Mercedes Mullins
Honda generators are popular for their fuel efficiency, but some users have reported challenges with extending the fuel tank to accommodate longer run times. This is a common issue for those who use their generators for camping, racing, or production work, where refuelling interruptions are undesirable. Extended run fuel tank systems are available for purchase, but they can be expensive, so some people opt to modify their own using boat fuel tanks or gas cans with DIY airtight caps. However, this requires careful consideration of the generator's fuel pump, gravity feed, and venting to ensure the system functions safely. Online forums and YouTube videos provide valuable resources for those seeking to extend the fuel capacity of their Honda generators.
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What You'll Learn
Honda generator fuel extender kit
The Bergs System Dual 6-Gallon Fuel Extender is a popular Honda generator fuel extender kit. It is a simple way to extend the run time of a suitcase-style generator and can be purchased on Amazon. The Bergs System uses a vacuum draw system, meaning there is no need to elevate a gas can above the generator. This patented product will extend the run time of the generator by up to 72 hours.
There are also a variety of DIY methods for extending the fuel tank of a Honda generator. One method involves purchasing an extended run cap from Amazon and a 6-gallon outboard boat tank. This method uses boat engine quick connectors. It is important to note that the auxiliary tank must be vented as that is now the generator's new tank vent. If it is closed, the system will lock and cannot suck fuel. Another DIY method involves drilling a hole through the top cap of a poly fuel can and running a hose from the adaptor cap on the generator into the can.
There are also a variety of extended run fuel tank kits available for purchase. These kits typically include a fuel cap and an approved extended run tank. It is recommended to use regular fuel line (1/8") and valves as needed when using these kits.
The price of extended run tanks for Honda generators can vary, with used tanks being sold for between $600 and $800.
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Using a boat fuel tank
There are a few things to consider when using a boat fuel tank for this purpose. Firstly, you will need to purchase an extended run cap for your Honda generator, as well as an approved extended run tank. You can find these on Amazon. The cap is important because it ensures that your auxiliary tank is vented, allowing the generator to suck fuel. If the vent is closed, the system will lock and be unable to draw fuel.
In addition, you will need to use a regular fuel line (1/8") and valves as needed, depending on whether you are running your system in parallel. It is also recommended to use a fuel pump to pump fuel from the boat tank to the auxiliary tank, as this will make the process easier and reduce the risk of spilling fuel.
When choosing a boat fuel tank, consider the Moeller brand, which is known for its durability and ability to withstand hot weather without becoming misshapen. You can also look for used outboard motor tanks at yard sales or on Craigslist to save money. Ensure that the tank you choose is EPA-certified and has the correct connector style and size for your Honda generator.
Finally, keep in mind that you will need to modify the original Honda gas caps by removing the plastic retainers. This is necessary to use the extended run caps when the extended tank is in use, and then replace the Honda caps during transport for safety.
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DIY options
If you're looking to extend the fuel tank on your Honda generator, there are a few DIY options you can consider. Here are some detailed instructions and suggestions to help you get started:
First, it's important to determine the model of your Honda generator and whether it has a fuel pump or is gravity-fed. This will impact the approach you take for your DIY project. Some Honda generators, such as the EU2000, have a fuel pump that can draw fuel from an auxiliary tank. For gravity-fed generators, you may need to install a Y-valve to allow fuel to flow from the external tank.
One option for extending the fuel tank is to purchase an extended run cap and an auxiliary tank. You can find these on Amazon or other online stores. The auxiliary tank should be vented to prevent the system from locking and ensure proper fuel suction. You can elevate the auxiliary tank to improve fuel flow, but make sure to use a fuel pressure regulator to prevent over-pressurizing the carb.
When connecting the auxiliary tank, use a fuel line with quick-connect fittings for a secure and fast connection. Ensure that all connections are airtight to maintain fuel flow and prevent leaks. You may need to drill holes and run hoses from the adaptor cap on the generator to the auxiliary tank.
