ONAN GENERATOR REPAIR: Tips and Tricks!
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- เผยแพร่เมื่อ 26 ก.ค. 2024
- In this video: We replace the Carburetor, Circuit board, fuel pump, Oil pressure switch, Fuel filter, air filter, Oil filter, oil, both spark plugs including the difficult rear plug (yes we have a trick for that too!)
Parts list:
Onan 309-0322 Oil Switch for RV Gensets, etc. $12.62
www.partsfortechs.com/asapcar...
Air Filter # 140-2379 for Onan RV $13.85
www.partsfortechs.com/asapcar...
149-2279 Fuel Filter, Onan $10.40
www.partsfortechs.com/asapcar...
Spark Plug # RS17YX for Onan 167-0272 on RV Gensets $3.49
www.partsfortechs.com/asapcar...
PC Board for Onan 300-3763, 300-3763-01, 02, 03, 04, 300-5268-01 $129.95
www.partsfortechs.com/asapcar...
Onan 122-0645 Oil Filter for RV Gensets & Onan Engines $7.78
www.partsfortechs.com/asapcar...
A047N926 Fuel Pump, Onan replaces 149-2311-02 $68.48
www.partsfortechs.com/asapcar...
Airtex E11009 Fuel Pump (aftermarket pump we used) $35.78
www.amazon.com/gp/product/B00...
146-0663 Carburetor, Onan $326.34
www.partsfortechs.com/asapcar...
About $550.00 was spent on parts.
Probably the best Onan Generator "refurb" video I've found on TH-cam yet (and I've been looking!)
Thanks!
Dang, exactly what I was looking for, thanks so much for such an awesome video! Step by step and all parts called out, you guys rock!
Excellent Video I have no xp with small engine repair. This video is the Holly grail in this specific onan emerald Gen set. I wanted to Thank you. You saved my family from alot of stress and disappointment! Keep making videos!
We have been looking for a video showing how to repair this generator for a while now. So glad to finally find yours! This is amazing! Thank you! Gonna try to repair our Emerald Plus that we have on our 93 fleetwood bounder! Thanks !!!!
Thank you for this video. I have a '91 Class A that came with a 6500 Onan that currently has about the same amount of hours as yours (as of taping). You have given me a great idea to get to the back spark plug. Thanks again!
I'm sure I'll be referencing your video several times as I go through and tune it up. Again thanks.
Thank you for creating this video and listing out each part number! I just did the full maintenance on my Emerald Onan 4000 GenSet on a 1997 Lazy Daze. It fired right up and is humming along nicely. Seriously, this video was extremely helpful and appreciated!!
I have one of those. A 93' they'll be around for another 50 years taken care of properly.
One of the best informational videos. Thanks for taking the time to put this together. Genset run once a month minimum is fine under 50% load or more. The more often, the better. As a tech, RV shops don't rebuild carbs either, they are just replaced. You technically can DIY, but expect mixed results. Off brand cheap China carbs also are hit and miss with how long they last.
This was a great video. Thanks for posting, we’ll be using this as a jumping off point tomorrow as we begin to work on our generator.
Can't believe how much information I got from this video and how much money this video is going to save me best video I've ever seen! great quality! good work! No just wish me luck on all this I have to do by myself
wow you spent a lot of time and money on this. I have the same coach with 350 hrs on the hobbs meter
I have the same generator in my van. This video is gold to me thank you very much :-)
Very good in-depth display of what to do, But I have a different generator so I'll have to find one with my model you gave me a lot to look for, thank you, great video.
I smiled when I saw that custom-built "stubby" 1/2 inch wrench
THANK YOU!!!! I have a 1993 Fleetwood Flair 22ft. This is soooooo helpful!!!!!
Thank you for your video. I have this same generator. Your video is the only one I could find with this specific generator. We just purchased our class C motorhome, and I wanted to do some general maintenance. It runs great. Thanks for the list of parts, and part numbers. Great video. Your video saved me alot of money by doing these things myself.
Stan, Thanks for your comment. If you get a chance, I would love to hear what year, make, and model your Class C Motorhome is.
@@welcometomoorerving5800 Its a 2002 E 450 Ford chassis. Gulf Stream 23 ft. It only has a little over 37,000 original miles. The generator has a little over 200 hrs. From what we can tell it had 3 owners. It ended up at the auto auction. A guy purchased it that sells R.V's from his home as a business. There were no signs of leakage from the roof. The amazing part, everything works. I don't think the onan generator was ever serviced. The oil was really, really black. Air filter didn't look bad. The exterior of the oil filter was rusted. And looked really old. So I figured basic maintenance was in line. I had no idea where anything was on the generator. Only the oil filter as It was right up front. Started searching the internet, when I came across your video. Again thank you for posting. It helped immensely. Now I need to replace radiator hoses, a coolant flush, and transmission fluid and filter replace.
