DIY Guide to a Honda EU2000i Extended Run Fuel System

Here is a video to show how easy it is to build one of these extended run fuel systems for yourself. This video shows how to build a dual generator fuel system however there are pre-made fuel line hoses you can buy pre-built from your local marine outboard motor shop that come with all of the basic fittings required.

One such pre-made fuel line is the "Yamaha Quick Connect fuel line kit Attwood 9360Y7", just be sure to purchase the matching Yamaha male fuel line quick connect "SEACHOICE YAMAHA MALE FUEL QUICK CONNECT PART #20641".

The only part that you would require to purchase online (unless you want to retrofit the Honda OEM fuel caps yourself) would be the "HONDA Eu2000i GENERATOR EXTENDED RUN FUEL GAS CAP" that fits the HONDA EU2000i, EU20i, EU1000i & EU10i Generators. So you could in theory make an extended run fuel system for any of these generators with the method I show in this video. (Don't forget the actual fuel cell which you can pick up in various sizes depending on your needs). Do an Ebay search for everything I have in parenthesis.

There are also Ebay stores that sell these units completely pre-made for you if you don't want the hassle of building one yourself.

Category:

Education

Tags:

• D.I.Y.
• Honda
• EU2000i
• Generator
• Extended Run Fuel System

[tsellers2]

Thanks for that. Time to do some maintenance replacement on my lines so tomorrow I was planning to buy a couple of cheap $2.00 inline filters as well. If I see a fuel guage maybe I'll put one in the common line as well. I still haven't achieved vacumm flow, I still have to move the tank higher for some reason. ALthough I cannot seem to find any air leaks, the fact I cannot get a vacumm must mean I have a leak somewhere I suppose.

[MrNightro]

@tsellers2 Try making your cable a little shorter & look out for air leaks. My first rendition eventually after the first summer had the same issue you mention where I had to elevate the fuel tank above the generators to maintain fuel flow. I found that the OEM cap that I had modified had air leaks where the fuel ate away at the epoxy used to secure the fuel line adapter.

[tsellers2]

If you are always going to use this system you do not need to purchase a new fuel cap for the Gennys. You can remove the air valve assembly from the middle of the existing cap, and thread in an appropriate diameter 90 degree fitting, sealing the thread as it screws in. The glass filter is a great idea that I plan to incoporate into mine. I don't understand why it is only on one side of the 'T", would it not be better to have one inline before each fuel cap so you can ensure flow to each side?

[MrNightro]

@tsellers2 My first rendition of the fuel cap was a DIY job as you explained but eventually the epoxy that I used to seal it up was ate up by the fuel & air leaks formed. The fuel filter is placed on the common line so both generators receive filtered fuel (plus both gens come with a basic filter inside of the its' OEM tank). The T is partially transparent so you can check flow there (as the initial air bubbles work themselves out of the fuel line). A flow meter can be used if you wish instead.

[tsellers2]

Just got back from the city with new 1/4" fuel line, clamps, and some in-line filters. Will have a go at rebuilding the line tomorrow and see if I can eliminate those air demons. Will report back, thanks for the suggestions.

[rhythmkyng]

@MrNightro THANK YOU!!

[MrNightro]

@rhythmkyng To drain the extended run fuel line unscrew the caps off & use the fuel pump that I show in this video to push the excess fuel out of the lines.

[MrNightro]

@rhythmkyng Continued----- One more trick for the refuelling just came to mind, 4) you can get a spare fuel cap adaptor & install in on the extended fuel tank side so that the air valve would then be kept open. I however would personally shut my generators down during refuel but really the run time given with this system is so long that utility power has been restored before needing to refuel.

[MrNightro]

@rhythmkyng with a potential run time exceeding 24 hours you should give you generators a chance to rest, however there are a couple options available for what you wish to do. 1) use the OEM cap during refill, 2) have an extra extended run fuel tank so it,s just a case of doing a swap out, 3) use a 6 gallon jerry jug to refill the extended fuel tank (being sure to keep away from the running generators since really you shouldn't refill a running generator).

[rhythmkyng]

@MrNightro Sorry. Lets say I want the generator to continue running on it's internal fuel while I take the external tank off for refueling. Once I disconnect the line, that aluminum cap is now unvented. Yes, I could loosen it to allow for venting, but fear the cap could vibrate loose resulting in a fuel spill. Do I simply put on the OEM plastic cap at that point?? Also, fuel sitting in the line can't be good. How do u drain the line of fuel before storing it away?