torque. [4] [2]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

[3]
[1]
[5]
[6]
Turn the starter reel [1] 2 turns counterclockwise to

preload the return spring.
Be sure to hold the starter reel.
[1]
Pass the end of the recoil starter rope [1] through the
rope hole [2] in the recoil starter case and install the [3]
recoil starter grip [3], and make a figure eight knot at the
rope end.
Check the operation (page 10-6).
[2]
[1]
10-5
dummyhead
STARTING SYSTEM
RECOIL STARTER INSPECTION
Check the operation of the ratchet [1] by pulling the
recoil starter rope out several times. [1]
10-6
dummytext
11. MUFFLER
MUFFLER REMOVAL/INSTALLATION······11-2
11
11-1
dummyhead
MUFFLER
MUFFLER REMOVAL/INSTALLATION
MUFFLER
EP1000N
The muffler becomes very hot during operation and

remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.
Remove the rear cover (page 5-2)
OUTER MUFFLER
PROTECTOR
INNER MUFFLER
PROTECTOR
MUFFLER GASKET
BOLT (6 x 16 mm) (3)
BOLT (6 x 10 mm) (3)

NUT (6 mm) (2)
MUFFLER
BOLT (6 x 12 mm)
11-2
dummyhead
MUFFLER
EG1000N
The muffler becomes very hot during operation and

remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.
MUFFLER GASKET
NUT (6 mm) (2)
BOLT (6 x 12 mm) MUFFLER
11-3
dummyhead
MEMO
dummytext
12. ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATION ·········12-2
12
12-1
dummyhead
ENGINE REMOVAL/INSTALLATION
EP1000N
– Control panel (page 8-4)
– Fuel tank (page 6-2)
– Muffler (page 11-2)
– Recoil starter grip (page 10-2)
FRAME
ENGINE/GENERATOR
NUT (6 mm) (4)

8.3 N·m (0.8 kgf·m, 6.1 lbf·ft)
RUBBER MOUNT A (2) BOLT (8 x 18 mm) (4)

INSTALLATION:
Do not interchange with the RUBBER MOUNT B (2)
rubber mount B. INSTALLATION:
Do not interchange with the
rubber mount A.
12-2
dummytext
13. CYLINDER HEAD
TOOLS·························································13-2 CYLINDER HEAD/VALVES

INSPECTION··············································· 13-5
CYLINDER HEAD
REMOVAL/INSTALLATION························13-3 VALVE GUIDE REPLACEMENT ················ 13-9
CYLINDER HEAD VALVE GUIDE REAMING ························ 13-10

DISASSEMBLY/ASSEMBLY ······················13-4
VALVE SEAT RECONDITIONING············ 13-11
13
13-1
dummyhead
CYLINDER HEAD
TOOLS
CYLINDER HEAD
Seat cutter, 20.5 mm (45° IN/EX) Flat cutter, 20 mm (32° IN/EX) Interior cutter, 20.5 mm (60° IN/EX)
07780-0011000 07780-0013200 07780-0014300
Cutter holder, 5.0 mm Valve guide driver, 5 mm Valve guide reamer 5.010 mm
07781-0010400 07942-MA60000 07984-MA60001
13-2
dummyhead
CYLINDER HEAD
CYLINDER HEAD
Set the piston at top dead center of the cylinder compression stroke (page 3-6).
Remove the fan cover (page 9-3).
After installation, inspect following:
– Valve clearance (page 3-6)
– Cylinder compression (page 13-5)
CYLINDER HEAD COVER BOLT CYLINDER HEAD COVER

10 N·m (1.0 kgf·m, 7 lbf·ft)
PACKING
RUBBER MOUNT
INSTALLATION: SPARK PLUG
Install the rubber mount with
12 N·m (1.2 kgf·m, 9 lbf·ft)
mark facing up.
(Threads and seating surface) ROCKER ARM SHAFT (2)

CYLINDER HEAD BOLT (6 x 50 mm) (4)
9.5 N·m (1.0 kgf·m, 7.0 lbf·ft)
(Sphere surface
REMOVAL/INSTALLATION:
and shaft holes)
Loosen and tighten the bolts in a
crisscross pattern in 2 or 3 steps. ROCKER ARM (EX)
TAPPET ADJUSTING SCREW (2)
TAPPET ADJUSTING NUT (2)

7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
WAVE WASHER (2) (EP1000N only)