@@stanweiler4344 That's a real nice size motorhome. The advantage with that size is way more state park and National park camp sites available to you. I can't tell you how many times I have found a campsite "on line" only to find that the limit was 24 feet. As they say "you can park a smaller rig in a larger spot, but you can't park a larger rig in a smaller spot." Also, Most single parking spots are 20 feet so you can back that rig in and get it to easily to fit in single spot. Sounds like you really did your homework.
A great detailed video. Thank you
Thank you so much for such a good quality and helpful video. I have one of these generators in a 2002 R-Vision Trail-lite Class A Motorhome and need to service it.
Great Video. You did a great job explaining everything. They want $662 for this carburetor now. I was going to follow your lead but now I'm thinking of getting a new inverter generator instead. It will cost 200 less then the carburetor.
Thanks for the great detail on part numbers. I have the exact same model, so I've copied all of that data into my notes. :-)
Great video... thank you.
Dwight Jones: Thanks so much for you comment.
Well done!
Thanks for the video my generator is not working this gives me a good place to start.
Thanks for the heads-up on your video i have actually wat hed this a few times lol
I just worked on this generator yesterday. Had not run in 7 years. 2001 RV and onan had just over 200 hours. I didn’t have a cut down wrench but even loosening the front bolt which I could just get on it started to spin the bolt and zero way to hold it I thought. I was able to remove float bowl and clean jet and emulsion tube. I was unable to remove pilot jet though. Everything was full of gunk but amazingly it fired up and after a little adjustment it ran pretty well. I couldn’t run AC, microwave, and hairdryer all at once but perhaps that’s normal
"Older one like this 1994"... I'm working on a 77 buddy, mine's old
Hello, Great Video that you guys have created! On other hand I have the same unit I replaced my carburetor and fuel pump and filter to my surprise I fired it up and fuel was leaking out from under the exhaust behind the unit 😢
Can you help maybe I did something wrong??
THIS IS HOW I FIXED MINE, IN THE CASE OF....
"I CAN'T START MY GENERATOR"
It's has been two years since last time it was running, so I started by checking oil level full at gen dipstick (it won't start if low oil because of sensors) then I checked gasoline more than 1\4 tank in the RV (also safety sensors), sparkplug checked for good spark, also checked the manual reset circuit braker ( to be ON) at front motorhome engine compartment for 12v current to the generator to be able to start it, also cleaned the carburetor and even installed new one but same situation, then checked wires and found some has been chewed like gum by rats at the back of starting switch generator panel so I replaced them, at this time the generator started but stay running only by keep pushing the switch on all the time, so then finally I knew it was internal electrical problem from the engine itself, so I took the generator out from my RV to work in my garage, (I did this by myself with some tools and old Mayan tricks ) lol, it's really heavy for one person.
I disassemble the unit at my garage and started by removing the cover, then the cooling fan or flywheel unit (it's 2 items in one) until finally I was at the gen rotor and brushes assembly area and this is what I found: one more wire chewed by filthy rats plus the stinky rat nest in the middle of the generator motor coil, I fixed the wire and sanded the commutator copper contacts where the brushes are sitting becouse they were real duty with old urine from the rats, and of course I got rid off the stinky nest, lol!!!
Then I assembled everything back together and... bingo it's runing like a champion!!!
For this project materials involved was about $60.00 including an aftermarket new carburetor and an harmonic balancer/steering wheel puller (available at any auto parts for $25.00) to pull the aluminum fan out and (flywheel).
Just picture this: (Any gasoline engine run smooth if gasoline and DC current aren't interrupted) so following this important principle you'll always find the problem to be fixed.
Also if you have a onan microlite 4000 like mine, don't run it for more than a minute without the cover because you'll cook the engine real fast, also keep the eye on the aluminium fan and your fingers after cranking it in case you missing one or two members...just kidding, lol!!!
After testing the gen then I did put the air cooling assembly back and the rest of components including the cover, now it's ready to be installed at my RV.
Once the gen was installed back at my motorhome I started it to be tested for electric power but not before flipping the electric switch (on) at the gen starting control panel (sometimes hiding under or around the panel) to transfer power to my RV GFCI main outlet and electric panel as well, my motorhome it's equipped with GFCI so I reset it and tested for green led light indicating power is ready at my main breakers panel, so I turned my main breaker (on) along the others ones but no power was present at my breaker main switch (faulty main braker) so I flipped it many times, sometimes you can make it work again, mine did work, lol!!!
I'm happy because everything works now including the ref for cold drinks and AC for this crazy summer, lol! Later I'll buy me a new main braker, for now this is a resurrected generator story that needed to be shared.
