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Old 11-28-2014, 08:53 AM   #1
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Honda Generator worn out, Options?

After 10 years of use the engine on my EU 2000 has worn out. When it is cold it won't build up oil pressure and has to be re started numerous times.
If it is hot started, it will emit a puff of oil smoke and now burns oil.
Who has had this problem, what are the solutions and what is the cost of repair?

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Old 11-28-2014, 09:16 AM   #2
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Take it to a small engine Honda shop. Could be any number of things.

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Old 11-28-2014, 09:20 AM   #3
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The best with any of these small engines is to replace the engine. It may be less to buy a new generator. Sell old one cheap.
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Old 11-28-2014, 09:22 AM   #4
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Originally Posted by handn View Post
After 10 years of use the engine on my EU 2000 has worn out. When it is cold it won't build up oil pressure and has to be re started numerous times.
If it is hot started, it will emit a puff of oil smoke and now burns oil.
Who has had this problem, what are the solutions and what is the cost of repair?
The cost of labor to fix things such as your generator, far exceeds the cost of a new one, especially if you want to rebuild an engine, correctly. It not only pistons rings, but the walls of the engine that the rings traveled in, would also have to be fixed, at least if you wanted a first class job.

Plus, because you have years of useage experience, you could update with perhaps something a little better than the original.

Your present cost per year of use, is peanuts.

Time for new.

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Old 11-28-2014, 10:01 AM   #5
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I agree with Gary. It might not be as bad as you think.
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Old 11-28-2014, 10:05 AM   #6
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It is going to depend on how reasonable replacement parts are. I am betting they are not that reasonable, if even available.

Honda is going to want to sell a new generator after ten years.

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Old 11-28-2014, 10:46 AM   #7
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Honda is pretty good about stocking parts. I use to rebuild Honda 70 engines a lot when I was a kid. A set of rings and a new oil pump are probably all it needs. There might be an internal filter than needs cleaning. It might also need valve seals.

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Old 11-28-2014, 11:16 AM   #8
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Ten years good service would lead me to a new Honda, if not reasonable to rebuild the old one.
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Old 11-28-2014, 01:27 PM   #9
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If everything else works well, drain out the dino oil, and replace it with Mobil 1. It will no longer smoke, and may well run better.
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Old 11-28-2014, 02:00 PM   #10
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I agree. Try synthetic oil. it may extend the generator's life. If not, it is an easy, inexpensive fix to try.

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Old 11-28-2014, 02:15 PM   #11
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We seem to have a difference of opinions here. So, I have questions that nobody has bothered to ask.

1) How many hours are on this unit? Ten years seems like a long time, but most folks don't put that many hours on these little generators.

2) Are you trying to convince yourself that you should have a new one no matter what?

If you really want a new one, go buy it. If you would rather not have to spend the money for a new one, have this one checked out. (The oil change to Mobil 1 is a good place to start.)

If you're looking for a place to take it, I would suggest a Honda motorcycle, ATV, generator dealer. They will have trained mechanics who know what they are doing. If it were mine, I would go to the dealer, buy another one, and have this one tuned up. Then you have two, and you can run everything or have a backup.
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Old 11-28-2014, 02:16 PM   #12
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I have Honda 500 gen that is over 30 years old. I have rebuilt it twice. I am not a mechanic by any means but I am pretty good at swapping out parts. Cost to rebuild was not over $30. Parts are readily available for older Honda power plants. My lawn mower uses a Honda motor. I rebuilt it this past summer for about $50 in parts. We live in a disposable society and people are quick to tell others how to spend their money. At least I would give it a try before buying a new one.
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Old 11-28-2014, 04:49 PM   #13
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I would check into the rebuild first. I have a Honda construction generator that has over 4,000 hours on it (probably closer to 6k) It is overdue for an overhaul, but will be well worth it.

I detest throw away stuff and do my best to purchase durable items that can be repaired. Honda is one of the best when it comes to getting parts and it is for just about everything they make. I just ordered a full gasket and seal set from my 1984 Honda CH125 scooter, they also had quite a few other parts still available. Amazing for a product that is 30 years old and has been out of production for 25.

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Old 11-28-2014, 05:57 PM   #14
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I had virtually the same issues with a friend's Honda 2000 which is used as his backup generator for his off grid solar powered home in NM. It probably has 4000 hours or more on it.

The hard starting or hard to keep running issue when first started is most likely the oil level switch. It is not oil pressure, but oil level which is monitored and the switch causes shutdown. It is a simple part, however it is very difficult to access requiring total disassembly of the unit and as I recall, separation of the engine and attached generator. I was not up to a total tear down of the unit to get at the switch, and he is incapable of doing it at all.

The oil using problem is also common when you get a lot of hours (thousands) on thees engines. The parts are available, but again the access is exceptionally difficult. There is no head that can be detached, the piston has to come out of the engine from the bottom and the major disassembly, unless you do it yourself, is costly at a Honda shop rate of probably $100 an hour. It is very easy to put more money into labor than a new generator would cost.

So, what my friend did was buy a new Yamaha Generator to try it out. I put a by pass switch on the oil level sensor, so the old Honda would start, and once it ran for about 5 minutes, the original switch would loosen up and the by pass switch could be turned off, so the low oil protection was still there. The oil consumption was not excessive after warm up (no smoke, little use) so he now has a backup generator, the old Honda 2000.

Anything can be repaired, the problem is the cost of labor if you take it to a shop. It is sad, but sometimes a new unit is the better solution from a dollar standpoint. For those of you who can, and like to, tear things down, you may find the parts cost is quite reasonable and rebuild is an option.

BTW, the Honda repair manual is available from Honda, but it alone costs in the range of $70. I would highly recommend the purchase of one if you are going to get into these generators. They tell you how to tear them down and what needs to be done to get at certain parts, such as that oil level switch I mentioned above. I got the manual prior to my going into the one I worked on.

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