Honda EU2000i Starter Rope Replacement

Honda EU2000iIt’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
10mm wrench
(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: Left Side Cover & Maintenance Cover

Overview: Front Cover

Overview: Front Cover

Overview: Right Side Cover

Overview: Right Side Cover

Overview: Rear Cover

Overview: Rear Cover

Step 1: Remove Maintenance Cover

Step 1: Remove Maintenance Cover

Step 2: Remove Back Cover - (4) Philips P3 Screws

Step 2: Remove Back Cover – (4) Philips P3 Screws

Step 3: Remove Front Cover - (4) Philips P3 Screws

Step 3: Remove Front Cover – (4) Philips P3 Screws

Step 4: Remove Feet - (4) 10mm Bolts

Step 4: Remove Feet – (4) 10mm Bolts

Step 5: Disconnect (2) Fuel Drain Tubes

Step 5: Disconnect (2) Fuel Drain Tubes. Pull up from bottom. See Step 6 photo.

Step 6: Remove Left Side Under Plate

Step 6: Remove Left Side Under Plate

Step 6a: Left Side Under Plate Removed

Step 6a: Left Side Under Plate Removed

Step 6b: Remove Right Side Under Plate

Step 6b: Remove Right Side Under Plate

Step 7: Remove Handle Screws on Left Side Cover - (2) P3 Philips Screws

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 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

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

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 11: View of Right Side Cover Removed

Step 12: Locate Fuel Tubes on Left Side

Step 12: Locate Fuel Tubes on Left Side

Step 12a: Slide Clip Back and Disconnect Top Fuel Tube

Step 12a: Slide Clip Back and Disconnect Top Fuel Tube

Step 12b: Top Fuel Tube Disconnected

Step 12b: Top Fuel Tube Disconnected

Step 12c: Bottom Fuel Tube Disconnected

Step 12c: Bottom Fuel Tube Disconnected

Step 13: Disconnect Lead to the Engine Switch

Step 13: Disconnect Lead to the Engine Switch

Step 14: Remove Left Front Frame Screws - (2) P3 Screws

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

Step 14a: View of Left Front Frame – NOTE: Do Not Disconnect Longer Fuel Tube. Just lay frame aside once screws are removed.

Step15: Remove Pull Handle Cover and Untie/Cut Frayed Rope Knot

Step15: Remove Starter Grip Cover and Untie/Cut Frayed Rope Knot

Step 16: Remove Left & Right Front Frame Brackets & Fuel Tank

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 16a: Remove Left & Right Front Frame Brackets & Fuel Tank – ANOTHER VIEW

Step 17: Remove Bolt #1 on Starter Case (10mm)

Step 17: Remove Bolt #1 on Starter Case (10mm)

Step 17a: Remove Bolt #2 on Starter Case (10mm)

Step 17a: Remove Bolt #2 on Starter Case (10mm)

Step 17b: Remove Bolt #3 on Starter Case (10mm)

Step 17b: Remove Bolt #3 on Starter Case (10mm)

Step 18: Remove Starter Case

Step 18: Remove Starter Case

Step 18a: Thread Broken Cord Through Hole

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 18b: Remove Broken Cord

Step 18c: Insert New 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 18d: New Cord Knotted

Step 19: Attach Starter Case

Step 19: Attach Starter Case

Step 20: Thread Rope Through Starter Rope Guide and Knot End to Starter Grip.

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.)

42 thoughts on “Honda EU2000i Starter Rope Replacement

  1. You lovely, saintly human being. Mine is a eu1000i, but with your photos, I’m sure I can adapt the instructions for minor differences. Thank you! Cord is about to fail, and I do not have the confidence in my knowledge to attempt this without photos. Thank you so much for taking the time to illustrate this to “the rest of us.” ;-)

  2. Thank You so much for taking the time to post these clear photos and lookouts. I would probably have tried to take the pull cord assembly off without taking the covers off and would have spent hours eventually taking them all off one by one and experiencing a very frusterating learning curve. Thank You so much!

  3. The bolts holding the front frame would not budge, but once the top of the frame was separated, the plastic frame was able to be bent enough to move the tank away from the starter case. This was also important, since the tank was almost full and I did not want to disconnect the hoses. I also did not remove the wires from any of the terminals, just pushing the front panel out. this gave me enough room to get the starter case removed using a box wrench. This took a little time to turn these bolts but kept more of the generator together which saves some time.
    Your step by step was very helpful!

