Onan 4000 Starter Problem

[@d19jordan57]

Well, you had a great sense of humor about the whole thing. I guess I'll go out and check for loose wires and hope for the best. Update (03/21/2024): my problem turned out to be that the flange by which the starter is bolted to the generator was no longer grounded to the starter. In testing I accidentally discovered that if I touch the black cable of my jumper cables to the metal starter case then the starter works. I then determined that the two smaller, unused terminals of the starter were grounded to the starter, so I ran a wire from one of them to one of the flange bolts, thus re-grounding the bolt flange. I bolted the starter to the generator and tested it and the generator starter was back in business. I put the generator back on the RV, reconnected all the wires, held my breath and tested it again -- it still worked. I'm guessing I saved myself $500 to $1000? Anyway, thanks for the howto on getting at the starter and putting things back together.

[@gabrieluribe1852]

I just replaced the starter on my RV's Onan 4000 but not even my wife and I couldn't align the screws, So my plumber son and his helps had to come and finish it up for us. 7/9/24.

[@locopilot1]

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 (it won't start if low oil becouse of sensores), gasoline more than 1\4 tank in the RV (also safety censors), sparkplug checked for good spark, check the manual circuit braker ( to be ON) at front motorhome engine compartment for 12v current to the gen 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 by rats so I replaced them, by this time it started but stay running only by keep pushing the switch on all the time, so I knew it was 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 unit) 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 becouse 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 put the air cooling assembly back and the rest of components including the cover, now it's ready to be installed at your RV. Once the gen it's installed back at your motorhome or RV start your gen to be tested for electric power but don't forget to flip the electric switch (on) at the gen electric panel (sometimes hiding under or around the electric controls) to transfer power to your RV GFCI main outlet and electric panel as well, if your it's equipped with GFCI reset it and tested for green led light indicating power is ready at you main breakers panel, flip your main switch (on) along the others ones at this moment if you still don't have power then it's a faulty main braker, flipping it many time sometimes make it work again, mine did it, lol!!! If yours didn't buy a new main breaker. If this can help eaven one person save time and $$$ it'll make me more happy, thanks for reading!!!

[@gabrieluribe1852]

Anyway, at least we got to see your nice gulf cart.👍

[@RiverratGoRVing]

Know what your going through had the frount of stater where spring and pin come apart and they don't sell those parts and to redizine to get stater to crank and start. Took me about the same amount of time.

[@asphaltadventurer]

Well, sure made for a cool video so we can all see what it looks like when pulled.

[@ottosaeroescapadesandwhatn8219]

Thanks, figured it might help someone

[@christopherbroderick535]

There's no video what's up with that

[@fsafety1391]

I appreciate your hard work and you saved a few bucks. Time to go camping.

[@gmccontractors]

Unreal

[@DieselRamcharger]

those amazon/china solenoids are pure crap.