If this can help eaven one person to save time and $$$ it'll make me more happy, thanks for reading!!!
Nice video.
I just bay a 1991 chevy motorhome.
Pace arrow by fleetwood.
And it will not do anything for the dash and for the generator switch.
What do you think it's will be.
I hope you answered my question
Thanks and God bless
Hi I have a a 1991 onan emerald plus gen set. It runs fine and powers the rv for 5minutes. Then surges, the house power goes out, it stays running but makes a loud clanking sound like there are loose
screws jumping around inside of it. When it calms down (idling) the house power comes back on.
Take carb apart blow all all the jets with compresses and carb cleaner.
Carburetor will work perfectly..
I did mine very simple.
I'm trying to get a spark from plug wires and no spark when I checked it. So should I replace the coil cylinder thing the wires are connected to? I have same generator
can i change out a circut board to a elecrtonic module on a 1970s 6kv diesel genset.
Wish I had seen this video before I changed out the carb on my generator
I like to know what replacement carburetor is used for this Genset Emerald 2 146-0663 Carburetor, Onan
My Onondaga marquis 5500 carb bowl don't have a nut or bolt ..so can't take off the float bowl ??help
You likely didn't need to replace the carbureator. All you had to do was blow it out with a few cycles of Sea Foam. Also, if you want to make a useful change, put in a fuel cut-off on the generator fuel line, then shut off the fuel and run the generator dry before storing/extended parking to avoid leaving gas in the system. Onan (surprisingly...or not) never provided this feature even though they know their products sit idle for long periods of time (eventual parts revenue ++ and design-for-failure). Also, you can easily bypass the main fuel line to a small gas can as needed to run a periodic cleaner cycle on the carb (since it is hard to do that effectively via the main RV gas tank). So, buy a 1 gallon can, a few feet of 1/4" fuel line, some Sea Foam and store with your maintenance gear. It is also possible to remove and periodically clean the oil sensor to help maintain smooth operation and it would be helpful if you indicated the fuse holder part #. With a little patience, I just restored a 1991 Emerald Plus 4000 to normal operation that had been idle *for years* for less than 1/10th of your shotgun-method repair cost. Replacing the carb should be the last thing to consider and only after some effort with a $7 can of Sea Foam (and again, it may take repeated cycles to fully eliminate the surging associated with clogged jets and/or poor fuel supply).
PlanetInanimate: Thanks for you comments. I would agree with you that a gas shut off switch would be a good item to have. We use our motorhome about 3 times a month. We have added an additional 100 hours onto the generator without any problems. The fuse holder part # was not given because we did not need to replace it ( the kit came with a fuse not the fuse holder).
Mine has a gray rectangular spare fuse holder for 2x glass fuses on the outside of the main panel. Still looking for a comparable (waterproof) part, since the end-cap was very old and fell off (missing). Harder to find than I thought it would be. Also, the ROP Shop 2-way, 1/4" valve ($15 on ebay) is a good choice for the generator to connect to the main gas tank and to allow for periodic clean-out from a small gas can. And...on the oil pressure switch, the opening pressure is only around 5psi, so it's easy to spray clean it periodically - it typically requires a 1 1/16" deep socket to remove it from the generator housing.
I added a fule shut off to my generator i get home shut off gas let run till it stops and and have no carb problems
@@johnmayfield7068 Hi John, I think that is a wonderful Idea. Thanks for your comments!
@@PlanetInanimate my fuse holder cap fell off from age. It is a 1992 year make. 341 hrs. On gen. I also changed to rubber gas line w/ added shut-off you did a pro job on vdo. Great help.
Necesito saber sobre graduación, de la aguja de mezcla de gasolina.
Nice video and Narration; Great music selection; suspect you cudda gotten away w/ simply a Fuel Pump change if a no start or surge was the issue?
Hi Terence, sorry it took awhile to get back to you. We drove the motorhome down to Los Angeles to help my older son move to Las Vegas. Rather than renting a U-Haul, we packed all of his furniture and belongings into the motorhome and drove it to Las Vegas! After moving him we stayed 4 nights at an Elks lodge in Henderson that did not have hookups. So it was great having the generator. It is still running great after the repair! We feel looking back that the carburetor was the number one reason why the generator was not performing correctly. However, because the other parts we so in expensive vs having a professional deal with just one item, not knowing when or if the others were also bad, it just made sense to do the other items. Just to have a professional look at the problem, not even fix it was $150.00, so you can understand why we replaced those parts. Hey thanks again for your comment!
Where did you get the parts for that older generator ?
I’m here because my copper fuel line snapped, I got a new fuel pump , can I just use a rubber fuel line?