INSTALLATION:
Install the wave washer [1] as shown.
ROCKER ARM (IN)
ROCKER ARM (Sphere surface
and shaft holes)
DOWEL PIN (2)
CYLINDER CYLINDER HEAD
[1] HEAD
PUSH ROD (2)
CYLINDER HEAD GASKET
13-3
dummyhead
CYLINDER HEAD
CYLINDER HEAD
Remove the cylinder head (page 13-3).
VALVE SPRING RETAINER (2)
VALVE COTTER (4)
VALVE GUIDE (EX)
VALVE SPRING (2)
VALVE STEM SEAL
CYLINDER HEAD
VALVE GUIDE (IN)
(Sliding surface
VALVE (EX) and stem end)
ASSEMBLY:
Do not interchange with the intake valve.
The exhaust valve is smaller than the
intake valve. (Sliding surface
VALVE (IN) and stem end)
ASSEMBLY:
Do not interchange with the exhaust valve.
The intake valve is larger than the exhaust
valve.
13-4
dummyhead
CYLINDER HEAD
CYLINDER HEAD/VALVES
INSPECTION
CYLINDER COMPRESSION CHECK
Start the engine and warm up to normal operating
[1]
temperature.
Turn off the engine stop switch to stop the engine.
Turn the fuel valve lever to the OFF position, and then
loosen the drain screw of the carburetor to drain the fuel
completely.
Remove the spark plug (page 3-5).
Pull the recoil starter several times to expel unburned
gas.
Attach a commercially available compression gauge [1]
to the spark plug hole.
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER COMPRESSION:
0.50 MPa (5.1 kgf/cm2, 73 psi)/600 min-1 (rpm)
CYLINDER HEAD WARPAGE

Remove the carbon deposits from the combustion
chamber (page 3-4). [1]
Clear off any gasket material from the cylinder head

mating surface.
Check the spark plug hole and valve areas for cracks.
Check the cylinder head warpage using a straight edge
[1] and feeler gauge [2].
• Be careful not the damage the mating surface.
SERVICE LIMIT: 0.10 mm (0.004 in)

If the measurement is more than the service limit, [2]
replace the cylinder head.
13-5
dummyhead
CYLINDER HEAD
ROCKER ARM SHAFT O.D./ROCKER
ARM I.D./ROCKER ARM SHAFT
HOLDER I.D.
Measure the rocker arm shaft O.D.
STANDARD: 5.952 – 6.000 mm (0.2343 – 0.2362 in)

ROCKER ARM SHAFT
O.D.
If the measurement is less than the service limit,
replace the rocker arm shaft (page 13-3).
Measure the rocker arm I.D.
STANDARD: 6.000 – 6.030 mm (0.2362 – 0.2374 in)
ROCKER ARM I.D.
If the measurement is more than the service limit,
replace the rocker arm (page 13-3).
Measure the rocker arm shaft holder I.D.
STANDARD: 6.010 – 6.022 mm (0.2366 – 0.2371 in)
ROCKER
SERVICE LIMIT: 6.04 mm (0.238 in) ARM SHAFT
HOLDER I.D.
replace the cylinder head (page 13-3).
VALVE SEAT WIDTH

Remove the carbon deposits from the combustion
chamber (page 3-4). [1]
Inspect each valve face for irregularities.

If necessary, replace the valve.
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to the each valve seat.
Insert the valve, and snap it closed against its seat
several times using a valve lapper [1]. Be sure the valve
does not rotate on the seat.
The transferred marking compound will show any area
of the valve face that is not concentric.
Measure the valve seat width of the cylinder head.
STANDARD:
IN/EX: 0.7 – 0.9 mm (0.03 – 0.04 in)

recondition the valve seat (page 13-11). TOO LOW
Check whether the valve seat contact area of the valve
is too high.
VALVE SEAT
If the valve seat is too high or too low, recondition the WIDTH
valve seat (page 13-11).
TOO HIGH
13-6
dummyhead
CYLINDER HEAD
VALVE GUIDE I.D.
Ream the valve guide [1] to remove any carbon
deposits before measuring. HANDLE
(Commercially
TOOL: available)
Valve guide reamer 5.010 mm [2] 07984-MA60001 [2]
• Turn the valve guide reamer (special tool) clockwise,

never counterclockwise.
• Continue to rotate the special tool while removing it [1]
from the valve guide.
Measure and record each valve guide I.D.
STANDARD: 5.000 – 5.012 mm (0.1969 – 0.1973 in)

If the measured valve guide I.D. is more than the
service limit, replace the valve guide (page 13-9).
VALVE STEM O.D.

