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12-03-2017, 01:42 PM #1
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Honda EU2000i kill switch, no permanent mods to generator
I recently purchased two Honda EU2000i generators for emergency/RV use. I wasn’t crazy about the fuel cutoff and kill switch being one unit. I like to run the gas out of my infrequently used power tools. For the first few uses I would just open the side cover and unplug the kill switch. A bit of a pain but doable. I’m not comfortable just leaving the switch unplugged though.
There are many write ups about kill switch mods to this generator. They all required some kind of potential warranty ending cutting. Usually cutting or tapping into the kill switch wires, and a hole in the plastic to mount the switch. I wanted the convenience of a separate kill switch but no permanent mods to the generator.
I dug through thousands of Google images trying to figure out what connector this generator uses. It was not a common connector. I finally found what looked like a match. Had to order from China and keep my fingers crossed. Luckily my Google-fu was working that day. I didn’t know what end of the plug I needed, so I just got both.
Then I needed to find a kill switch that wouldn’t break the bank and could be mounted on the carry handle. I found a motorcycle switch that looked like it might work, but it was for much smaller diameter bars than the carrying handle was. I wired the plug to the switch and set about mounting them.
The plug just barely fit through the choke lever hole. Plenty of room in there for wire and lever both though. I ran it through the hole and plugged it into the kill connector that runs from the motor toward the on/off switch. I had to drill out the aluminum mounting clip where the screw threaded into so the zip tie would fit. I also had to straighten out the mounting clips some to fit the contour of the carrying handle. Wrapped a piece of rubber around the handle so the switch wouldn’t mar it. Zip tied it all together and gave it a test run. Works great! Kill switch button kills the motor, but the on/off switch just cuts off the gas. Now I can run my carbs dry but not kill my warranty.
If I need warranty work I just clip some zip ties, unplug my switch, and plug the motor kill wires back into the on/off switch.
Sorry, forgot part numbers:
Connector: 6090-1031 6090-1001 Sumitomo 2 Pin Female Male Automtive Connector Wiring Harness Connector For Motorcycle Plug ($15.83 for 20 sets, shipped from China, AliExpress). I might be convinced to mail off a fitting or two for the price of postage...I’ve got 18 extra.
Switch: Kill Switch KTM ATV Motorcycle Dual Sport Dirt Bike Start Horn Button Red Button https://rover.ebay.com/rover/0/0/0?m...2F111575992252
Eric & Sandra
2018 Grand Design Imagine 2670MK
2000 Ford Excursion 7.3 Diesel 4x4
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12-03-2017, 02:22 PM #2
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Thanks, Eric. Would you mind posting the plug info for those not master-Googlers?
Al and Kathe
House: Bass Harbor, Maine
Home: Wherever we're parked
[SIGPIC][/SIGPIC]
Highlighted states are those we have camped in for at least one night in our Solitude.
2018 Solitude 310GK 110463 (Rhett) / 2018 F350 CC DRW 4x4 Lariat (Scarlett)
Follow us: http://lobstersontheloose.com
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12-03-2017, 02:29 PM #3
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Sorry. Added that info to original post. PM me if interested in some connectors.
Eric & Sandra
2018 Grand Design Imagine 2670MK
2000 Ford Excursion 7.3 Diesel 4x4
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12-04-2017, 05:15 PM #4
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So
Let me see if I understand this.
With the kill switch wired in, the on / off switch on the generator will not kill the engine.Backpacker and tent camper all my life, including BSA as a kid and adult.
Motorcycle trips across the USA with a tent - 1978 to Present.
02-10-2005 - 2002 F350 SWD PSD and 2003 Citation 10'8S mostly for Crater Lake Ski Patrol.
10-29-2015 - 2016 Grand Design 380TH. It's HUGE compared to a camper.
10-19-2018 - traded truck for a 2016 Ram 3500 DRW Laramie CC 4 X 4 Long Box.
