It’s inevitable… if you own a Honda EU2000i generator, sometime during your ownership you are going to have to replace the starter rope. We’ve heard from other owners that their starter rope frayed and had to eventually be replaced. And, so it happened to us. At first glance this will seem like a daunting task, and rest assured… it is. ;) But the end result is achievable.
So now we are about to take you through our journey, step-by-step, and show you how painless this process really is. Hopefully doing this yourself will save you a few bucks from a visit to your local authorized Honda service center. So let’s get on with it.
We’d like to credit tripledir on the RV.Net Open Roads Forum for their instructions that were instrumental in our success.
Disclaimer: We are not responsible in any way, shape, or form if you mess up your generator by following the steps below. But they worked for us. :)
The basic tools you will need are:
10mm socket (deep socket) with ratchet
(2) Philips screwdrivers; one with a P2, and one with a P3 head.
3′-4′ of ParaCord
Dab of Axle Grease
If all goes smoothly and according to plan, the above items will be all you need for this project. However, we hit a few snags along the way. Mainly being unable to easily remove some of the screws and stripping two of the Philips drives in the process. Unfortunately, since we live in a remote location and being an overcast day (which didn’t help our solar panels) our alternative power was limited, and we ended up drilling out the two screw heads. So we were left with two missing screws when we reassembled the covers. Just a heads up. Okay. onward.
Overview: Left Side Cover & Maintenance Cover
Overview: Front Cover
Overview: Right Side Cover
Overview: Rear Cover
Step 1: Remove Maintenance Cover
Step 2: Remove Back Cover – (4) Philips P3 Screws
Step 3: Remove Front Cover – (4) Philips P3 Screws
Step 4: Remove Feet – (4) 10mm Bolts
Step 5: Disconnect (2) Fuel Drain Tubes. Pull up from bottom. See Step 6 photo.
Step 6: Remove Left Side Under Plate
Step 6a: Left Side Under Plate Removed
Step 6b: Remove Right Side Under Plate
Step 7: Remove Handle Screws on Left Side Cover – (2) P3 Philips Screws
Step 8: Remove Screw Above Starter Handle on Left Side Cover – (1) P2 Philips
Step 9: Remove Long Bolts on Bottom Right Side Cover – (2) 10mm Bolts NOTE: USE A DEEP 10mm SOCKET
Step 10: View of Left Side Cover Removed NOTE: Examine how the Covers are connected together around the frame and fuel tank. This was one of the difficult tasks of reassembling the covers.
Step 11: View of Right Side Cover Removed
Step 12: Locate Fuel Tubes on Left Side
Step 12a: Slide Clip Back and Disconnect Top Fuel Tube
Step 12b: Top Fuel Tube Disconnected
Step 12c: Bottom Fuel Tube Disconnected
Step 13: Disconnect Lead to the Engine Switch
Step 14: Remove Left Front Frame Screws – (2) P3 Screws – NOTE: Do Not Disconnect Longer Fuel Tube. Just lay frame aside once screws are removed. There is no photo of Right Front Frame (1) P3 Screw. So wing it yourself.
Step 14a: View of Left Front Frame – NOTE: Do Not Disconnect Longer Fuel Tube. Just lay frame aside once screws are removed.
Step15: Remove Starter Grip Cover and Untie/Cut Frayed Rope Knot
Step 16: Remove Left & Right Front Frame Brackets & Fuel Tank – (set aside the fuel tank bracket -On/Off- pull cord bracket as a unit)
Step 16a: Remove Left & Right Front Frame Brackets & Fuel Tank – ANOTHER VIEW
Step 17: Remove Bolt #1 on Starter Case (10mm)
Step 17a: Remove Bolt #2 on Starter Case (10mm)
Step 17b: Remove Bolt #3 on Starter Case (10mm)
Step 18: Remove Starter Case
Step 18a: Thread Broken Cord Through Hole and Pull Until it is all the Way Extended and Knot is Adjacent to the Outlet Hole (i.e. Aligned Holes). Then insert a small screw driver through cage to keep Starter Reel in Place.
Step 18b: Remove Broken Cord
Step 18c: Insert New Cord – Note: (1) Screw Driver Insert to Hold Starter Reel, (2) Put a small light dab of Axle Grease Here, (3) Aligned Holes. Give the Starter Reel another Wind before adding New Cord Since You Probably Lost a Wind When Your Old Cord Broke.
Step 18d: New Cord Knotted
Step 19: Attach Starter Case
Step 20: Thread Rope Through Starter Rope Guide and Knot End to Starter Grip.
Reassemble by reverse order.
We hope these photos and instructions helped. Please let us know if they did. We’d appreciate it.
We also have the Honda EU2000i Repair Manual (Not the Owners Manual) available in PDF. Download it here. (Please don’t hotlink this, or we’ll have to remove it, and you’ll spoil it for everyone else.)