Inspect each valve for bending or abnormal stem wear.
If necessary, replace the valve.
Measure and record each valve stem O.D.
STANDARD:
IN: 4.975 – 4.990 mm (0.1959 – 0.1965 in)
EX: 4.955 – 4.970 mm (0.1951 – 0.1957 in)
SERVICE LIMIT:
IN: 4.97 mm (0.196 in)
EX: 4.95 mm (0.195 in)
replace the valve.
GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
valve guide I.D. to obtain the stem-to-guide clearance.
STANDARD:
IN: 0.010 – 0.037 mm (0.0004 – 0.0015 in)
EX: 0.030 – 0.057 mm (0.0012 – 0.0022 in)
SERVICE LIMIT:
IN: 0.060 mm (0.0024 in)
EX: 0.080 mm (0.0031 in)
If the calculated clearance is more than the service limit,
replace the valve and valve guide at a set (page 13-9).
13-7
dummyhead
CYLINDER HEAD
VALVE SPRING FREE LENGTH/
PERPENDICULARITY
Measure the free length of the valve spring.
STANDARD: 29.5 mm (1.16 in)

If the measured length is less than the service limit,
replace the valve spring.
Measure the valve spring perpendicularity.
SERVICE LIMIT: 2° max.
If the measured perpendicularity is more than the
service limit, replace the valve spring.
PUSH ROD RUNOUT

Check both ends of the push rod for wear.
Check the push rod for straightness.
If necessary, replace the push rod.
13-8
dummyhead
CYLINDER HEAD
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer section
of a refrigerator for about an hour.
Use a hot plate or oven to heat the cylinder head evenly
to 150°C (302°F).
To avoid burns, use heavy gloves when handling

the heated cylinder head.
• Do not use a torch to heat the cylinder head;

warpage of the cylinder head may result.
• Do not get the cylinder head hotter than 150°C
(302°F); excessive heat may loosen the valve seats.
Remove the heated cylinder head from the hot plate

and support it with wooden blocks.
Drive the valve guides [1] out of the cylinder head from
the combustion chamber side.
[2]
TOOL:
Valve guide driver, 5 mm [2] 07942-MA60000
• When driving the valve guides out, be careful not to

damage the cylinder head.
[1]
Remove the new valve guides [1] from the refrigerator

[2]
one at a time as needed.
Install the valve guides from the valve spring side of the
cylinder head.
TOOL:
Valve guide driver, 5 mm [2] 07942-MA60000
Drive the exhaust valve guide to the specified height
(measured from the end of the valve guide to the
cylinder head as shown).
Drive the intake valve guide to the specified height
(measured from the end of the valve guide to the
cylinder head as shown).
VALVE GUIDE INSTALLATION HEIGHT: IN: EX:
IN: 5.8 – 6.2 mm (0.23 – 0.24 in) 5.8 - 6.2 mm 3.3 - 3.7 mm
EX: 3.3 – 3.7 mm (0.13 – 0.15 in) (0.23 - 0.24 in) (0.13 - 0.15 in)
After installing the valve guide, check the guide for
damage.
Replace the valve guide if damaged.
Let the cylinder head cool to room temperature.
[1]
Perform valve guide reaming (page 13-10).
13-9
dummyhead
CYLINDER HEAD
VALVE GUIDE REAMING
For best results, be sure the cylinder head is at room
temperature before reaming valve guides [1]. HANDLE
(Commercially
Coat the reamer and valve guide with cutting oil. available)
Rotate the reamer clockwise through the valve guide [2]
the full length of the reamer.
TOOL:
Valve guide reamer 5.010 mm [2] 07984-MA60001
[1]
• Turn the valve guide reamer (special tool) clockwise,
never counterclockwise.
• Continue to rotate the special tool while removing it
from the valve guide.
Thoroughly clean the cylinder head to remove any
cutting residue.
Check the valve guide bore; it should be straight, round

and centered in the valve guide. Insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged (page
13-9).
Check the valve guide-to-stem clearance (page 13-7).
13-10
dummyhead
CYLINDER HEAD
VALVE SEAT RECONDITIONING
Inspect the valve seat contact area (page 13-6).
Using a 45° seat cutter, remove any roughness or
irregularities from the seat. 45°
If the contact area is too low on the valve, the seat must
be raised using a 60° interior cutter. TOO LOW
If the contact area is too high on the valve, the seat 60°
must be lowered using a 32° flat cutter.
TOO HIGH
32°
Valve seat cutters [1]/grinder or equivalent valve seat

[1]
refacing equipment is recommended to correct a worn
valve seat.
• Turn the cutter clockwise, never counterclockwise.

