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Open Roads Forum  >  Tech Issues

 > Honda eu2000i pull cord replacement

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tripledir

Payson AZ

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Posted: 11/02/05 01:17pm Link  |  Print  |  Notify Moderator

Went out to start up the Honda this morning and it finally happened. The pull cord broke. After a couple cups of coffee, I figure I’m awake enough to start tearing down the gen. This was the procedure:
  1. Remove access panel
  2. Remove muffler end panel (4 screws)
  3. Remove (4 screws) that hold plastic power end panel to frame
  4. Detach carburetor drain tubes from side panel at bottom
  5. Slide black trim at bottom right side (facing gen. from the power panel) down to remove
  6. Remove (2 long bolts-10mm) at bottom right side
  7. Remove (2 screws) at handle
  8. Remove (1) screw just above pull cord
  9. Remove sides
  10. Disconnect gas lines (2) just above pull cord
  11. Disconnect elect. connector (1) to On/Off switch
  12. Remove (2) screws at base of fuel tank cradle bracket (pull cord side)
  13. Remove (1) screw at base of fuel tank cradle bracket (other side)
  14. Remove fuel tank cradle brackets (2) (fuel tank cradle-On/Off- pull cord bracket as a unit) (set aside)
  15. Swing aside power end panel
  16. Remove pull cord assembly (3 bolts-10mm)
  17. Thread broken cord thru hole and pull until it is all the way extended and knot is adjacent to outlet on cage and insert a small screw driver thru cage to hold in place
  18. Pull out the old cord
  19. Measure new cord (note: give yourself 6” to 8” extra) and install (note: you might want to give the spring winding an extra wind because when the cord broke it probably lost a wind)
  20. Now put her back together in reverse order


When it’s all back together and you’re ready to install the pull cord handle, take a pointed tool (I used an ice pick) and pry off the cap on the cord handle. Install the new cord thru the handle and tie off so that the cord is slack ¼” to ½” when released and latching mechanism to flywheel is fully retracted.

Some of the Phillips head screws were pretty tight so make sure you have good pressure on them when unscrewing. Make sure all the body parts are clean where they should fit tight before reassembly. When I put mine back together, I used Loctite thread lock (very sparingly) on all screws and bolts. That’s it!

This text has been edited from the original. Removing the feet was deleated and you only need to remove the right side black trim in #5.

* This post was last edited 11/05/05 07:22am by tripledir *   View edit history


1988 33' Four Seasons Tourcrusar
Ford 460 / GEAR VENDORS / John Deere Chassis / 4 Wheel Disc Brakes / Air Suspension
Onan 6.5 / HONDA EU2000i / Freedom 458-20 Invrtr / 6-6V Batteries / 3-120w Kyocera Solar Panels w/4 way tilts
HONDA XR650L / Tilt A Rack


Momma

Eastern Oregon

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Posted: 11/02/05 01:27pm Link  |  Print  |  Notify Moderator

That's it??? Sounds like you took the everything off except the motor.

tripledir

Payson AZ

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Posted: 11/02/05 01:34pm Link  |  Print  |  Notify Moderator

Momma wrote:

That's it??? Sounds like you took the everything off except the motor.

Honda doesn't make it easy, but at least there are no special tools required. [emoticon]

Wind River

wyoming

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Posted: 11/02/05 01:36pm Link  |  Print  |  Notify Moderator

Thanks for the great info. I printed your directions and will keep them with my owner's manual.


2019 Ford F250 XLT Super Duty 4X4 6.7 Power Stroke
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Twin Honda 2000i w/parallel kit


YoDude9999

San Martin, CA

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Posted: 11/02/05 05:34pm Link  |  Print  |  Notify Moderator

I hope you didn't use the 'red' loctite.


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tripledir

Payson AZ

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Posted: 11/02/05 05:51pm Link  |  Print  |  Notify Moderator

YoDude9999 wrote:

I hope you didn't use the 'red' loctite.

Thread lock = Green

32dgrz

Iowa

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Posted: 11/02/05 08:26pm Link  |  Print  |  Notify Moderator

tripledir wrote:

YoDude9999 wrote:

I hope you didn't use the 'red' loctite.

Thread lock = Green

Green= It will never come apart in our shop.
If I remember correctly it is blue, then red, then green

tripledir

Payson AZ

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Posted: 11/03/05 07:34am Link  |  Print  |  Notify Moderator

32dgrz wrote:

Green= It will never come apart in our shop.
If I remember correctly it is blue, then red, then green
Hmm, it's called a wicking grade. I use it very sparringly and is what I had on hand. The blue would be my choice if that is what I had on hand.

* This post was edited 11/04/05 03:48am by tripledir *

PackerBacker

Montreal (Qc) Adirondacks (NY) Myrtle Beach (SC)

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Posted: 11/03/05 03:55am Link  |  Print  |  Notify Moderator

Drop it off at my local repair guy and say "here, fix it!"


Eric
2014 Enterra 314RES (Cruiser RV) TT, Equal-i-zer 12K, Honda 2000 Genny
2022 Ford F-150 Sport 4X4

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