03-16-2019 - Traded Momentum for a New 2018 374TH-R Solitude
FULL TIME RV'er Nov 2021
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12-04-2017, 07:34 PM #5
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Eric & Sandra
2018 Grand Design Imagine 2670MK
2000 Ford Excursion 7.3 Diesel 4x4
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12-04-2017, 07:39 PM #6
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John & Cheryl
Sold: 2017 Tiffin Allegro 31SA Motorhome
Sold: 2017 Reflection 337RLS, dual pane windows, 2nd A/C, Go Power! Solar Elite w/2000 watt inverter, Titan electric/hydraulic brakes, Goodyear Endurance ST235/85 R16 tires
Sold: 2015 Chevy Silverado LTZ 3500HD, SRW, Duramax/Allison, 50 gallon Transfer Flow auxiliary tank
States we have camped in with an RV:
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12-04-2017, 08:04 PM #7
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Eric
Can you post a few pictures of the wire connections and / or a wiring diagram?
Thanks
This is a great idea. KENBackpacker and tent camper all my life, including BSA as a kid and adult.
Motorcycle trips across the USA with a tent - 1978 to Present.
02-10-2005 - 2002 F350 SWD PSD and 2003 Citation 10'8S mostly for Crater Lake Ski Patrol.
10-29-2015 - 2016 Grand Design 380TH. It's HUGE compared to a camper.
10-19-2018 - traded truck for a 2016 Ram 3500 DRW Laramie CC 4 X 4 Long Box.
03-16-2019 - Traded Momentum for a New 2018 374TH-R Solitude
FULL TIME RV'er Nov 2021
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12-08-2017, 12:17 PM #8
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How does a kill switch work? From Google: “kill switches work by either grounding out the ignition to chassis ground or interrupting the ignition supply voltage so there is no spark. ... The switch works by interrupting the spark to the plugs in some way. If it is a coil ignition then the switch is placed in the circuit and just breaks the connection.”
This picture shows the on/off switch and the kill wire plug. The on/off switch, in normal operation, interrupts the spark and simultaneously the fuel. If you stop the generator this way the carburetor is still full of fuel. Over time this fuel will evaporate off and leave varnish that potentially plugs up the jet. This is even worse with gasoline that has ethanol in it. Fuel stabilizers help, but eventually your carb jet will clog over time if your generator isn’t run often.
This picture shows a closeup of the connector between the on/off switch and the motor. It has black/green wires.
To run the carb dry, simply unplug this connector. This could be done while the generator is running. Or, just start it back up after unplugging, but with the on/off switch in the off position. In 3-4 minutes the generator will start to sputter and eventually die. Make sure you don’t have anything using the generator power when you kill it. It could damage either the external electronics or the generator circuitry.
I’ve attached the new remote kill switch into the motor side of the kill plug.
This is how I routed the wire from the connector to the choke lever hole. It goes over the screw boss for the removable panel. It is a tight fit, but the connector barely fit through the hole.Eric & Sandra
2018 Grand Design Imagine 2670MK
2000 Ford Excursion 7.3 Diesel 4x4
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12-08-2017, 12:22 PM #9
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Completed installation. Now the kill button completes the kill circuit to stop the motor when pushed. If I only use the on/off switch I run all the gas out of the carberator. Call me paranoid, but I also run only non-ethanol gasoline through my generators. I want them to start every time. Hope this helps with any questions.Eric & Sandra
2018 Grand Design Imagine 2670MK
2000 Ford Excursion 7.3 Diesel 4x4
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05-27-2019, 11:06 AM #10
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Understand this is an old post but... I installed a switch like this on my Onan 5500 to kill fuel pump and burn carb fuel dry. It works very well and leaves just a drop or two in the carb after it runs out of fuel. On my Honda 2000 generators I had read up on this kill switch and liked the idea. I unplugged the two wire electrical connector and started the generator to run it out of fuel. After it died, I put the choke on and started it up again and it ran for several seconds until it again ran out of fuel. Then I opened the carb drain screw and about 1/4 of the tube length full of gasoline ran out. Too much for my comfort. I will just continue to manually drain the carb on the Hondas. YRMV.
Steve
2017 F350 6.7 Lariat DRW
2017 Momentum 388M
North of Houston
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