  4. The pictures were very helpful. Thank you. I spent all day today working on my Hondas. I replaced the pull cords on both of my EU2000’s. While I was at it I used the air compressor to blow out years of dirt and grime, and changed the oil and spark plugs. I also cleaned the air filters, carb-sprayed the carbs, the chokes and the on/off switches and gave both my gennys an overall cleaning. Seven hours well spent.

    The first one took about 5 hours and after having done that one the second one was easy and only took about 2 hours. Of course that time included a couple of good cigars, getting side tracked on other little garage projects and a trip to the hardware and auto parts stores. :-) It was a productive day. Again, thanks for the write up.

  5. Just a line to say thank you for these instruction on replacement of pull cord. Every place I called to get repaired they said one to two weeks out. I boat every weekend need Honda generator for air condition. Anyone can follow along very easy.
    Thank you again you saved my weekend.

  6. Cord project went great! Excellent instructions! However, after starting, it no longer has any output. Double checked all electrical connectors, took it all apart again, and still no luck. Typical …

  7. Thanks for the detailed instructions, the pictures are great. Saved me a lot of time. I was able to skip steps 12 & 13 (removing the fuel tubes and connector) there is enough room to get every thing out with them still connected. The frame bolts were very tight in step 14, I needed an impact driver to get one out. I also added 2 turns to the starter coil, 1 wasn’t enough.

  8. Thank you so much for taking the time to do this detailed descriptionfor us all! I just changed the cord on mine and without your directions I don’t think I’d have been able to do it. Bless you!

  9. A big happy shout out to you for your preparation of this information, and for making it available. Your clear written guidance coupled with the photographs made the change out of the starter rope as easy as child’s play. The hardest part was finding a 10mm socket! And oh…the side panel cowlings went back together easily enough with some manipulation, squeezing twisting and the occasional expletive! Thanks so much!

  10. We are sailing in Haiti and I had not enough confidence to take the Honda Generator apart to fix the broken starter cord till I found your website. I copied it onto my iPad and followed your instructions step by step. Two things threw me for a loop for a short period. The first one was Step 7/10. The rubber insert around the handle screws rolled around the boat, but was found before I started putting things back together. It took me only a short time but then I figured where it belonged. The second item was Step 14, Remove Left Front Frame Screws. Because we have had the generator around salt water for several years, they did not want to come undone and the result was a shattering of the plastic frame. All is glued back together with Max1 glue (found at the Miami boat show), but a review of the frame showed that it could probably have been left alone and the tank removed by slightly bending the Left and Right frame parts apart. Before reassembly, all the screws and bolts received a good amount of Tef Gel, so the next time it will come apart nice and easy.

    Anyway, your write-up made it a very doable project. I am very much indebted to you for showing such a clear way of repairing the generator. Thanks a million.

    Henk

  11. Thanks for the step by step instructions. The pictures help me alot.

    With the tight phillips screws I have a certain amount of success using a 3/8 socket and a cordless impact.It hits the screws hard and fast. With minimal damage.

  12. Thanks heaps guys. Followed your instructions to the letter and geny is back up ang going first try as always. Legends!!

  13. Great Directions!!! Was able to do this in about a little over an hour! My handle screws were on the right side not the left, but no big deal! Thank You!!!!!

  14. Ours has broken in the middle of nowhere, but luckily we have internet (high gain aerial fixed to the side of the caravan) and these instructions. Bottom frame Phillips studs are however not moving so presently have them soaking in WD40. Fingers crossed. May need to be brutal – drill them out! Had to improvise for the long 10 mm socket as had no extension for small 3/8 drive sockets. A large blade screwdriver did the trick.

  15. By the way we are in Western Australia. I broke the plastic base trying to undo the Phillips studs, but some wire and the drill gave an adequate fix. Used an old shoe lace as the replacement cord. All working well now.

  16. Thanks for the detailed tutorial…..I haven’t tried it yet, but having to pay $150 to have
    the local Honda motorcycle dealer do it is a great incentive!
    Also read all the previous replies for tips.
    I like Bob’s idea of using a shoestring….Aussie ingenuity!
    I’m up for it now.
    Thanks mate! ;)

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