Honda EU2000i gas cap rattle.

3oaks wrote:
If not maybe Honda changed the design to allow air in while the gas is being consumed without flipping the little lever. :@

Original EU2000i models, up through about 2010, used a loose (not tethered) fuel cap with a flip-lever to open/close the vent. It tightens like any other small gas engine cap, just twist it until snug.



Later/current production uses a larger, fatter cap (it has a charcoal donut inside to help capture evaporative emissions). This cap also has the flip-lever for venting, and is tethered to the filler neck. The new-style cap also has a positive, ratcheting "click" design, which tells the operator the cap is properly tightened.

The original small cap should not rattle at all when tight. The newer cap does have a tiny bit of 'slop' due to the ratchet design. However, it is not enough to cause any noise. If there is an actual rattle from the cap, and it's been tightened enough to make the proper 'click' sound, there may be an issue with the cap or filler neck.

Honda's warranty covers defective parts, and a dealer can inspect and tell you if the cap is indeed defective.

- - -
I work for Honda, but the preceding is my opinion alone.
Robert@Honda

I just got a new EU2000 and the cap rattles. My cap is one that clicks when it is tight but the top part moves when you touch it. I think they changed the cap.

3oaks wrote:
Just checked inside of my cap and there is a rubber gasket inside the top of the cap. Check yours out.

Also, does your cap have a little lever on it to close or open the vent while running the generator like my Honda EU2000 does? If not maybe Honda changed the design to allow air in while the gas is being consumed without flipping the little lever. :@

The newer cap is much bigger than the old Honda EU2000i , still has the vent lever. Hard to explain, new cap is like old cap but with a separate plastic cover over it. The gas cap itself is sealing but the cover is loose.

Just checked inside of my cap and there is a rubber gasket inside the top of the cap. Check yours out.

Also, does your cap have a little lever on it to close or open the vent while running the generator like my Honda EU2000 does? If not maybe Honda changed the design to allow air in while the gas is being consumed without flipping the little lever. :@

I took the genset back to the store and they looked it over. On their display model the cap has some movement but not as much as mine. The manager (bless his heart) took the cap off the display and put it on mine.

Brought it home and it still rattles, not as bad but not what I expect from Honda.

I was looking and wondering about swapping out the cap from the old one and noticed if I pulled up on the new cap it kind of locks in place and stops rattling. Not a clear lock a kinda locks. I checked and nothing in the manual about it. Thanks Jim

Duct Tape over top of cap.

Look. Wet a towel and place it atop the cap. The noise will be chopped in half. This shouldn't become a "Vacation Ruiner"

Trying to get ready to go on vacation, but if I must go, I must go to the store then I must go.

Really not the answer I was looking for but many thanks. Jim

The Correct answers are above. My answer is below:

New Honda anti-theft non electrical alarm. When you can't hear the rattle, your generator is gamboling away through the woods.