Onan’s plastic starter motor gear breaks easily Alternative?

[rajdude]

Hello everyone,
I am really tired of my Genset’s starter motor gear breaking or stripping.

This has happened twice in the past two years. Every time it happens, I replace the gear and the bendix drive…only to break again after some time. it is a royal pain to replace it. I have to drop the whole genset out of the Motorhome.


I see many other threads on the internet about people having the same problem. People say Onan makes it out of plastic to prevent damaging the flywheel. I say that is BS. All other starters I have seen have metal gears, nothing damages that heavy flywheel.



I have tried calling people who make aftermarket starters, hoping someone makes a different design…. Hopefully something with a metal gear but have not found any luck, yet.

Any alternative / solution?
Tips on getting the starter last longer?

By the way, Onan makes a Starter drive kit (p/n 191-2313, 191-2157). I can find it online for around 25 bucks. I can also find a aftermarket starter for $35. Last two times, I have replaced the drive kit only. This time I am thinking about trying to replace the whole starter.



My Genny’s Technical details:
Onan Model 4KY (Spec K)
4000 watts
Onan Starter. p/n 191-2351 (we have older p/n 192-2312)
Drive Gear: 24 teeth

[rajdude]

I have not tried to check that. I have ordered a new starter motor for it. Once I drop the genny, I will check the flywheel.

Not sure if that is the problem though.....because when the genset runs, it runs absolutely fine....runs fine on load as well.

Kpackpackkelley wrote:
How hard is the flywheel to turn by hand ? If its to hard to turn the valves may need set to spec.

[rajdude]

No I am not doing that. I always let the genny stop rotating before re-trying to start it.

Generator Jim wrote:
Could it be that you are reengaging the starter before the engine comes to a complete halt. ONAN specifically mentions that in their manual/s

JimL

[Kpackpackkelley]

How hard is the flywheel to turn by hand ? If its to hard to turn the valves may need set to spec.

[Generator_Jim]

Could it be that you are reengaging the starter before the engine comes to a complete halt. ONAN specifically mentions that in their manual/s

JimL

[MEXICOWANDERER]

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(425) 264-1700