How To Change the Pull Rope on a Honda 7000 Watt Inverter Generator


To change the pull rope on a Honda 7000 watt inverter generator:

  1. Remove the recoil starter assembly by unscrewing the mounting bolts.
  2. Pull out the old rope and untie it from the starter grip handle.
  3. Thread the new rope through the recoil pulley, tie a knot, and wind it around the pulley.
  4. Thread the rope through the starter grip, tie another knot, and melt the ends.
  5. Wind the recoil spring, reinstall the assembly, and test the new rope.

In this guide, we will walk you through the step-by-step process of changing the pull rope on your Honda EU7000iS generator. We’ll cover everything from the tools and materials you’ll need to the detailed instructions for removing the old rope and installing a new one.

Tools and Materials Needed

Before you begin, gather the following tools and materials:

  • Replacement pull rope (Honda part number 28462-Z37-V31 or equivalent)
  • Needle-nose pliers
  • Flathead screwdriver
  • Phillips head screwdriver
  • Lighter or matches
  • Scissors
  • Safety glasses
  • Work gloves

Step 1: Prepare the Generator

  1. Make sure the generator is turned off and cooled down completely.
  2. Disconnect the spark plug boot to prevent accidental starting.
  3. Place the generator on a flat, stable surface.

Step 2: Remove the Recoil Starter Assembly

  1. Locate the recoil starter assembly on the side of the generator engine.
  2. Remove the four bolts securing the recoil starter assembly to the engine using a 10mm socket or wrench.
  3. Carefully lift the recoil starter assembly off the engine and set it aside.

Step 3: Remove the Old Pull Rope

  1. Locate the rope guide on the recoil starter assembly. It’s the small plastic or metal piece that the rope passes through.
  2. If there is any rope remaining, pull it out of the assembly until you feel resistance from the recoil spring.
  3. Hold the rope securely and allow the recoil pulley to slowly unwind until all tension is released from the spring.
  4. If the rope is broken, you may need to use needle-nose pliers to grab the end of the rope inside the pulley and pull it out.
  5. Once the rope is fully extended, untie the knot at the end of the rope that secures it to the starter grip handle.
  6. Remove the old rope completely from the recoil starter assembly.

Step 4: Install the New Pull Rope

  1. Cut the new pull rope to the same length as the old rope using scissors. It’s better to have it slightly longer than too short.
  2. Melt both ends of the new rope with a lighter or matches to prevent fraying.
  3. Thread one end of the new rope through the hole in the recoil pulley and tie a secure knot. Make sure the knot is tight and won’t slip through the hole.
  4. Wind the rope counterclockwise around the pulley, following the grooves. Leave about 12 inches of rope unwound.
  5. Thread the loose end of the rope through the rope guide and then through the starter grip handle.
  6. Tie another knot at the end of the rope, securing it to the starter grip handle. Melt the end of the rope once again to prevent fraying.

Step 5: Wind the Recoil Spring

  1. Hold the recoil starter assembly in one hand and the loose end of the rope in the other.
  2. Slowly turn the pulley counterclockwise 4-5 full rotations to pre-tension the recoil spring. You should feel the resistance increase as you wind.
  3. While holding the pulley in place, pull the rope out until the starter grip handle is about 12 inches from the recoil starter assembly.
  4. Slowly release the pulley, allowing it to wind the rope back onto itself. The starter grip handle should retract until it rests against the rope guide.

Step 6: Reinstall the Recoil Starter Assembly

  1. Place the recoil starter assembly back onto the engine, aligning the mounting holes.
  2. Secure the assembly to the engine using the four bolts you removed earlier. Tighten the bolts evenly using a 10mm socket or wrench.
  3. Reconnect the spark plug boot.

Step 7: Test the New Pull Rope

  1. Ensure the area around the generator is clear of any obstructions.
  2. Put on safety glasses and work gloves.
  3. Grip the starter handle and pull the rope slowly to feel for any resistance or binding. The rope should pull smoothly and retract fully when released.
  4. If everything feels normal, give the rope a few quick, firm pulls as if you were starting the engine. The rope should continue to function smoothly.

Troubleshooting

What if the rope doesn’t retract fully?

If the rope doesn’t retract fully or feels sluggish, the recoil spring may not have been wound tightly enough. Remove the recoil starter assembly and repeat step 5, adding an extra turn or two to the pulley when pre-tensioning the spring.

What if the rope binds or gets stuck?

If the rope binds or gets stuck, there may be an issue with the rope guide or the pulley. Disassemble the recoil starter and inspect these components for damage or obstruction. Clean or replace parts as necessary.

Can I use any rope as a replacement?

While it’s best to use a genuine Honda replacement rope or an equivalent, in an emergency, you can use a similar-sized nylon or polypropylene rope as a temporary fix. However, make sure to replace it with the correct part as soon as possible for optimal performance and reliability.

Preventive Maintenance

To extend the life of your pull rope and avoid premature failure, follow these maintenance tips:

  • Inspect the rope regularly for signs of wear, fraying, or damage. Replace the rope at the first sign of deterioration.
  • Avoid letting the rope snap back violently when starting the engine. Always guide the rope back gently to prevent damage to the recoil mechanism.
  • Store your generator in a dry, protected area to prevent moisture and debris from affecting the recoil starter components.
  • If your generator sits unused for extended periods, occasionally pull the starter rope a few times to keep the recoil mechanism and engine components lubricated and moving freely.

Conclusion

Changing the pull rope on your Honda EU7000iS generator is a straightforward task that can be completed with basic tools and a little know-how. By following the steps outlined in this guide and adhering to the preventive maintenance tips, you can ensure that your generator’s recoil starter remains in good working order, ready to provide reliable starting power when you need it most.

Remember, if you encounter any difficulties or are unsure about any aspect of the repair process, consult your generator’s owner’s manual or seek the assistance of a qualified technician. With proper care and maintenance, your Honda generator will continue to serve you well for years to come.

Justin

Hi, I'm Justin, a car enthusiast turned mechanic. The garage is my second home, where each engine and part tells a unique story. Seeing car owners frustrated with issues inspired me to start DIY Car Expert, offering reliable solutions to tackle problems with ease. 🚗✨

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