Thank you so very much for this video. You are a great help. I just bought a 1991 allegro 24.5 motorhome with the exact same generators. I changed the fuel pump and the fuel filter the oil the spark plug on the generator. I also drained 25 gallons that was in the motorhomes fuel tank that had sat since 2006. The gas was practically red in color. Put some seafoam treatment in the new fuel and then started the generator and it ran for about an hour fairly well with just a little bit of surging went under load. But now it has stopped running. It’s surges but won’t stay on. I suspect the carburetor must be disgusting from all that red fuel sitting in since 2006. My question is should I replace the carburetor or should I give cleaning the Carburetor that’s on there now? The generator is fairly new at only 85 hours total time on it. Your thoughts?
If you have time. Try rebuilding the Carburetor yourself. You have nothing to lose and everything to gain. Remember, there are 2 spark plugs. So if you haven't already, change that rear spark plug after you have removed the carburetor (just like we showed in the video). After you have cleaned the carburetor yourself, cleaned out all the lines leading to the carburetor, installed a new fuel filter, then try starting it again. If it still runs poorly either you did not build it correctly or the lines did not get cleaned. If you feel the lines are clean then find a shop when you can take the carburetor in to have it rebuilt. Make sure you find out the price because the labor might be more costly then a new one. This is what you don't want: Get so frustrated after cleaning your carburetor that you throw the rest of the good generator away. That is what we saw on a TH-cam video and had made the decision to purchase a new carburetor. I hope this helps. Please keep us a informed. I'm cheering for you!
Welcome to Moore RVing Thank you, I’m taking the carb off Friday and will clean it out.. eBay has a new carb for $185.00 and I’ll buy it if cleaning this old one does not work ... I’ll keep you posted. Thanks for the advice!
Welcome to Moore RVing success!! Thank you so much for all the help.. pulled the carb out. The back carb bolt was welded to a small flange so I had to screw the head of the bolt and not the nut... other than that it was just like the video. I soaked the carb fully submerged overnight in carb cleaner. Then a good scrub, another soak and fully blown out with air compressor.. put it back in and it fired right up and stayed running for over an hour. Put it under load (ac and microwave on) and it ran perfectly ... thanks again!!!
@@DoAnythingNew Nicely done!
Hello, could you help me in the video? They don't show how to remove the part where the fuse goes. I can't remove it. Could someone help me?
Would a 1/2” crows foot work you think? It would absolutely allow me to use one for the first time ever.
In the video you can see the angles that you are working with. It's certainly not going to hurt anything by trying.
Which starter does this take?
Nothing, that's the way I wanna spend my next fishing/camping trip,/ vacation. FIXING MANUFACTURED JUNK!
What about a clicking solenoid. Replaced control board, starter, solenoid and batteries topped off. No changes.
Hi Chris, that's one I have not come across. Sorry can't be of more help.
I'm having difficulty loosening that back half inch nut on my carburetor. I've sprayed it a few times with WD40 with no luck. Any suggestions?
Make sure you cut your 1/2 wrench so that it still fits into the box but long enough to give you the leverage to break it loose. Make sure you are using a good quality wrench in the first place so that you do not strip the corners of the nut. They make a penetrating oil for stubborn nuts. Check with home depot or Lowes to see what they recommend. I hope you get that taken care of.
@@welcometomoorerving5800 I picked up a 1/2 inch stubby wrench at home depot. So now I have the clearance. But still having difficulty getting it loose.
Hi is there any way that I can get in contact with you I have the same generator it was given to me I did a tune up but when I connected the battery nothing happened I took apart the black housing where the mother board is located I have tow wires disconnected and I don't know where they go is a white and black wire can you please help me thank you ñ
Hi Carlos, If you want to take several good quality pictures of the the area and email them then we will see if we can find where the wires go. No promises, remember we are not professional mechanics but we will do our best. just type in the name of our youtube channel (all one word) @gmail.com.
Great I'll send you pictures as soon as possible
Hi I sent you an email with the pictures I hope you understand what I'm talking about thank you
@@carlosmfk5459 I sent you 4 pictures to your email. Looks like the inside of your box is different than mine. I hope the picture still help. Thanks Greg.
very good video no if you could help me I have the same generator in my homage engine year 99 I tried to start it and apparently I did not have enough gasoline and I was forcing it or trying to start it too many times that now it does not try to start it just makes a different sound someone read this message that can help me
Make sure you have a fully charged battery, and ALL electrical connections are super clean and tight including the 2 battery terminals, and the large cable that goes to the starter on the generator. Usually electronic/electrical problems are from loose/dirty connections. I use steel wool or a file or sandpaper to get connections clean and then spray with any brand of plastic safe electronic cleaner. Any Wal-Mart or auto parts store sells it. Good luck.