Onan 4KY on a 2001 Minni Winnie would not run until!!
Thought I would post problems with an Onan 4KY model not running. I spent nearly two days on this with success and no injuries!
Flooded when first tried. Gas coming out the air cleaner housing.:EError 36 on the indicator lamp. attemp #1 at cleaning and reassembling carb resulted in error 14 after running a few minutes.(over frequency which I confirmed with Fluke meter) Read all the info on this forum and decided to take the Carburetor off and clean it the best I could again though it is deemed not serviceable by Onan in the maintenance service manual. 250$ American to replace!!!:(
TURN OFF 12 VOLT POWER TO THE COACH OR LIFT BATTERY NEGATIVE. NO ARCHY SPARKY! or booms for that matter!
After removing the air cleaner and the two through bolts mounting the carburetor.(do not loose washers) Loosen two torx #30 screws of the air cleaner housing and as one post said: loosen the air cleaner housing and pry it out so the choke plate can clear to remove the Carburetor. Putting one of the wing nuts on backwards helps with this prying!That is critical and certainly not mentioned in the Onan manual. Disconnect the fuel solenoid wiring and fuel line. (Slip connector behind the carb for +VDC and a torx #30 for the ground. Don't loose the two star washers)Lift Carburetor out toward you and Carefully disconnect the Choke linkage (to your left and NOTE THAT THE LEVER FACES TOWARD THE BACK OF THE CARBURETOR. THIS IS OPPOSITE OF ONE VERY WELL MEANING POSTED PICTURE in the RV.Net archives on this subject. The linkage hooks into this lever and must be this way as the choke spring PULLS on this lever to open as the engine warms! Will not work and interfere with the throttle governor linkage if not correct. (Ask How I Know) Disconnect the throttle linkage and the tiny spring of the linkage in the same hole with needle nose pliers.
Take Carburetor to a safe location and have at least one can of Gumout or other cleaner.Remove the bottom screw on the bottom of the bowl which is the bowl drain. Remove the fuel solenoid with wrenches and set aside after cleaning. This allows you to clean this jet inside the carburetor and the solenoid itself. Gently, FIRMLY, PERSISTANTLY PRY THE ALTITUDE BLACK LEVER OFF WHILE NOT ROTATING. After removing black plastic lever set it aside. Mark metal adjustment knob and turn in this screw until it bottoms out. Record the number of turns. Mine was 1.75 turns out from seated. Unscrew and remove this needle jet with spring and set aside after cleaning it. Clean the tip with gumout.
Now you must hose the******out of every orifice on that Carburetor. I cut the red sprayer tube end at a 45 degree angle to get it inside the small ports better. Note the two brass colored small ports on the air cleaner side of the carburetor bore. Spray Spray Spray and look for the exit of the spray. KEEP IT OUT OF YOUR FACE AND EYES Use the whole can. You do not want to repeat this whole procedure or go to the Doctor!
Install altitude adjustment screw the same number of turns you recorded from seated and install the fuel shutoff solenoid and bowl drain screw.
Note the little spring on the Choke lever that it stayed in place and survived the procedure. There are many pictures on this forum and Google images to see this. Position Carburetor in place. Connect the fuel shutoff solenoid wiring and position the choke lever AWAY FROM YOU. Connect the choke and throttle linkage. Don't forget the little spring in the same hole as the throttle linkage. Press out the air cleaner housing to get the carburetor in place.
Fight the through bolts to get them mounted and threaded in without losing washers!. I used 1/4 inch drive ratchet with extension with #10 socket. Persistence will pay off. #30 torx for the air cleaner housing screws that were loosened. If you like you can test the fuel pump before you connect it back to the carb. Connect battery power back to your motor home. Press PRIME button on generator to pump gas into a coffee can to verify pump operation. Connect fuel line to Carburetor.
Do three Hail Marys and apply mirical spring water from Peter Popoff!
Prime Carburetor first and make sure any loads in coach are minimal.
Pray and Start Gen Set! If successful test with various loads including the grand poopah Air Conditioner. Monitor voltage and frequency.