• Continue to turn the cutter as you lift it from the valve
seat.
TOOLS:
Cutter holder, 5.0 mm 07781-0010400
Seat cutter, 20.5 mm (45° IN/EX) 07780-0011000
Flat cutter, 20 mm (32° IN/EX) 07780-0013200
Interior cutter, 20.5 mm (60° IN/EX) 07780-0014300
Make a light pass with the 45° cutter to remove any

possible burrs at the edge of the seat.
Be sure that the width of the finished valve seat is within
specification.
STANDARD:
IN/EX: 0.7 – 0.9 mm (0.03 – 0.04 in)
45°
Lap the valves into their seats, using a commercially

[1]
available valve lapper [1] and lapping compound.
After lapping, wash all residual compound off the
cylinder head and valve.
• Do not push the valve against the seat with force

during lapping. Apply a light pass with the valve
lapper.
• Avoid lapping the valve in the same position as it
causes uneven wear. Lap the valve by turning the
lapper slowly.
• Take care not to allow the lapping compound to
enter the gap between the stem and guide.
13-11
dummyhead
MEMO
dummytext
14. CYLINDER BLOCK
CRANKCASE COVER CRANKCASE COVER/CYLINDER BARREL/

REMOVAL/INSTALLATION························14-2 PISTON/CONNECTING ROD/CRANKSHAFT/
CAMSHAFT INSPECTION·························· 14-5
CRANKSHAFT/PISTON
REMOVAL/INSTALLATION························14-3 CRANKSHAFT BEARING/OIL SEAL
REPLACEMENT ······································· 14-11
PISTON DISASSEMBLY/ASSEMBLY········14-4
14
14-1
dummyhead
CYLINDER BLOCK
CRANKCASE COVER
CYLINDER BLOCK
Drain the engine oil (page 3-3).
Remove the generator (page 8-5)
DOWEL PIN (2)
BEARING (6203)
SEALING WASHER
OIL DRAIN PLUG

18 N·m (1.8 kgf·m, 13 lbf·ft)
GASKET OIL SEAL

(17 x 30 x 6 mm)
OIL FILLER CAP (Lips)
OIL FILLER PACKING
BOLT (6 x 28 mm) (7)

12 N·m (1.2 kgf·m, 9 lbf·ft)
CRANKCASE COVER
14-2
dummyhead
CYLINDER BLOCK
CRANKSHAFT/PISTON
– Flywheel (page 9-4)
– Cylinder head (page 13-3)
– Crankcase cover (page 14-2)
PISTON (Outer surface and big end bearing)

INSTALLATION:
[1]
Install the piston
assembly to the
cylinder barrel with
the mark [1] on the
piston head toward
the push rod hole [2]
of the cylinder barrel.
[2]
(Bearing, profile, weight,

CAMSHAFT sliding portion and gear)
(Cylinder inner surface)
INSTALLATION:
CYLINDER BARREL [2]
Install the timing
gear [1] of the
crankshaft and
camshaft [2] by
aligning the
punch marks [3].
[1] [3]
(Stem, stem end

and slipper surface)
VALVE LIFTER (2)

OIL SEAL INSTALLATION:
(17 x 30 x 6 mm) Attach the valve lifters to the
BEARING (6203)
cylinder barrel immediately
(Lips)
before installing the camshaft.
(Big end bearing) (Pin and gear teeth)

CONNECTING ROD LOWER END CRANKSHAFT
INSTALLATION: INSTALLATION:
Set the connecting rod lower end with Be careful not to damage
(Threads and seating surface) the oil dipper toward the camshaft. the oil seal lips.
CONNECTING ROD BOLT (5 x 24.5 mm) (2)
5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)
14-3
dummyhead
CYLINDER BLOCK
PISTON DISASSEMBLY/ASSEMBLY
Remove the piston (page 14-3).
"TOP" MARK
PISTON RING SET (Entire surface)
INSTALLATION:
TOP RING To install the oil ring, install the spacer
[1] first, and then install the side rails [2].
Be sure that the top ring [3] and second
ring [4] are not interchanged.
Install the top ring and second ring on
the piston with the top mark side facing
120° up.
SECOND RING 120° Check that the piston rings rotate
120° smoothly after installing them.
Space the piston ring end gaps 120°
apart, and do not align the ring end gaps
with the piston pin bore.
SIDE RAIL (2)
OIL RING [3]
(COMBINATION RING) 10 mm (0.4 in)
[4]
SPACER
[2]
10 mm (0.4 in)
[1]
(Ring groove and
piston pin hole) [2]
PISTON
PISTON PIN
(Outer surface)
"IN" MARK
PISTON PIN CLIP (2)

INSTALLATION:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
CONNECTING ROD UPPER END
holding the other end with needle nose pliers,
(Small end bearing)
and rotating the clip in.
INSTALLATION: Do not align the end gap [1] of the piston pin
"IN" mark is facing the same direction clip with the cutout [2] of the piston pin bore.
as the "IN" mark on the piston head.
[1]
[2]
14-4
dummyhead
CYLINDER BLOCK
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CAMSHAFT HOLDER I.D.
CRANKCASE COVER SIDE
Measure the camshaft holder I.D. of the crankcase
cover.
STANDARD: 10.000 – 10.015 mm (0.3937 – 0.3943 in)

replace the crankcase cover.
Inspect the camshaft O.D. (page 14-10).
CYLINDER BARREL SIDE

Measure the camshaft holder I.D. of the cylinder barrel.
STANDARD: 10.000 – 10.015 mm (0.3937 – 0.3943 in)

replace the cylinder barrel.
Inspect the camshaft O.D. (page 14-10).
CYLINDER SLEEVE I.D.

