Onan Starting issues

[wayne rogewski]

Good Morning.

So Im having an odd issue with the Onan 6K and the starter making contact with the flywheel. I have taken the starter off, cleaned it, inspected and
tested it. It works just fine and when energized the starter gear throws out and retracts just fine. I dont think there is an issue with the starter
per se.

I replaced the Starter Bracket with one from Ragusa a few years back. I have replaced all 4 cushions earlier this year.

So when I hit the start button most of the time I can just hear the starter gear spinning. There is no meshing with the flywheel.

Id say I can hit the start button 50 times and 1 time it will make contact with the flywheel and start up right away. It runs fine when running,
makes power. No other issues at all.

I did have the flywheel off when I replaced the starter bracket a few years back. Im wondering if I did not torque it down enough?? Possibly this is
causing the flywheel to be "off" when the starter gear comes out to do its job?

What say the group? and Thank you as always.
--
77 Royale, Rear Dry Bath. 403, 3.55 Final Drive, Lenzi goodies, Patterson carb and dizzy.
Mid Michigan

 

[Ken B]

Well you have looked at the common things. The flywheel torque is not that much - 35 to 40 ft pounds. Do not over torque it because the shaft is
tapered and it will crack the flywheel at the key if driven on too much.

That said, I would be looking for a worn gear in the starter or worn fly wheel teeth. Then, I would be looking at the starter armature bushing.
Worn ones are common. Finally I would be looking the lubrication on the shaft where the gear moves in and out.

By the way. This is a common problem on airplane engines that do not get flown much. The armature shafts get rusty and the gear will not go out
all the way. On these engines we engage the starter bendix when parking them so the gear in in the flywheel for next time. Can't do that on an
Onan because the gear is retracted when the power is removed. On an airplane starter the bendix is only retracted when the engine actually starts.

Verify that the new starter bracket is still good and firmly attached.
--
Ken Burton - N9KB
76 Palm Beach
Hebron, Indiana

 

[jim kanomata1]

Your Bendex clutch is out, replace it.

> Well you have looked at the common things. The flywheel torque is not
> that much - 35 to 40 ft pounds. Do not over torque it because the shaft is
> tapered and it will crack the flywheel at the key if driven on too much.
>
> That said, I would be looking for a worn gear in the starter or worn fly
> wheel teeth. Then, I would be looking at the starter armature bushing.
> Worn ones are common. Finally I would be looking the lubrication on the
> shaft where the gear moves in and out.
>
> By the way. This is a common problem on airplane engines that do not get
> flown much. The armature shafts get rusty and the gear will not go out
> all the way. On these engines we engage the starter bendix when parking
> them so the gear in in the flywheel for next time. Can't do that on an
> Onan because the gear is retracted when the power is removed. On an
> airplane starter the bendix is only retracted when the engine actually
> starts.
>
> Verify that the new starter bracket is still good and firmly attached.
> --
> Ken Burton - N9KB
> 76 Palm Beach
> Hebron, Indiana
>
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--
Jim Kanomata
Applied/GMC, Newark,CA
jimk
http://www.appliedgmc.com
1-800-752-7502

 

[wayne rogewski]

Conclusion, its fixed and working correctly!

Ken was spot on as well as a few kind folks who emailed me. I replaced the armature bushings in the nose and the rear. Cleaned the commutator, and
lubricated the starter gear where it surrounds the armature shaft as this was dry and sticking. This also let some lubrication get down a bit more
and totally free up the action on the throw out when the solinoid engages.

In cleaning up the outside of the starter I noted the Onan Sticker which indicated part number 191-1052. This still seems to be a good newer number
for replacement starters. Amazon had them for like 70 bucks or so. Unknown quality, but at least that number is a bit newer and the photos do look
like correct replacements.

Really appreciate all the help. If anyone needs a nose bushing or rear bushing please PM me. Happy to mail you the bushings for the cost of postage.


--
77 Royale, Rear Dry Bath. 403, 3.55 Final Drive, Lenzi goodies, Patterson carb and dizzy.
Mid Michigan