Onan generator starter noise and more

scott shean

New member
Sep 26, 1998
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I have been a GMC owner for 16 years, and a subscriber to this list for more
than a year. I think Patrick Flowers is doing a great job of managing the
"net", and I have learned a lot from the comments of the participants.
Thank you Patrick.

The recent thread about a strange noise coming from the Onan generator
starter reminded me to comment to this list the solution of an intermittent
starting problem on my 6KW Onan generator.

My GMC has the generator battery installed in the front driver's side engine
compartment, and is connected to the generator through a 50 amp thermal
breaker located near the battery. Sometimes, during starting, the starter
would engage for a few seconds and then trip the breaker. During those few
seconds, the starter did not sound "normal". The main lead to the starter
would become noticeably warm to the touch, so I suspected a poor connection
was causing a voltage drop and corresponding high current. I checked the
voltage at the starter, and there was some drop from the static condition,
but the breaker would trip before a good reading could be taken. I then
cleaned all of the 12 volt connections. The problem went disappeared, and I
thought I had actually fixed it. But it didn't take long for the problem to
return. I then removed the starter and disassembled and cleaned the starter
and the starter solenoid. The problem remained. Next I replaced the
solenoid, using a 1976 Mazda (based upon the good advise of the GMCnet).
The problem remained. Next I changed the bushings on the starter. The
problem continued.

In desperation, I went to an RV repair shop, where it took the mechanic only
a minute to notice that the wire to the electric choke was shorting on the
choke housing. He moved the wire slightly and the problem was solved. I
have since insulated the wire with electrical tape in an effort to avoid the
$100+ that Onan wants for their precious choke.

As this is the my first venture onto the GMC Net, I want to also comment on
the fine assistance I received recently from Jim Bounds when I was traveling
through Florida with an engine overheating problem. Given the description
of my problem, and the direction that I was heading, (I thought I had blown
a head gasket---or worse) Jim suggested that I travel to Alex Sirum's in
Okeechobee, FL. It was a gratifying experience to receive friendly
assistance on the road from Jim, and to finally visit a shop of Master
Mechanics of GMCs. Alex and Jeff really know what they are doing. They
adjusted their busy schedule to accommodate me, and had me going again the
same day. These are really nice people too. You can't go wrong by visiting
their shop for GMC maintenance.

Scott Shean
Baton Rouge, La
shean