General splitting an alternator on an EG1500X-B generator

Discussion in 'Energy & Marine' started by Harvey, Friday 24th Oct, 2014.

  1. Harvey Expert Advisor ★ ★ ★ ★ ★

    Hi guys, just wanted to know, and if anyone knows if there is a special method for splitting the alternator houseing on a Honda EG1500X-B generator.

    The generator smokes like hell so I want to take the engine appart to replace the piston rings, I've got all of the electrical stuff taken off, but can't seem to get the aluminium end housing off and I don't want to smash it with a hammer as the end housing is out of production and hence no longer available.

    This is the machine in question.
     
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  2. ArcticFire-Account Closed Banned Getting Started

    Scotland Graham Scotland
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  3. Ichiban Founder Staff Team

    England CJ Leeds
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    It needs a rebuild mate its seen too many hours of service with little or no maintenance, its been ragged to its knees. If you plan to keep it get a hour meter


    Then you can go oil changes and other routine maintenance without stretching the genie.
     
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  4. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    Sounds like an interesting project, get some pictures up @Harvey so we can follow along
     
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  5. Harvey Expert Advisor ★ ★ ★ ★ ★

    An hour meter may be on the list as are a few repairs, and yes its been ragged to death, but it still runs and makes power, which is amazing, or it did untill I took it appart.
    @SpeedyGee I'll get some picks up when I get a mo.
     
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  6. hanel44 New Member Getting Started

    United States hanel44 Losa angeles
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    Thanks for sharing this video buddy. I am also looking to buy a generator and my friend suggested me buying it from Honda generator Atlanta sales and I am planning to pay a visit to their website.
     
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  7. Harvey Expert Advisor ★ ★ ★ ★ ★

    no worries, but this is not a fine example of a perfectly running generator
     
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  8. Harvey Expert Advisor ★ ★ ★ ★ ★

    Good news ladies and gents, after a while of sitting in my shed half stripped down, I have managed to get the end plate and magnets off the generator, using of all things an old steering wheel puller. The only thing to come off now is the stator, which I need an m10 bolt and a long rod for, so that I can pop it off the shaft. Then it is to proceed to strip down the engine and replace the piston rings. Once that is done and I know I'm gonna need a torque wrench to torque up the conrod bolts, I may take the head and get some new valve guides put in to make sure, that way the old GX140 engine can as far as I can say be fully rebuilt. Though I'm tempted to replace the alterator side bearing and oil seal, whilt it is all appart just to make sure it doesnt leak and gives me years of good service.
     
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  9. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    :Whistle:

    I'm really interested to see more of this, upload some photos as you go mate :Smile:
     
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  10. Harvey Expert Advisor ★ ★ ★ ★ ★

    Ok mate, the only problem I have now is the weather, most of what im doing is outside and its raining at the moment, but as it stands I could document the cleaning up of the parts also.
     
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  11. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    I know what you mean man, it's miserable here and I needed go do some bits on the car today aswell.
     
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  12. Harvey Expert Advisor ★ ★ ★ ★ ★

    Think thats called sods law. I too needed to do some car bits, like find a drivers side window regulator for a 4th Generation golf, but i said to myself, sod getting soaked for one.
    though at the moment. its a case of making the special took to remove the rotor, and then ordering the parts and tool I need to finish the job, namely a torque wrench that will go as low as 14 ftlb
     
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  13. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    Aye that it is mate. What tool do you need to remove the rotor (never disassembled an engine myself to date)?
     
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  14. Harvey Expert Advisor ★ ★ ★ ★ ★

    Its actually on the generator side Leo. some might refere to it as an armature, like on an electric motor. It fits quite snug on a tapered shaft, and its normaly held in place by a long bolt, that bolts into the tapered output shaft of the engine. however to get it off I need to insert a rod into the centre of the shaft, that is smaller in diametre than the securing bolt then use IIRC an M10 or M12 bolt, that screws into some threads in the end of the armature, so that it pops it off in one chunk without damaging it.
    like this video which explains it perfectly


    Honda have a special tool for the job, which basicly acts as a small slide hammer. Once this is out of the way, then I can take the engine side plate off.
     
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  15. Harvey Expert Advisor ★ ★ ★ ★ ★

    Finaly split the alternator from the engine, with not much hastle at all really. block of wood and a hammer and it came off.
    here are a few photos of the generator in bits, ready for cleaning. I cleaned it up and all the parts look so much better for it, though have no photos of that yet.

    20150224_110256. 20150224_110630. 20150224_110635. 20150224_130810.
     
    Last edited by a moderator: Tuesday 24th Feb, 2015
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  16. Harvey Expert Advisor ★ ★ ★ ★ ★

    More updates.

    I have now removed the cylinder head from the engine, and discovered that the cylinder was indeed full of oil, now I had run this engine today so that I could drain the oil from it, and to be honest, it was a pretty disgusting creamy colour, reminiscent of a head gasket leak on a car engine, it looked like it had alot of moisture in it or perhaps even fuel?
    Now admittedly I had washed the engine down with jizer and water, so its possible that some had got in via the oil filler, which seems unlikely, and the engine doesnt leak.

    When I removed the head, I found that the piston was absolutely spotless and fitted tightly into its bore, with no movement at all. I beleive that the piston rings might not be shot after all and that all of my problems are in the cyclinder head. So at the moment I have poured oil into the cyclinder and proped the engine up so that it can't fall over. My theory is is, if the piston rings are gone, then the oil will completely drain into the crank case, if the rings are fine, then most if not all of the oil will stay in the cylinder. i will check this a little later and tomorrow to see how that has gone. My theory is if I do not have to replace the piston rings, then I won't.

    The next thing to do is source some new valve guides, though I do have brand new valves, springs and rotator cap. but I will need a head gasket and someone to insert the new valves and ream them to the correct spec of 5.5mm and most likely cut new valve seats.

    before i do that though, I will soak the cylinder head to remove as much of the carbon build up from exhaust valve as possible.

    20150225_182759. 20150225_182809. 20150225_183538. 20150225_183545. 20150225_184906.
     
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  17. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    Good stuff Gareth, you're getting there.
     
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  18. Nels Moderator Staff Team

    It'll be all worth it in the end @Harvey.
     
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  19. Harvey Expert Advisor ★ ★ ★ ★ ★

    There is some more updates for this little project of at least mechanical restoration.
    I phoned up Holdcroft Honda and unfortunately they cannot order generator/motorbike spares, so had to phone up a local Honda bike specialist in Shrewsbury. II've ordered new valve guides, gasket and also the little clips that help hold them in. This came to £29.

    I have also spoken to M J Engineering In Rednal and they have quoted around the £40 to replace the guides and lap the valves in, which when the parts arrive should be the end of the week.
     
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  20. Harvey Expert Advisor ★ ★ ★ ★ ★

    More news in progress, some new parts arrived today, aka the valve guides, clips and head gasket, then it was off to M J Engineering in Rednal for them to be fitted, though probably won't get it back untill Monday or Tuesday, but then in no big rush at the moment, as its still a project at the end of the day.

    20150305_125913.
     
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