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That’s a good point, but I did manages to rebuild the original head, and she runs and purrs to this day! Puts out good power too, my lithium battery bank is happy, as well as my AC unit when I’m camping and fishing! I know I’m no generator expert, but with the help of some nice people, I was able to bring her back to life with the original power head!

Ha! I could always just tie a bunch of hairdryers together and call it my “load bank” haha! My next project involving that Genset needs to be an auto priming system for cold starts. That would be a cool addition!

I’m not sure myself, but someone did commend about that, maybe they could help you? I’m sure it’s possible,but the retrofit may be more expensive than rebuilding the original. Try and budget out both before making the decision for sure!

I have an older 6500 watt Emerald 3 in my rv that doesn’t produce good power anymore. To replace the entire unit would cost me close to 10k. I did much research and found a place that will ship a replacement head to mate with my onan motor for about 1300 plus shipping. If you call them up, they’ll send you an email with instructions and a video of the measurements they need to make sure you get the right unit. Central Georgia Generator.

@@ErikL-qr8lr Do you by chance still have that company name or number to help out @mafosa8519? I’m sure he would appreciate it. Also, side question, are they really selling old Onan 6.5 gensets for 10K? That just sounds a lot to me. I remember buying mine for $300 used and not running. And spending $800 on all parts to get her running great again. So unless maybe it’s a new Genset that is rated at 6500watts, then I would be able to see that maybe running 10k.

@@ErikL-qr8lr that's great news for sure! you ever put a oscope on it? just curious about the power.

Sorry for my late response, this is what I believe my Genset serial number is to the best of my ability, it is quite worn after all. 6.5NHEFR26100E Hope that helps, and I’m glad my video could help you! I will try and answer any other questions you may have a bit faster, just have been busy with school haha!

I’m glad that you found my videos helpful, I know it can sure be a job to separate these things and put them back together, but once you do, they seem to just keep running forever, so they are worth it for sure! As for the Marquis, I am not as familiar with that models specifications, but that does sound kind of odd to put a part like that in a hard to reach area. But I do wish you the best of luck with it, I hope you can get it replaced successfully! If you have any questions, feel free to comment them here, and I will do what I can to answer them, to help out! Anyhow, take care and good luck on your Onan!

Rotor was Junk already, windings had failed, plus the flywheel was warped. The only reason you usually remove a rotor is to replace it with a new one. Which is what I did, and my Genset runs and purrs like a cat every day!

@@warriorcatsfan310 understood but, to a person that might have a good rotor or stator and is tearing into it should know that, don't you think?

@@deanhauser6626 Well it's a good thing for the comment section then, most people will read these when watching a video like this, and see important info then. I imagine not very many people will be doing a job like this unless they are replacing their rotor, but just in case to help people then, I will pin your comment at the top, so they are the most likely to see it, how's that sound? I will also add a note that my rotor was so easy to take off, that likely hitting it with that hammer probably wasn't even required, as once I used the impact gun method on the screw, it came sliding right off! So to anyone currently attempting this job, try the screw insert method first, and you might just find that, that's all it needs to come off, no banging necessary, unless its really stuck, and then use a rubber mallet instead, which I didn't own at the time, best of luck everyone!

Well hello again over here! Once again, I'm just gonna pin your comment for future viewers to see. Also fun fact, I never ended up using that bearing, because when I ordered the new rotor, it had the bear already pressed onto it, which is supposed to be how it goes on actually, as if I were to have tried to insert the bearing onto the rotor with it attached to the stator housing, it would have been a bad day. At the end of the day, pressing it onto the rotor first with Loctite bearing glue would be best, followed by a new gasket on the stator housing and that's it, and push the stator housing over the rotor with the bearing attached to the rotor firmly. Onan gensets are always a fun thing to deal with, that's for sure, I am just glad to be done working on mine, and it does a great job keeping my 13KW lithium system charged up with my 120A charger and keeps my inverter rig ready to go!

Thanks, I appreciate it! I hope it helped on whatever you may be doing to your genset! Take care and good luck!