Measure and record the cylinder I.D. at three levels in
both the “X” axis (perpendicular to crankshaft) and the
“Y” axis (parallel to crankshaft). Take the maximum X
reading to determine cylinder wear and taper.
TOP Y
STANDARD: 46.000 – 46.015 mm (1.8110 – 1.8116 in)

MIDDLE
replace the cylinder barrel.
Inspect the piston skirt O.D. (page 14-6). BOTTOM
14-5
dummyhead
CYLINDER BLOCK
PISTON SKIRT O.D.
Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90° to the piston 90°
pin bore.
STANDARD: 45.965 – 45.985 mm (1.8096 – 1.8104 in)

replace the piston.
10 mm
Inspect the cylinder sleeve I.D. (page 14-5). (0.4 in)
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston skirt O.D. from the cylinder sleeve
I.D. to obtain the piston-to-cylinder clearance.
STANDARD: 0.015 – 0.050 mm (0.0006 – 0.0020 in)

replace the piston and recheck the clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel.
PISTON PIN BORE I.D.

Measure and record the piston pin bore I.D. of the
piston.
STANDARD: 12.002 – 12.008 mm (0.4725 – 0.4728 in)

replace the piston.
Inspect the piston pin O.D. (page 14-6).
PISTON PIN O.D.

Measure and record the piston pin O.D. at three points
(both ends and middle). Take the minimum reading to
determine piston pin O.D.
STANDARD: 11.994 – 12.000 mm (0.4722 – 0.4724 in)

replace the piston pin.
Inspect the piston pin bore I.D. (page 14-6).
Inspect the connecting rod small end I.D. (page 14-9).
14-6
dummyhead
CYLINDER BLOCK
PISTON PIN-TO-PISTON PIN BORE
CLEARANCE
Subtract the piston pin O.D. from the piston pin bore
I.D. to obtain the piston pin-to-piston pin bore
clearance.
STANDARD: 0.002 – 0.014 mm (0.0001 – 0.0006 in)

replace the piston pin and recheck the clearance.
the new piston pin, replace the piston.
PISTON RING SIDE CLEARANCE

Measure the clearance between each piston ring and
ring groove of the piston using feeler gauge.
STANDARD:
Top: 0.035 – 0.070 mm (0.0014 – 0.0028 in)
Second: 0.045 – 0.080 mm (0.0018 – 0.0032 in)
SERVICE LIMIT:
Top: 0.20 mm (0.008 in)
Second: 0.20 mm (0.008 in)
If any measurement is more than the service limit,
inspect the piston ring width.
If the piston ring width is normal, replace the piston and
reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set and reinspect the clearance.
If any measurement is still more than the service limit
with the new piston rings, replace the piston.
PISTON RING WIDTH

Measure each piston ring width.
STANDARD:
Top: 0.950 – 0.970 mm (0.0374 – 0.0382 in)
Second: 0.940 – 0.960 mm (0.0370 – 0.0378 in)
SERVICE LIMIT:
Top: 0.968 mm (0.0381 in)
Second: 0.938 mm (0.0369 in)
If any measurement is less than the service limit,
replace the piston rings (top, second, oil) as a set.
14-7
dummyhead
CYLINDER BLOCK
PISTON RING END GAP
Before inspection, check whether the cylinder sleeve
I.D. is within the specification (page 14-5).
Measure each piston ring [1] end gap using a feeler
gauge.
STANDARD:
Top: 0.15 – 0.35 mm(0.006 – 0.014 in)
Second: 0.15 – 0.35 mm(0.006 – 0.014 in)
Oil (side rail): 0.20 – 0.70 mm(0.008 – 0.028 in)
SERVICE LIMIT:
Top: 1.0 mm (0.04 in)
Second: 1.0 mm (0.04 in)
Oil (side rail): 2.0 mm (0.08 in) [1]
If any measurement is more than the service limit,

replace the piston rings (top, second, oil) as a set.
CONNECTING ROD BIG END SIDE

CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
STANDARD: 0.10 – 0.40 mm (0.004 – 0.016 in)
replace the connecting rod (page 14-4) and recheck the
clearance.
the new connecting rod, replace the crankshaft.
CONNECTING ROD BIG END OIL

