Onan Microquiet 4000 making grinding noise, won't start.

I'm guessing it was the starter gear not fully engaging the fly wheel. The battery needed charged a bit and then the starter was able to full engage.

That's a good sound when they start. Did you figure what was grinding or chattering ?

UPDATE:
I got it started! I took the access panel off and I notices the throttle pushing up against a metal clip (I'm assuming it s the choke?). I moved the clip and pushed the start button and it started right up. Left it running for 2 hours and shut it down. Seems to be working fine now. Thanks for all the posts!

gotsmart wrote:

Kpackpackkelley wrote:
Here's your service manual 981-0530c onan service manual.
Before you try to start it anymore open the front and stick your http://www.cumminsonan.com/www/pdf/manuals/981-0530C.pdf hand to the left around the air cowling and turn the flywheel to see how hard it is to turn. If its really hard to turn clockwise its going to be hard for the starter to turn it too.
If you have to pull the starter to check the plastic gear you have to pull the top cover off the gen that's the hardest part you need torques head bits I don't remember the size.

Kpack, your link has 108 pages and includes the 2000W through 2800W KYD gensets. It may be a condensed/combined manual.
This one has 158 pages and is 4000W only: http://www.cumminsonan.com/www/pdf/manuals/981-0503.pdf
:h

To the OP: page 7 of the 0503 link shows how to decipher the model and serial numbers. Here is a Quickstart Guide for RV owners. Here is a spec sheet with a diagram that is a PITA to read.

Thanks I have the manual you posted. I searched and found this one on spec j thought maybe it was a little different. He's got both so that is a good thing.
Sounds like the the starter gear is bad. Those little things are a pain to change out. They have the cheaper versions on ebay of those starters I bought one of them one time and it was a pretty nice little starter.

OP, I'm not sure what kind of RV the Onan is in. But if it's an A, B or C with its own engine, try starting the chassis engine first and letting it run. Then try starting the Onan. Sometimes the higher voltage from the alternator is what the starter needs to spin thing fast enough to get the engine to start. (And if you already said you tried this, apologies.)

Jim, "I'm retired. Go around me."

Kpackpackkelley wrote:
Here's your service manual 981-0530c onan service manual.
Before you try to start it anymore open the front and stick your http://www.cumminsonan.com/www/pdf/manuals/981-0530C.pdf hand to the left around the air cowling and turn the flywheel to see how hard it is to turn. If its really hard to turn clockwise its going to be hard for the starter to turn it too.
If you have to pull the starter to check the plastic gear you have to pull the top cover off the gen that's the hardest part you need torques head bits I don't remember the size.

Kpack, your link has 108 pages and includes the 2000W through 2800W KYD gensets. It may be a condensed/combined manual.
This one has 158 pages and is 4000W only: http://www.cumminsonan.com/www/pdf/manuals/981-0503.pdf
:h

To the OP: page 7 of the 0503 link shows how to decipher the model and serial numbers. Here is a Quickstart Guide for RV owners. Here is a spec sheet with a diagram that is a PITA to read.

OK, battery is fully charged and the fly wheel turns easy. the crunching noise is minimal now but, it wont start. I still get an error code 4 and got a 36 yesterday? The fuel tank is at 1/2 tank. Any ideas???

The Torx size I needed to work around the blower housing on our 4KY was T-30. Tee-Thirty. I remember because I lost it and had to order another. Went out and tried T-30 just now to be sure, so be sure you have that size.

My guess is Low Temp, Thick Oil, Low Battery. It balked trying to crank then very likely damaged the drive gear. Or, hopefully, it just stayed out in the cranking position, jiggling the flywheel will free it, and it'll crank again

But I suggest charging the battery first, even if you have to pull it and take it home or inside. Low voltage damages motors.

Here's your service manual 981-0530c onan service manual.
Before you try to start it anymore open the front and stick your http://www.cumminsonan.com/www/pdf/manuals/981-0530C.pdf hand to the left around the air cowling and turn the flywheel to see how hard it is to turn. If its really hard to turn clockwise its going to be hard for the starter to turn it too.
If you have to pull the starter to check the plastic gear you have to pull the top cover off the gen that's the hardest part you need torques head bits I don't remember the size.

If it was built approximately 2008 you could have been hit by the defective batch of valve springs. I don't think your symptoms indicate that, just something to keep on the list of possibilities.