Journeyman

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Converting a Honda eu2000i Generator to Run on Propane

Thiel

Okay.  So, this is going to be a long one.  I decided to get a generator (over solar, at least for now) to support my RV travels because of a confluence of events.

  • I realized that someone stupid (me) planned travel to the south in the middle of July. Including a few nights of boondocking without hookups.

  • I realized that with a Micro-Air Easy Start, I could run the AC in my trailer with just one small generator. I like that.

  • I realized that if I converted said generator to propane, I would not have to carry gas cans, refuel in the middle of the night, etc... because my trailer has an external LP port and 60 pounds of propane on board.

  • Propane also affords easier maintenance for the genny--and not being a "small engine guy," that was a very attractive feature.

  • Lastly, my RV is stored in a location without an electrical hookup, so the idea of having generator power for mid-winter maintenance etc. is quite attractive. Also, pretty sure I can use the genny for other things, living in New England and all.

  • My elaborate analysis was generally supported by the experienced denizens of airforums.com

So.. the result is that the combination of these factors lead me to the conclusion that I wanted to purchase a Honda eu2000i generator, convert it to propane, and install the Micro-Air Easy Start in my trailer.  This post is about the generator portion of that plan.

I bought the Honda over lots of cheap clones because I have great faith in the brand, and the many Honda cars I've owned over the years have never let me down.  ("Branding power" might never again ever enjoy such an apt metaphor.). The quietness of the generator--and its light weight--were critical product attributes in which the Honda leads as well.

So, let's get onto it.I chose a propane conversion kit from http://www.genconnexdirect.net because it created a clean, self contained installation. (Simplicity is clearly a theme in this endeavor.). There are other kits out there, many are cheaper, and some even offer simultaneous "tri-fuel" options, which would be my choice if I felt some apocalypse was imminent.

If you're interested in other options, here's a short list of conversion kits that I found out there:

Here's what came in the kit:

And here are ALL the tools I used to do the install. (The impact driver may not have been necessary if I just had a little more macho in me.)

As I mentioned, I'm not experienced (at all) with small engines, so taking on this work myself was a learning experience, and I thought it valuable to share.  First, you remove all the covers, which takes a screw driver, a socket wrench, and about 10 minutes.  (Since my generator was brand new, I did not need to drain all the gas and oil to start, but you might!).

Then you remove the gas tank, which leaves a gaping hole in the innards of the generator.

Then you start removing other pieces--mostly hoses, some screws.  While the included directions from Genconnexdirect are VERY DETAILED and well written, the pictures are UNBELIEVABLY AND UNUSABLY TINY.  I found it much easier to download the instructions onto my iPad so I could zoom in on the photos.  Still, even as someone who doesn't know a thing about engines, I found it difficult to screw up.  

Here I've removed the choke and begin to detach fuel lines.Eventually you pull the whole carburetor out.  (At least that's what I think that thing is.)

One of the key advantages of the Genconnexdirect kit is that the regulator fits inside the Honda casing.  Here it is, in its designated location.

I did get concerned about the proximity of this sharp-ish aluminum edge to the pull cord ...So I took matters into my own hands and added just a little bit of electrical tape.

After following very clear, very specific, step by step directions, I was able to reassemble the modified carburetor and reinstall the air filter.  Honestly, this seemed to be the easiest part of the process, mostly because there was really only one way the pieces could fit... but the directions really were quite clear.  In this image, the long threaded screws, the "double" aluminum plate, and the red/black plastic caps are the new pieces that came with the conversion kit.

Here's another view of the (nearly) completed assembly.  The darker hose will connect to the brass pipe, and the lighter grey hose (exiting the left side of the photo) will connect to the black port that's almost dead center in the photo (in front of the red plastic thing).

Here's a wide angle with those hoses in place:

Covers go back on (and there's even step by step instructions for that, and they are actually helpful...).

The supplied stickers add a little bit of gaudy polish to the job.And here, I think, is one of the arguments for the (more expensive) Genconnexdirect kit.  The final fit and finish is super clean--as if it was made by Honda--even when a monkey like me does the install.

 The whole process took me about an hour and 30 minutes to complete; doing it myself saved a couple hundred bucks, so I'm happy with the hourly rate!Last but not least, I filled it with synthetic oil (5W-30), and I installed a Magnetic Oil Dipstick, thinking that was particularly nice to have during the breaking period.

Took a few pulls to start it (it's about 20 degrees here, so the propane may be flowing slow) but it fired right up.  To my surprise, the unit is VERY quiet--more quiet than I had hoped! For the sake of comparison, I actually look carefully for tools that are quiet since my home shop is in the basement of my house.  The Honda generator is quieter than both my Festool vacuum and my Makita MAC2400 compressor--and I consider both of those quiet enough to use with people sleeping one floor above me.  Very pleased!