Yes I did, the icy carb issue was resolved by two parts, the first by moving the Genset to a move enclosed space, and the second by slightly increasing the temperature of the air passing into the Genset by setting the rod between summer and winter air on the selector. Also this issue only occurs in very hot and humid places like where I live, so in the winter or colder days (below like 75) this issue doesn’t really occur so there is no need for those precautions (of course my Genset is permanently installed inside my RV so the heat in the compartment helps to keep the carb from getting icy at all). As for your issue, find that fuel leak and fix it immediately, as fuel can drip onto a hot surface and possibly ignite causing a fire or worse situation. The fuel on the Genset follows a simple path from the input line going into the fuel pump, then the metal line that snakes from the fuel pump to the carb, and then from there, there should be no more possibilities of fuel leaking past the intake. So try and locate when and how the fuel leak starts and then try and localize the area it is coming from. Let me know if you find a general area the fuel is coming from 👌🏻. Lastly the choke kicking back is likely it stumbling, check my older videos of this same Genset for when it was stumbling and see if it matches the description you are telling me, if so, you need to calibrate your carb fuel mixture (possibly clean the carb deeply which I have a video on too) and check governor adjustments, and if that doesn’t do it, also check your points and condenser, as well as your electric choke adjustments. All of those work together to make your set run smooth, and if one or more fall out of whack, they can all cause the Genset to bog down and die out. The choke kicking back is a sign of loss of vacuum, so it can just be a sign of the engine not getting good fuel mixture and ignition timing (or plugs, also check your coil too while you are at it) doesn’t hurt to check all these things and make sure your set is healthy and in order. Anyhow, I wish you the best of luck, and let me know how things go! Take care and have a good one! ~ Will

I figured back then that, that’s what they were for, but it’s good to have confirmation! Thanks I appreciate it, it was a long rebuild process on my Genset, and I am happy to say that it’s purring along to this day!

Unfortunately I don't have a source myself that can provide a new governor rod, but I may know a group of people who could help. I would recommend going to a website known as SmokStak, they are an online forum and you can post a question in the Onan generator section. That's where I learned the majority of the things that I know today about my genset. Anyhow, I wish you luck, and have a good rest of your week!

Wow, well that does really suck honestly. down here in Florida the gas isn't much better, but I have had any issues at least with my Onan's rubber degrading due to the content of the gas being higher than advertised. I have had it ruin one of my boats and had to re-do the fuel system in it, but soon after that issue I just started running ethanol free gas in all my boats and lawnmowing equipment. As for my motorhome today, I still use standard 87 octane in it for the gas, which both the main engine, and my Onan Genset feeds off of. So far so good on that, however I don't live full time in my RV, as well as I also have a hybrid inverter system that is heavy duty and picks up a lot of slack from the genset. So my Onan doesn't work very hard all in all. I mostly just use it to recharge my 12KW battery bank that my inverter uses to run everything in my RV, including the rooftop air unit. Hopefully you can find a trustworthy gas source then, and I would upgrade to Neoprene rubber for anything coming into contact with ethanol that is degrading (fuel lines, washes, ETC.). Hopefully that does it for you at the end of the day, and if you have any further questions, feel free to leave a comment! I hope you can fix your gas situation with your Genset, it is truly sad to see how much damage ethanol can really cause, I wish you the best of luck! ~ Will

That's truly unfortunate, I'm sorry to hear about your forest that burned up in 21', as well as your faithful genset. As for Onan as a long term genset, I cant say I run mine continuously for 5 hours a day for 7 days a week, that is a heavy amount of runtime for any genset. Of course with proper maintenance done at the proper intervals, most gensets should be able to output at that level for extended periods of time. But that's like the equivalent of putting 30,000 miles a year on your car. Yeah its going to hold up if its reliable, but even after holding up for so long, even the most durable of parts will wear out and need replacing. That's the big fault of any engine, or anything with a large amount of moving parts, friction is the true enemy of time, and it will patiently destroy everything. That's why for my RV off-grid set up, I mostly rely on a 4000W pure sine wave inverter, that is powered by 5 LiFePo4 batteries, at a total of 1000AH in parallel. The inverter system has proven to me to be extremely reliable, to the point where I would basically only run my genset for around 3-4 hours a day to run everything in my RV, including charging up my battery bank, and then just switch over to my inverter for the rest of the night, and into the next morning. It really saves my Genset being able to put the heavy lifting on the inverter, which has less moving parts, and saves me long-term in time and money for upkeep and repairs. I can't say I've ever really been disappointed by my Onan after I finished repairing it, and documenting my repairs for TH-cam, but I sure am glad to have a duel system, that rely on each other to share the load, rather than loading my genset constantly. At the end of the day, reliability is hard to find today, especially in moving parts, so if you manage to find it, be sure to hold on to it for sure! Or just make the ones you have last as long as possible, by caring extra for them, and change their oil early every time. That's the least we can do for our hard working machines, especially when they do so much to keep us comfortable. I hate how intricate they have made modern items as well with computers and too many sensors, but sometimes we just have to learn to adapt and go with the flow when there is no other option, and just learn to make it work as best as possible. If your Onan is still having trouble today, feel free to leave another comment detailing what's going on, and maybe I can help a bit, or at the least point you into a direction that will. Many kind and knowledgeable people helped me get my Onan where it is today, running smooth and strong, and I couldn't have done it without them, its always nice when you have others to help. So I wish you luck with your genset, and I hope you take care and stay safe out there! ~ Will