CLEARANCE
Clean all oil from the crankpin and connecting rod big
end surface.
Place a piece of plastigauge on the crankpin, install the [1]
connecting rod upper end and the connecting rod lower
end, and tighten the connecting rod bolts [1] to the
specified torque.
• Do not rotate the crankshaft while the plastigauge is

in place.
14-8
dummyhead
CYLINDER BLOCK
Remove the connecting rod and measure the
compressed width of the plastigauge [1] using the scale [2]
printed on the bag [2] of the plastigauge.
STANDARD: 0.036 – 0.057 mm (0.0014 – 0.0022 in)

If the clearance is more than the service limit, inspect
the connecting rod big end I.D. and the crankpin O.D.
If necessary replace the part that is not within the
service limit and reinspect the clearance.
[1]
CONNECTING ROD SMALL END I.D./

BIG END I.D.
Measure the connecting rod small end I.D.
STANDARD: 12.005 – 12.020 mm (0.4726 – 0.4732 in)

replace the connecting rod.
Check the piston pin O.D. (page 14-6).
Set the connecting rod lower end to the connecting rod
SMALL END
upper end and tighten the connecting rod bolts to the
specified torque.
Measure the connecting rod big end I.D.
STANDARD: 20.016 – 20.027 mm (0.7880 – 0.7885 in) BIG END

replace the connecting rod.
Check the crankpin O.D. (page 14-9).
CRANKPIN O.D.
Measure the crankpin O.D. of the crankshaft.
STANDARD: 19.970 – 19.980 mm (0.7862 – 0.7866 in)

replace the crankshaft.
14-9
dummyhead
CYLINDER BLOCK
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.
STANDARD:
IN: 19.599 – 19.999 mm (0.7716 – 0.7874 in)
EX: 19.641 – 20.041 mm (0.7733 – 0.7890 in)
SERVICE LIMIT:
IN: 19.40 mm (0.764 in)
EX: 19.44 mm (0.765 in)
replace the camshaft.
CAMSHAFT O.D.
Measure the journal O.D. of the camshaft.
STANDARD: 9.972 – 9.987 mm (0.3926 – 0.3932 in)

DECOMPRESSOR WEIGHT
Check that the decompressor weight [1] moves
smoothly.
If the decompressor weight does not move correctly,
[1]
CRANKSHAFT BEARING
Turn the inner race of the bearing with your finger and
check for play.
Replace the bearing if it is noisy or has excessive play.
14-10
dummyhead
CYLINDER BLOCK
CRANKSHAFT BEARING/OIL SEAL
REPLACEMENT
CRANKSHAFT BEARING
CRANKCASE COVER SIDE/CYLINDER BARREL
SIDE
Remove the oil seal and drive out the crankshaft
bearing.
Drive a new crankshaft bearing [1] until it is fully seated
on the end.
• Install by pressing the outer race squarely.
[1]
CRANKSHAFT OIL SEAL

CRANKCASE COVER SIDE/CYLINDER BARREL
SIDE
Remove the oil seal.
Drive a new oil seal [1] in the position as shown.
INSTALLATION HEIGHT: 0.5 – 1.5 mm
(0.02 – 0.06 in)
• Install by pressing the outer area of oil seal squarely.

• Be careful not to damage the seal lips.
[1]
14-11
dummyhead
MEMO
dummytext
15. WIRING DIAGRAMS
WIRING DIAGRAMS ···································15-2
15
15-1
WIRING DIAGRAMS
15-2
82Z36000.book
EP1000N R type
2 ページ
dummyhead
GENERATOR BLOCK CONTROL PANEL BLOCK

WIRING DIAGRAMS
Br Y/G EG1000N K,LS,M,R,S types

WIRING DIAGRAMS
CONDENSER AC
CIRCUIT Br W
PROTECTOR N
AC RECEPTACLE
FIELD
WINDING Bu
CONDENSER
WINDING
Bu
Br
MAIN
２０１２年１２月１１日　火曜日　午後１２時１１分
WINDING
W
ENGINE
SWITCH
E
Y/G Y/G Y/G
Y Y IG
Bl
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT
ENGINE SWITCH Bl Black Br Brown

CONTINUITY
ENGINE OIL IGNITION Y Yellow O Orange
GROUND LEVEL SPARK COIL IG E Bu Blue Lb Light blue
TERMINAL SWITCH PLUG G Green Lg Light green
OFF
R Red P Pink
ENGINE BLOCK ON W White Gr Gray
82Z36000.book
3 ページ
dummyhead
EG1000N L type
R Y/G
CONDENSER AC
CIRCUIT R W
PROTECTOR N
FIELD AC RECEPTACLE
WINDING Bu
CONDENSER
WINDING
Bu
R
MAIN
WINDING
W
ENGINE
SWITCH
E
Y/G Y/G Y/G
Y Y IG
Bl
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT

