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Spark Plug Service
28 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Spark Plug Service
To ensure proper engine operation, spark plug must be
properly gapped and free of deposits.
Recommended Spark Plug Replacement: 100842A
*
1. Stop engine if it is running. Allow to completely cool.
2. Place the generator on a flat, level surface.
3. Remove spark plug cap.
4. Clean any dirt from around spark plug base.
5. Using a 13/16” spark plug socket wrench, loosen and
remove spark plug.
6. Inspect spark plug.
If spark plug is damaged or excessively worn, or if
insulator is cracked or chipped, use a new spark
plug.
If spark plug is in good condition, reuse existing
spark plug.
7. If reusing spark plug, clean spark plug with wire
brush.
8. Measure spark plug gap with spark plug gauge.
Gap should be: (0.028-0.031 in) (0.70-0.80 mm).
9. If necessary, adjust gap by carefully bending side
electrode.
10. Inspect spark plug washer and verify it is in good con-
dition.
11. Reinstall spark plug by hand to prevent cross-thread-
ing.
12. After spark plug is seated, tighten with spark plug
wrench to compress washer.
If installing a new spark plug, tighten l/2 turn after
the spark plug seats to compress the washer.
If reinstalling a used spark plug, tighten l/8 - l/4 turn
after the spark plug seats to compress the washer.
If engine has been running, muffler will reach tem-
peratures that could cause severe burns. Do not
touch.
Bosch W20EPR
Champion RN9YC
Denso WR7DC
TABLE 5. Spark Plug Equivalents to 100842A
To service spark plug, you will need:
Clean cloth
13/16” spark plug socket wrench
New spark plug (if existing spark plug is exces-
sively worn or damaged)
Wire brush
Spark plug gauge (for setting spark plug gap)
* See Maintenance Parts at end of this manual.
FIGURE 57: Spark Plug Cap Removal
FIGURE 58: Spark Plug Removal
WARNING
FIGURE 59: Correct Spark Plug Gap
NOTICE
Spark plug must be securely tightened. An improperly tight-
ened spark plug can become very hot and could damage
engine. Never use spark plugs that have an improper heat
range. Use only recommended spark plugs or equivalent.
0.028-0.031 in
(0.70-0.80 mm)