So while I do have the original “new carb” part number, I HIGHLY do not recommend buying one, as all mine did after doing this was spiral downword until I eventually removed the cheap carb, and rebuilt the original Nikki carb that it came with. As long as your original carb is intact, I recommend rebuilding it and getting new gaskets for it, as that will give you the best possible results. And I even made a video on this channel on how to completely rebuild and clean this exact original carburetor that is on this model! So check it out if you need guidance on how to completely rebuild the carb. Anyhow, if you have any further questions, just feel free to let me know, and good luck on your rebuild!

If you are holding it open all the time while it is running nag, and when you let go of it, it then closes and starves the engine of air, means that the vacuum pull off is not functioning, and should be examined for broken diaphragm, cracked vacuum hose, or missing linkage. If you have any further questions feel free to let me know!

Sorry for the late reply! If the choke isn’t moving on it’s own from the beginning, once the Genset has started. Then the vacuum pull off for the choke is malfunctioning. The choke should essentially be closed during cold start, and then once the engine is running it should pull a manifold vacuum, and a little vacuum powered choke puller, should pull and hold the choke open at all times while it’s running. Now the purpose of the heated choke element you see in this video that I adjusted, is to hold the choke open, even if the Genset is off, while it is still hot. That way if you were to start it again, while the Genset is hot, it wouldn’t have the choke closed on it, and would start just fine and not be flooded. If you have any further questions, please feel free to leave them here, and I will try to be quicker on my response next time! So take care, and good luck on your Emerald Genset!

I’m glad it helped you! If you have any questions, as always feel free to ask, and good luck on your Genset!

It’s been a while, but I’m pretty sure for my idle screw I started with it just barely making contact with the throttle. And then I adjusted it using frequency and voltage. While it’s running, you use a meter to check the frequency and set it to 60 HZ when it is idling. Also make sure you push the throttle against the screw while you are adjusting it and taking readings, since the governor will usually keep it away from it. As for the bowl adjustment, I believe I started with 2 and half turns out and went from there. If you have any more questions just feel free to let me know, and good luck with your Genset!

@@warriorcatsfan310 Using your recommendations I was able to get my carb set correctly. I bought a device at Harbor Freight to measure frequency at an outlet and got it dialed in to 60hz, give or take 1.

It’s been a while, but I’m pretty sure for my idle screw I started with it just barely making contact with the throttle. And then I adjusted it using frequency and voltage. While it’s running, you use a meter to check the frequency and set it to 60 HZ when it is idling. Also make sure you push the throttle against the screw while you are adjusting it and taking readings, since the governor will usually keep it away from it. As for the bowl adjustment, I believe I started with 2 and half turns out and went from there. If you have any more questions just feel free to let me know, and good luck with your Genset!

Yeah, you would be right. I ended up replacing that small little vacuum line, and the vacuum powered choke puller, and it works like a charm now!

That’s great! I’m so glad my videos have helped, I hope your Onan Genset is running smooth after being rebuilt!

Of course! I’m glad I was able to help and offer some insight for you! If you have any questions feel free to comment them here or on any of my videos and I will always do my best to respond. Take care and have a good one!