CONTINUITY
OFF
R Red P Pink
WIRING DIAGRAMS
15-3
15-4
82Z36000.book
4 ページ
dummyhead

EG1000N LB,SB types
LB type:R
WIRING DIAGRAMS
SB type:Br
Y/G
AC
CONDENSER CIRCUIT LB type:R
W
PROTECTOR N SB type:Br
AC RECEPTACLE
FIELD
WINDING Bu
CONDENSER
WINDING
Bu
LB type:R
SB type:Br
MAIN
WINDING
W
ENGINE
SWITCH
E
Y/G Y/G Y/G
Y Y IG
Bl
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT

CONTINUITY
OFF
R Red P Pink
82Z36000.book
5 ページ
dummyhead
EG1000N RA type
Br
AC
CIRCUIT AC RECEPTACLE
PROTECTOR
N
CONDENSER
W Br
FIELD
WINDING Bu
CONDENSER
WINDING
Bu
Br
Y/G
MAIN
WINDING
W
ENGINE
SWITCH
E
Y/G Y/G
Y Y IG
Bl
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT

CONTINUITY
OFF
R Red P Pink
WIRING DIAGRAMS
15-5
15-6
82Z36000.book
6 ページ
EP1000N RDN type

dummyhead

WIRING DIAGRAMS
Br Y/G
AC
CONDENSER CIRCUIT
N
PROTECTOR
W Br
FIELD AC RECEPTACLE
WINDING Bu
CONDENSER
WINDING
Bu
Br
MAIN
WINDING
W
ENGINE
SWITCH
E
Y/G Y/G Y/G
Y Y IG
Bl
Bl Bl
Y/G Y/G
OIL ALERT
Y Y UNIT
Bl Bl
Tr-MAG
UNIT

CONTINUITY
OFF
R Red P Pink
INDEX
dummytext
INDEX
AC CIRCUIT PROTECTOR INSPECTION ·····················8-9 IGNITION COIL REMOVAL/INSTALLATION ················· 9-3
A
AC RECEPTACLE INSPECTION ···································8-9 LUBRICATION & SEAL POINTS···································· 2-5

L
AIR CLEANER CHECK/CLEANING ·······························3-4 MAINTENANCE SCHEDULE ········································· 3-2

M
AIR CLEANER REMOVAL/INSTALLATION ···················6-4 MAINTENANCE STANDARDS ······································ 2-2

CABLE/HARNESS ROUTING ········································2-6 MUFFLER REMOVAL/INSTALLATION························ 11-2
C
CARBURETOR BODY CLEANING ································6-7 OIL ALERT UNIT INSPECTION ····································· 9-8
O
CARBURETOR DISASSEMBLY/ASSEMBLY ················6-6 OIL LEVEL SWITCH INSPECTION································ 9-7

CARBURETOR INSPECTION ········································6-7 OIL LEVEL SWITCH REMOVAL/INSTALLATION ········· 9-5
CARBURETOR REMOVAL/INSTALLATION··················6-5 PERFORMANCE CURVE ·············································· 1-6
P
CHOKE REPLACEMENT ···············································6-8 PISTON DISASSEMBLY/ASSEMBLY·························· 14-4

COMBUSTION CHAMBER CLEANING ·························3-4 RECOIL STARTER DISASSEMBLY/ASSEMBLY········ 10-3
R
CONTROL PANEL DISASSEMBLY/ASSEMBLY ···········8-7 RECOIL STARTER INSPECTION································ 10-6

CONTROL PANEL REMOVAL/INSTALLATION·············8-4 RECOIL STARTER REMOVAL/INSTALLATION ········· 10-2
CRANKCASE COVER REMOVAL/INSTALLATION·····14-2 ROTOR BEARING REPLACEMENT···························· 8-13
CRANKCASE COVER/CYLINDER BARREL/PISTON/ SERIAL NUMBER LOCATION ······································· 1-2
S
CONNECTING ROD/CRANKSHAFT/CAMSHAFT SPARK PLUG CAP INSPECTION ································· 9-6

INSPECTION ································································14-5 SPARK PLUG CHECK/ADJUSTMENT/
CRANKSHAFT BEARING/OIL SEAL REPLACEMENT····························································· 3-5
REPLACEMENT ·························································14-11 SPARK TEST ································································· 9-6
CRANKSHAFT/PISTON SPECIFICATIONS·························································· 1-4
REMOVAL/INSTALLATION ··········································14-3 SYSTEM DIAGRAM
CYLINDER HEAD DISASSEMBLY/ASSEMBLY ··········13-4 GENERATOR ···························································· 8-2
CYLINDER HEAD REMOVAL/INSTALLATION············13-3 IGNITION SYSTEM ··················································· 9-2
CYLINDER HEAD/VALVES INSPECTION ···················13-5 TOOLS
T
DIMENSIONAL DRAWINGS·········································1-10 CYLINDER HEAD ···················································· 13-2