Hope this post helps a few Rvers out there. Rv.net really helped me out on this one! Thanks
Flooded when first tried. Gas coming out the air cleaner housing.:EError 36 on the indicator lamp. attemp #1 at cleaning and reassembling carb resulted in error 14 after running a few minutes.(over frequency which I confirmed with Fluke meter) Read all the info on this forum and decided to take the Carburetor off and clean it the best I could again though it is deemed not serviceable by Onan in the maintenance service manual. 250$ American to replace!!!:(
TURN OFF 12 VOLT POWER TO THE COACH OR LIFT BATTERY NEGATIVE. NO ARCHY SPARKY! or booms for that matter!
After removing the air cleaner and the two through bolts mounting the carburetor.(do not loose washers) Loosen two torx #30 screws of the air cleaner housing and as one post said: loosen the air cleaner housing and pry it out so the choke plate can clear to remove the Carburetor. Putting one of the wing nuts on backwards helps with this prying!That is critical and certainly not mentioned in the Onan manual. Disconnect the fuel solenoid wiring and fuel line. (Slip connector behind the carb for +VDC and a torx #30 for the ground. Don't loose the two star washers)Lift Carburetor out toward you and Carefully disconnect the Choke linkage (to your left and NOTE THAT THE LEVER FACES TOWARD THE BACK OF THE CARBURETOR. THIS IS OPPOSITE OF ONE VERY WELL MEANING POSTED PICTURE in the RV.Net archives on this subject. The linkage hooks into this lever and must be this way as the choke spring PULLS on this lever to open as the engine warms! Will not work and interfere with the throttle governor linkage if not correct. (Ask How I Know) Disconnect the throttle linkage and the tiny spring of the linkage in the same hole with needle nose pliers.
Take Carburetor to a safe location and have at least one can of Gumout or other cleaner.Remove the bottom screw on the bottom of the bowl which is the bowl drain. Remove the fuel solenoid with wrenches and set aside after cleaning. This allows you to clean this jet inside the carburetor and the solenoid itself. Gently, FIRMLY, PERSISTANTLY PRY THE ALTITUDE BLACK LEVER OFF WHILE NOT ROTATING. After removing black plastic lever set it aside. Mark metal adjustment knob and turn in this screw until it bottoms out. Record the number of turns. Mine was 1.75 turns out from seated. Unscrew and remove this needle jet with spring and set aside after cleaning it. Clean the tip with gumout.
Now you must hose the******out of every orifice on that Carburetor. I cut the red sprayer tube end at a 45 degree angle to get it inside the small ports better. Note the two brass colored small ports on the air cleaner side of the carburetor bore. Spray Spray Spray and look for the exit of the spray. KEEP IT OUT OF YOUR FACE AND EYES Use the whole can. You do not want to repeat this whole procedure or go to the Doctor!
Install altitude adjustment screw the same number of turns you recorded from seated and install the fuel shutoff solenoid and bowl drain screw.
Note the little spring on the Choke lever that it stayed in place and survived the procedure. There are many pictures on this forum and Google images to see this. Position Carburetor in place. Connect the fuel shutoff solenoid wiring and position the choke lever AWAY FROM YOU. Connect the choke and throttle linkage. Don't forget the little spring in the same hole as the throttle linkage. Press out the air cleaner housing to get the carburetor in place.
Fight the through bolts to get them mounted and threaded in without losing washers!. I used 1/4 inch drive ratchet with extension with #10 socket. Persistence will pay off. #30 torx for the air cleaner housing screws that were loosened. If you like you can test the fuel pump before you connect it back to the carb. Connect battery power back to your motor home. Press PRIME button on generator to pump gas into a coffee can to verify pump operation. Connect fuel line to Carburetor.
Do three Hail Marys and apply mirical spring water from Peter Popoff!
Prime Carburetor first and make sure any loads in coach are minimal.
Pray and Start Gen Set! If successful test with various loads including the grand poopah Air Conditioner. Monitor voltage and frequency.
Hope this post helps a few Rvers out there. Rv.net really helped me out on this one! Thanks