@@warriorcatsfan310 I was having the “hunting” problem as well, I watched the video and I think you solved my problem. Keep up the good work, the world needs problem solvers😊

@@matthewsentman5016 that’s good,‘I’m glad I could help! Just make sure for your Genset, that you test it at different load levels, like unloaded, 1000W, 1500W and so on to ensure the hunting condition doesn’t return. For my set it was multiple problems that caused it, like a bad governor spring, and the governed tension being improperly set. As well as the carb jets being dirty, and the carb not being tuned properly. Since my Genset sat for a long time, it had a good bit of kinks to work out, but I’m confident you can solve whatever issue you are having with your set, and I hope you permanently solved your hunting issue for good! Take care, and have a good one! ~ Will

Hope it helps! Good luck with your rebuild, let me know how it goes! If you have any questions, feel free to post them here and I will try to respond quickly! Anyhow, best of luck and take care!

I’m glad you found some useful tips and tricks from my Onan videos! If you have any questions feel free to post them here and I will do my best to help answer them! I may have one more video on my Onan coming in a month or two, now that the one in my videos is fully installed into my motorhome. Anyhow, thanks! And good luck on your 5500! I hope you are able to achieve whatever you are after with your rotor being removed!

Sounds like you had a challenge there, I'm glad you were able to overcome it! I've sadly put way more than $60 in my Genset, but I validate it by saying that its basically a new one, for 1/4 of the cost of a new one haha... but anyways, I'm sure your comment will help many people out who visit this video looking for assistance, so thank you for posting it! These gensets can be difficult to figure out, so its nice when the community comes together to help people fix up their gensets! I know I had a lot of help in fixing mine, so it was only fair to share it everyone else! I still have another video to post in the future, but I have to film it first, once I get my genset wired up and run new fuel lines in my RV for it. Then I get to fire it up for the first time on the main gas tank instead of an auxiliary one! After that thought, that will probably be it for my genset videos, and I will just watch out for comments from new people attempting to repair their own Onans! but Anyhow, thanks again for your comment, I hope you take care and have a good one!

@@warriorcatsfan310 Thanks for taking your time to read my mesage, I didn't have much memory in my cell to make a video and post it in TH-cam, that is the reason I sheared my experience in text only 🤣🤣 🤣

With the power output in pure amps and watts I can grab from this thing, I could run several boomboxes turned up to 11 playing Stranglehold by Ted Nugent, and it wouldn't even drop the Hz below 59!

It was a combination of a lot of things, but If I had to narrow it down to just for the hunting issue. I would say, cleaning the carb (Which I have a full video on for my NHE set), Replacing the governor spring and ensuring the governor was properly adjusted, Ensuring that the Carb was fully adjusted on the main set screw, and the auxiliary, and lastly just making sure the points were gapped properly and that the plugs where getting good spark. I think that is what heavily contributed to solving my hunting problem. If you have any further questions, feel free to let me know, and take care!

@@warriorcatsfan310 If your onan twin starts but surges, change the plugs. 99.995% of the time fixes it.

I’m sorry my reply is only finding you just now, but I want to further dive into what ever issue you are having with your genset in your holiday rambler. I’m on my phone now, but tomorrow I will log into my computer, and get the link for my parts site and attach it to a more detailed comment on your genset. Anyhow, until then, take care and thanks for your comment, I’m glad you found my video informative! Thanks for watching, from FL!

Here is my Second reply; So first off, The website I used for my parts and my genset particularly (NHE, Spec: E) Website: www.partsfortechs.com/index.php?main_page=page&id=9 Secondly, your issue: For the no spark, I would check your coil and coil connections first, then your points to ensure they are functioning properly. if all of those check out fine, then you can take a look at your wires and plugs for damage. as for the no fuel, most likely fuel pump, you can unplug it and energize it separately to test it and see if it functions. If it is working, then ensure your fuel lines are clean, and the carb bowl and float are clean and functioning properly. ( Cleaning the carb no matter what isn't a bad idea, I would never recommend replacing the original Nikki carb with an aftermarket china one ). Now if you clean the fuel lines, carb, and fuel pump is good. Ensure that your RV has at least 1/4 or more in the gas tank, or else the genset wont pick up on fuel since the pickup only goes down to the 1/4 level to ensure the gas engine on the vehicle can still get somewhere to acquire more fuel. Anyhow, if you have any further questions, feel free to comment them here, and I will be a bit more watchful and hopefully find them faster than a month this time, thanks for watching, and take care!

Yeah, nowadays there’s no trouble starting up at all, and the Carb is doing great after being cleaned and maintained. And I also adjusted the Governor spring since this video, and it works very well nowadays, so it starts and runs perfectly. Thanks for your comment, I appreciate your input! Take care and stay safe out there! ~ Will

You are very welcome! I’m glad I could help you with my videos, and like I’ve said, if you have any questions just ask them here, and I will try to answer them for you. But good luck on your carb rebuild! It really does help when you clean it up, especially those hard to reach jets! Take care and have a good one!

