Onan Marquis 7000 generator starter failure
Went to start the generator before our annual trip to spring baseball in Lakeland. I could hear the starter motor engage, but the Bendix gears were just tearing themselves apart. Okay, 20 years is a...
Forum Discussion
A year or two ago I had to replace the starter on my Onan 4KY, which also involved dropping the generator as the starter motor was completely inaccessible without removing the outer case of the generator.
For me, at least, it was a tedious task, but fairly straightforward conceptually. Basically, disconnect the fuel line, the AC output wires (which in my case required removal of the voltage regulator and other control modules from the generator to get access to the connections), the chassis ground connection, the 12V power connection, and the wires for the remote control. After that, I supported the generator with a floor jack and took out the bolts holding it in its mounting cage, and then carefully lowered it with the jack. Reinstallation is just everything backwards.
I would suggest measuring and, if necessary, parking on ramps or whatever to provide plenty of clearance for the generator under the skirting of your motorhome so that you can move it entirely out if needed. Add a few inches for the jack, assuming you use a floor jack or transmission jack or similar. Maybe you won't need to pull it all the way out, but it is good to have that option if needed without undoing half your work should it become necessary.
I'd also suggest getting the fuel level in your tank below the point of the generator pickup so there's no chance of siphoning many gallons of fuel out of the tank when you disconnect the feed line. I plugged the end of the line with a stopper (a cork, in my case), but it was still good to know I wouldn't have a major spill regardless.
For me, at least, it was a tedious task, but fairly straightforward conceptually. Basically, disconnect the fuel line, the AC output wires (which in my case required removal of the voltage regulator and other control modules from the generator to get access to the connections), the chassis ground connection, the 12V power connection, and the wires for the remote control. After that, I supported the generator with a floor jack and took out the bolts holding it in its mounting cage, and then carefully lowered it with the jack. Reinstallation is just everything backwards.
I would suggest measuring and, if necessary, parking on ramps or whatever to provide plenty of clearance for the generator under the skirting of your motorhome so that you can move it entirely out if needed. Add a few inches for the jack, assuming you use a floor jack or transmission jack or similar. Maybe you won't need to pull it all the way out, but it is good to have that option if needed without undoing half your work should it become necessary.
I'd also suggest getting the fuel level in your tank below the point of the generator pickup so there's no chance of siphoning many gallons of fuel out of the tank when you disconnect the feed line. I plugged the end of the line with a stopper (a cork, in my case), but it was still good to know I wouldn't have a major spill regardless.
