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Kober's avatar
Kober
Explorer
Jun 14, 2018

Dumba$$ at it again

So after a two week trip and long trip home and 16 hours on the road we got home at 0300AM. Went immediately to bed and when I looked at the toyhauler the next morning I noticed the exhaust pipe from the 5500 Onan gen set was pointing back at about 45 degrees instead of straight out. I looked at the tailpipe and it has marks on it which lead me to believe I hit something pretty hard although neither my tow vehicle nor the RV steps or anything else on that side show any damage.
Long story short, it ripped the rubber strap holding it to the plumbers tape which is screwed to the frame. No biggie there but now the entire exhaust system is loose. I see where the system is resting on springs and it looks like it's come loose from the exhaust manifold.
Is this something I can fix myself? I have an extended warranty on the genset but will they cover that? Anyone with experience in this area? I can't be the only dummy that's ever ripped the exhaust loose like this, lol!
  • Onan 5500 generator from that era have 2 mufflers, the exhaust pipe connects directly to the second muffler. The Onan parts list has both the rear(which mine does) or side which yours does. It really is quite easy to look and see if the pipe is bent/damaged or the muffler is damaged.

    To really see anything of the muffler, you would need to remove the generator. Google the service manual and you can tell what the parts look like.

    On mine, the exhaust pipe mounts directly to the muffler and the threaded holes in the muffler's flange are perpendicular to the axis of the chassis, but mine is a rear exhaust. I believe yours will be the same but the exhaust pipe will have two bends while mine has just one.

    My 5500 has four mounting bolts to mount the generator to the MoHo, one two on each side in the corners.. When it was removed the tech used a pallet jack and supported the generator and removed the four bolts and dropped the generator straight down. Oh yeah, he removed the exhaust pipe, gas line and electrical first.
  • wa8yxm's avatar
    wa8yxm
    Explorer III
    The pipe can do this several ways.
    One way is to "Rotate" on the exhaust manifold If this happend rotate it back you may need to replace the manifold gasket (The one between mainfold and pipe) it is donut shaped gasket.

    If the manifold cracked, You need to remove and replace it.

    If the pipe bent. Cut generator side of the break and have an exhaust shop make you a new "extension" based on the part you cut off.

    While at it have 'em make it a couple inces longerm Swedge the end out and drill a hole for the pin to lock in a Gen-Turi and Add a Gen-turi for when you are using it (You stow the Gen-Turi when driving, only put it out when generating and parked.
  • Community Alumni's avatar
    Community Alumni
    Don't feel bad. I've seen several bent generator exhaust pipes. Usually in rented motorhomes.
  • JoeH's avatar
    JoeH
    Explorer III
    I had a truck in front of me loose a tire and I could not avoid it. It ripped the exhaust off the front mounted 10K gense. Fortunately that was the only damage. Got to the CG that we were staying at for a month , called Newmar and they sent me the replacement parts. Some things you just can't avoid.
  • wa8yxm's avatar
    wa8yxm
    Explorer III
    Happed to me when a DUI in a stolen pickup with stolen from a car plates creased my RV while it was parked. ... Insurance coverd that one.

    IF there is no damage to teh generator itself you can indeed fix it yourself.
  • Been there done that. On two motor homes. The rubber for myself lasted 5 years and 7 years. The pipe clamp is not very tight so you can get the pipe off when you have to work on the generator. Plumbers tape 2 1/4-20's and a couple of nylocks should be under $5 and you are good to go.
  • Not a warranty claim so much as an accident claim on your auto or RV insurance.

    Probably an easy fix but a few pictures would help with what to do.
  • j-d's avatar
    j-d
    Explorer II
    With some adaptive creativity I'm sure you can fix this unless say the exhaust manifold or muffler of the generator itself is damaged. Miscellaneous exhaust pipe, fittings, adapters, clamps and hangers are available at auto supply stores. I also found that "EMT" (meaning metal tubing) electrical conduit served as a curved tailpipe for an ONAN I installed in a coach awhile ago. That's available at big boxes like Lowe's and HD.

    Post a picture if you can. Should help us offer help.

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