I’m glad my video helped you out! If you have any questions you can also ask them here as well and I will do my best to answer! And there can be plenty of gremlins on these things, they are always fun to track down, but I think I got all of mine on my Genset luckily haha!

I used to store it at a friends house who had extra space, but nowadays I keep it in a RV storage facility not too far from my home. I am in Central Florida, if that’s also what the question was about, nice and hot here!

This video was intended to ask questions on what to do with those adjustments, I originally uploaded these videos to my forum on SmokStak, which detailed everything on how I repaired my genset. Now lucky for you, I do have a detailed choke adjustment video, you can find it on my channel, and it should help you adjust your choke properly. As for the carb, the only main adjustment you will need is the screw at the bottom of the bowl, and I have mine currently 2 turns out right now if I remember properly. Anyhow, if you have any questions about adjusting the Choke and carb, post them here and I can help you out!

Sir do you have the part number for the new carburator

Yeah I have the online manual link for it which I will include at the end of this comment. But you will find the wiring diagrams for all Specs. Of the Onan Emerald III in there. It’s in the B appendix of the manual, or PDF page 150-156, is all of the diagrams. There are a few more, but those are the majority of the systems. If you don’t mind me asking, what has caused your Onan Emerald III to stop working, and why do you suspect the wiring is bad? If you don’t mind giving the back story to your genset, I am curious as to why your genset is not running. Anyhow, I wish you luck with it nonetheless! Manual PDF Link; www.skilledcrafting.com/onanfiles/965-0528%20Onan%20BGE%20(spec%20F-K)%20NHE%20(spec%20E-K)%20Genset%20Service%20manual%20(09-1994)%20965-1060%20Supplement%20(spec%20M)%20(11-1995).pdf

Thanks, I appreciate it! I’m glad you found it helpful! My new (refurbished) rotor that I installed, I found with the help of my friends on a forum site called “smokstak” it was on eBay if I recall. And it was a lucky find. So you will probably have to do some digging and make sure you have the right model number of your rotor, and you may be able to find a re-wound rotor on Craigslist, or eBay, etc. it’s u fortunate they don’t manufacture these anymore, so the only way to get one is to find an old one that was refurbished, or the long way which is to buy to same genset as you already have (not running of course) and part it out to use it’s rotor for your genset (always make sure you test your windings before you buy a broken set to ensure the rotor is in good condition). You can also probably sell off the remaining parts of the donor set that you don’t want, and they will normally sell enough to get your money back on the donor set, or most of it at least. But sometimes that route is cheaper if you have the tools and patience. Anyhow, I hope this comment helped, and if you have any further questions, feel free to comment them below!

Thanks! One day it will look fancy, but for now, I’m not so worried about that haha

huh, I have been trying to figure the way mine was supposed to be connected. The original condenser was connected to the ground cable of the coil. but in some setups, I have seen the condenser mounted on the points breaker, so I think I am going to try and find a different style condenser and mount it on the points, and connect it to the positive feed side. I wont be able to connect it to my coil positive unfortunately, since the thread post broke, and I was forced to solder the main connection, so I will just probably keep it like that until I can get the new one. There was always a lot of strange things wrong with this genset when I got it, still working out those kinks. So thanks for the tip, I appreciate it!

I’m not sure exactly how much horse power the Cummins engine produces. The generator itself is rated at 6500 watts. With two plugs I would say it is at least 20 HP, but the exact number I do not know.

I’m glad my videos have helped you! If you have any questions about your set, feel free to comment them. And let me know how your Genset build goes! Take care and stay safe out there! 32746 USA says hello back!

sorry for my late response. The most I know about specialty output shafts for Onan Emerald sets, is that they did make a specialty shaft that was keyed and protruded from the end of the bell housing roughly 4 inches, and was keyed and had a threaded inner center. I believe they used that specialty shaft to drive something like a water pump or anything similar. That's about all I know, now if you or someone you know has the skills to weld on an extra extension to your existing shaft for an auxiliary drive, then you may be able to get it to do something extra for you, just be weary of how much strain you are going to put on the engine if you were to fully load down the genset. and your aux drive. But for small stuff I could see it being useful!