If you're using a boat-type tank as your auxiliary tank, you can benefit from their design for refilling without interrupting the generator's operation. Regular gas cans may not offer the same convenience. Additionally, consider using a fuel gauge and squeeze bulb for easy priming of the system.
Lastly, pay attention to any fuel lines and hoses. You may need to clip or clamp certain hoses to direct fuel flow and prevent air intake. Refer to diagrams or seek guidance from experts if you're unsure which hoses to modify. Remember to always prioritize safety when working with fuel systems.
By following these steps and adapting them to your specific Honda generator model, you can successfully extend the fuel tank capacity and improve the refueling process.
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Fixing fuel tank suction issues
One of the most common issues with Honda generators is a lack of fuel in the tank. This can be caused by a variety of factors, such as a clogged carburettor, a faulty fuel gauge, or a broken fuel hose adapter. If your Honda generator is not starting, it is important to check the fuel level and address any potential issues with the fuel tank or supply.
To fix fuel tank suction issues, you should first refer to your Honda generator's troubleshooting manual, which provides instructions on how to conduct maintenance and troubleshoot common problems. Additionally, Honda provides videos that can guide you through the troubleshooting process.
If your Honda generator is not drawing fuel properly, there may be an issue with the fuel pump or the fuel line. Check that the fuel pump is functioning correctly and inspect the fuel line for any blockages or leaks. If the fuel line is clogged, you may need to replace it. Additionally, ensure that the fuel tank is vented properly, as mentioned earlier. A blocked or closed vent can prevent the generator from sucking fuel.
In some cases, the fuel tank may be full of debris, as reported by some Honda EU6500is generator owners. This can prevent proper fuel flow and cause starting issues. To address this, you may need to remove and clean the fuel tank, which is a medium-difficulty task that may take about an hour to complete.
If you are using an extended run fuel tank, ensure that you have a proper seal on the generator so that it pulls a vacuum on the auxiliary tank. This will ensure that the generator can draw fuel effectively from the extended tank. Refer to YouTube videos or purchase a ready-made kit for guidance on setting up an extended run fuel tank system.
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Benefits of extended fuel tanks
The benefits of extended fuel tanks for the Honda 2000 generator include:
Reduced downtime
Extended run fuel tanks allow for uninterrupted fuel supply, reducing shutdowns and disruptions. This is especially useful if you need to run your generator for 24 hours a day for several days at a time.
Safe refuelling
Extended fuel tanks eliminate the need to refuel the generator directly, reducing the risk of fire hazards and personal injuries caused by spilled fuel. If refuelling is required, it can be done at a safe distance by refuelling the extended tank rather than the generator's fuel tank.
Convenience
The larger fuel capacity of extended tanks means you can run your generator for longer periods without needing to refuel. This is especially beneficial if you need to run your generator for an entire day, as you can avoid interruptions to your work or activities.
Cost savings
Extended run fuel tanks can help you save money by reducing fuel wastage and theft. Buying fuel in bulk and storing it securely in an extended tank gives you greater control over your fuel costs.
Portability
Some extended fuel tanks come with built-in wheels, making it easy to transport a full tank to your desired location. This is especially useful if you need to move your generator between different sites or locations.
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Frequently asked questions
An extended fuel tank for a Honda generator allows for safe, hazard-free operation for extended periods of time, eliminating the need to refuel the generator during a production day. This reduces the risk of extreme fire hazards caused by refuelling a hot generator.
The extended run systems are great but can be overpriced for what they are. Boat fuel tanks are also expensive, so it may be more cost-effective to buy the kit and DIY.
If you have a Honda and need to elevate your tank, check for a leak in your tubing or fittings as this may cause the pump to suck air instead of fuel. If your generator is gravity-fed, you can install a Y-valve to feed from the onboard tank and an external tank. Ensure your auxiliary tank is vented as this is now the generator's new tank vent.
There are kits available on Amazon and from IPI Industries that include extended run caps and fuel pumps.