D
ENGINE OIL LEVEL CHECK/CHANGE ·························3-3 SERVICE INFORMATION ········································· 2-5

E
ENGINE REMOVAL/INSTALLATION ···························12-2 TORQUE VALUES ························································· 2-4

ENGINE SPEED ADJUSTMENT ····································7-3 TROUBLESHOOTING
ENGINE SWITCH INSPECTION ····································8-9 ENGINE DOES NOT START WHEN ENGINE OIL
FLYWHEEL/STARTER PULLEY LEVEL IS SUFFICIENT ············································· 4-4
F
REMOVAL/INSTALLATION ············································9-4 ENGINE DOES NOT STOP WHEN ENGINE OIL

FRONT COVER/REAR COVER LEVEL IS LOW ·························································· 4-5
REMOVAL/INSTALLATION ············································5-2 ENGINE SPEED DOES NOT INCREASE OR
FUEL TANK AND FILTER CLEANING ···························3-7 STABILIZE ································································· 4-3
FUEL TANK REMOVAL/INSTALLATION ·······················6-2 GENERATOR ···························································· 8-2
FUEL TUBE CHECK·······················································3-7 HARD STARTING OR ENGINE STARTS BUT
GENERATOR INSPECTION ········································8-10 THEN STALLS ··························································· 4-2
G
GENERATOR REMOVAL/INSTALLATION ····················8-5 IGNITION SYSTEM ··················································· 9-2 16

GOVERNOR ARM/CONTROL BASE TYPE VARIATION ·························································· 1-3
REMOVAL/INSTALLATION ············································7-2 VALVE CLEARANCE CHECK/ADJUSTMENT ·············· 3-6
V
GOVERNOR DISASSEMBLY/ASSEMBLY ····················7-4 VALVE GUIDE REAMING ·········································· 13-10

ENGINE SPEED ADJUSTMENT ····································7-3 VALVE GUIDE REPLACEMENT·································· 13-9
I
IGNITION COIL AIR GAP ADJUSTMENT ······················9-6 VALVE SEAT RECONDITIONING ····························· 13-11
IGNITION COIL INSPECTION········································9-7 WIRING DIAGRAM······················································· 15-2
W
16-1

A Few Words About Safety: How To Use This Manual

Uploaded by

Copyright:

Available Formats

A Few Words About Safety: How To Use This Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

A Few Words About Safety: How To Use This Manual

Uploaded by

Copyright:

Available Formats

82Z36000.

book 1 ページ ２０１２年１２月１１日 火曜日 午後１２時１１分

How to use this manual

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How to use this manual

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

© Honda Motor Co., Ltd.

How to use this manual

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Use automatic transmission fluid.

( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

How to use this manual

Bl Black G Green Br Brown Lg Light green

SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVE ····························· 1-6

TYPE VARIATION ·········································1-3 DIMENSIONAL DRAWINGS······················· 1-10

The engine serial number is located on the cylinder barrel.

ENGINE SERIAL NUMBER FRAME SERIAL NUMBER

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

Model EG1000N EP1000N EG1000N

EG1000N M,R,RA types

404 (15.9) 352 (13.9)

MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-5

TORQUE VALUES ········································2-4 CABLE/HARNESS ROUTING ······················ 2-6

LUBRICATION & SEAL POINTS··················2-5

FRAME TORQUE VALUES

STANDARD TORQUE VALUES

CONTROL PANEL WIRE HARNESS

Engine earth terminal of the

EP1000N RDN type

STATOR HARNESS (Br) TERMINAL CORD (Br)

Bl Black Br Brown TERMINAL

EG1000N LB,SB types

Bl Black Br Brown TERMINAL

GROMMET HIGH TENSION CORD

VIEWED FROM LOWER SIDE:

OIL LEVEL SWITCH

OIL LEVEL SWITCH CORD (Bl)

FUEL VALVE FUEL TANK

TUBE CLIP (C11)

TUBE CLIP (B8)

3 mm (0.1 in) – 6 mm (0.2 in)

TUBE CLIP (B8)

DRAIN TUBE CLIP

10 mm (0.4 in) – 15 mm (0.6 in)

MAINTENANCE SCHEDULE························3-2 SPARK PLUG

FUEL TUBE CHECK ····································· 3-7

ITEM Perform at every REGULAR SERVICE PERIOD (2)

Oil is a major factor affecting performance and service [2]

Used engine oil contains substances that have

Check that the oil filler packing [4] is in good condition;

book 1 ページ２０１２年１２月１１日　火曜日　午後１２時１１分