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KendallP's avatar
KendallP
Explorer
Aug 04, 2016

1986 Onan BFA 4 - Suddenly running rough

Well... as they say... "spark or fuel." I have my own suspicion, but I'd like to hear yours...

She's been running great for the last 2 years / 25 to 30 hours since plugs, points, cap and rotor, oil once a year regardless of minimal use and I never let the oil get more than a cup low. I use her mostly for running the roof air down the road.

With a trip to the waterslides in Redding, California planned, I picked up the rig from the storage yard a week ago. As if the tough vacuum leak diagnosis weren't enough, the gennie gave me trouble too.

She was running smooth as ever and shortly after I had parked in front of the house, she just up and quit. After a few attempts, I got her started again and she ran great again. So I figured maybe some water in the gas.

Well upon start up the next day before driving down the road, she started surging. After a half hour or so she smoothed out and ran fine down the road. Thank God because it was 95 at 7 p.m. and we were headed into the lion's den of Redding with no chassis air.

On the Siskiyou pass, she quit again. She seemed not to like the hills. Was the oil balling up in the rear of the sump and making bogging 'er down?

Later on she was running, but now surging again. So I shudder' down for the remainder of the trip. At least I was smart enough to book us into full hookups in Redding... where it hit 108 Saturday afternoon.

Similar performance on the way back. Fortunately it had cooled down a little and we had a mostly morning drive planned.

Now back home and upon start attempt she won't keep running until a couple dozen start attempts and then really rough with the surging.

Your thoughts?
  • TEXAS wrote:
    ...Who put cap and rotor on a BFA. Doesn't have either one.

    Apparently we have some ingenious techs around here!

    Hey TEXAS,

    You helped me with the Onan back about 6 years ago. Good to hear from you again and thanks for chiming in. Nice to have voices of real experience.

    Yeah, I'm sure they didn't install a cap and rotor. Faulty memory on my part. I do recall the tune up kit didn't include those. What was it... just plugs, points and condenser?
    .
  • Ductape wrote:
    You put that 50w in there, didn't you?...

    Ha!

    No.

    Now I'm considering trying 15W-40 in the 454 again in order to keep one type of oil as a spare, but actually, I don't care anymore. Doesn't hurt to have a spare quart of each. If I only had one spare quart and the 454 needed 3/4 and the Onan 1/2... well... I would be short, wouldn't I.
  • Most common thing is dirty carb. Followed by bad fuel pump. Who put cap and rotor on a BFA. Doesn't have either one.
  • Try some Seafoam after replacing the filter. If that doesn't work you will probably need to remove and clean the carb.
  • You put that 50w in there, didn't you? :B

    Sounds like fuel to me. Float level, or partially plugged jet.
  • OK, I determined that she would smooth out when I manually applied choke of about 90%. Had to be in just the right spot within like a millimeter. A little too much and she would cough and die unless I backed it off quickly. This lead me to believe it had to be fuel supply. It's not getting enough gas so limiting the air would compensate.

    With no desire to pull that carb in that tights space, I took the rig to Cummins yesterday. Later in the afternoon they called back and said it's good to go. Tech notes said he basically made some adjustments. I'm perplexed as this gennie went from smooth running for 30+ hours to dying suddenly one day and then having surge issues after that. Sure seems hard to imagine it just fell out of adjustment in an instant.

    I also have to wonder if the drive over didn't dislodge something?

    Or if the tech's adjustments didn't dislodge something?

    I'm going to try and speak to the tech directly as I'm a bit nervous about our next boondock now.

    Any thoughts?
  • Sure sounds like a fuel delivery problem. With a rig that old, I'd be sure to check out the fuel lines for deterioration if they have never been replaced.
  • Gas, Spark, and Air.

    I had the same symptoms on my newer 5.5 Onan. Check the easy things first

    Float bowl: did a piece of dirt get through? Clean out float bowland jets.
    Plugs: is one fouling? Pull and check plugs.
    Fuel pump/filter: Is it pumping enough fuel? Is it getting weak after it gets hot? Is a dirty filter restricting flow? Check filter and pump.
    Vacuum leak: Vacuum leak will cause your symptoms. Check carb gaskets. Check vacuum line going to choke pull off. Check vacuum choke pull off.

    My issue ended up being the vacuum choke pull off. The pull off had a bad diaphragm. This caused the choke to stay completely engaged until the electric bimetallic spring opened the choke. This caused it to run rough the first few mutes until it warmed up. The secondary effect was once the choke was open the vacuum leak would cause the generator to run lean. Lean caused it to run hot. Eventually it would start to surge and then shut itself off.

    I replaced the pull off and no more issues.

    Good luck

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