Onan 4000 Watt Generator, Not Making Power Part 1 

By far, the best video of how to fix onan gen, you're the man thanks!!!

Great video. I spent 2 days working on my 4000 microlite, replaced fuel pump and installed new pump outside the compartment to have quick access as soon as the new pump fails again. Removed carburetor and cleaned I very well. I was so happy to get it running again without mechanical skills. This happiness lasted 1 day because today stopped working. Went to check why and smoke and burnt plastic smell coming from the rotor fan. The new fuel line was a bit large and rubbed against the fan almost getting destroyed creating a hazard fire. Now it only runs if I keep pressing the switch. Man if I need to do what I’m seeing probably I’ll need to throw the generator to the dump and get a second hand.

I love the way you tell it true thanks for the honest videos have a great day look forward to part two

Just wanted to say great video and thank you for answering many of your viewers questions. That always means a bunch to is

That was great! Sent a note to my brother about Mrs. Hill Billy’s puzzle from the last video I watched. Very entertaining as well as informative.

Good video. I think your one of those guys that could repair anything but a broken heart and the crack of dawn.

A lot of work. Waiting for the 2nd episode. Thanks Don

Great video.

Muy excelente trabajo

Awesome man thank you for sharing...

I ALWAYS make sure my repair men have overalls... they are the best!

Thanks

Thanks 😊

THIS IS HOW I FIXED MINE, IN THE CASE OF.... "I CAN'T START MY GENERATOR" It's has been two years since last time it was running, so I started by checking oil level full at gen dipstick (it won't start if low oil because of sensors) then I checked gasoline more than 1\4 tank in the RV (also safety sensors), sparkplug checked for good spark, also checked the manual reset circuit braker ( to be ON) at front motorhome engine compartment for 12v current to the generator to be able to start it, also cleaned the carburetor and even installed new one but same situation, then checked wires and found some has been chewed like gum by rats at the back of starting switch generator panel so I replaced them, at this time the generator started but stay running only by keep pushing the switch on all the time, so then finally I knew it was internal electrical problem from the engine itself, so I took the generator out from my RV to work in my garage, (I did this by myself with some tools and old Mayan tricks ) lol, it's really heavy for one person. I disassemble the unit at my garage and started by removing the cover, then the cooling fan or flywheel unit (it's 2 items in one) until finally I was at the gen rotor and brushes assembly area and this is what I found: one more wire chewed by filthy rats plus the stinky rat nest in the middle of the generator motor coil, I fixed the wire and sanded the commutator copper contacts where the brushes are sitting becouse they were real duty with old urine from the rats, and of course I got rid off the stinky nest, lol!!! Then I assembled everything back together and... bingo it's runing like a champion!!! For this project materials involved was about $60.00 including an aftermarket new carburetor and an harmonic balancer/steering wheel puller (available at any auto parts for $25.00) to pull the aluminum fan out and (flywheel). Just picture this: (Any gasoline engine run smooth if gasoline and DC current aren't interrupted) so following this important principle you'll always find the problem to be fixed. Also if you have a onan microlite 4000 like mine, don't run it for more than a minute without the cover because you'll cook the engine real fast, also keep the eye on the aluminium fan and your fingers after cranking it in case you missing one or two members...just kidding, lol!!! After testing the gen with the help of a gasoline container, a piece of hose and 12v battery, I did put the air cooling assembly back and the rest of components including the cover, then it was ready to be installed at my RV. Once the gen was installed back at my motorhome I started it to be tested for 120v electricity but not before flipping the AC circuit switch (on) at the gen starting control panel (sometimes hiding under or around the panel) to be able to transfer power to my RV GFCI main outlet and electric panel as well, my motorhome it's equipped with GFCI so I reset it and tested for green led light indicating power is ready at my main breakers panel, so I turned my main breaker (on) along the others ones but no power was present at my breaker main switch (faulty main braker) so I flipped it many times, sometimes you can make it work again, mine did work, lol!!! I'm happy because everything works now including the refrigerator for cold drinks and AC for this crazy summer, lol! Later I'll buy me a new main braker, for now this is a resurrected generator story that needed to be shared. If this can help eaven one person to save time and $$$ it'll make me more happy, thanks for reading.

Boy, I’ve changed oil a bunch on four of those we used at fiber optic regen sites along the pipeline. We had two in a small building mounted in a closet mounted on drawers. These things ran most of the day to charge batteries.

He's down to earth looks like stuff that would happen to me

Yep yep to clean up the slip rings with the Scotch-Brite pad. Then they look good as new.

Could you show how to install auto gen start directly to the gen

18:30 - I don't think my flywheel was threaded. I took a small punch and hit the key stock and the wheel just slipped off.

2021 onan 4000 generator ran last week now no solenoid click, no fault light on switch at generator silence. what do you think?

Yep same problem I had with mine one of the wires going to one of the brushes there was too short. I made a video about mine also. Can I have the same problem when I let go of the button the motor would die

Thanx for keeping it💯🇺🇸🇲🇽

I had the same problem would run 10 minutes to an hour. Ended up being the fuel pump. Most have auto shut off if they're low on oil also. Onan wanted 300.00 for fuel pump so I put a 12 volt electric fuel pump and rerouted line for under 25.00

My 6300 watts horse power are and if you got the manual servicio

Forgot one thing...Flight System sells a 'Slick stick' for cleaning the slip rings.

I am dealing with the exact same things and cannot get an answer as to which side of the brush block to plug the reattached F+ & F- to. The online wiring diagram only calls them F1 & F2. I also found the following in the service manual: "Connect the F2 lead wire to the outer brush terminal (near bearing) and the F1 lead wire to the inner brush terminal." This does not help me since my wires are F+ & F-. I wish someone could help me translate them. I watched a video from Flight Systems and he was working on a Marquis/Emerald generator and specifically said that the polarity mattered. I just don't know if that is the same with the 4000 micro quiet.

Love the video...great info. I have a question, my Onan 4000 it runs great but only puts out about 30V AC....my instinct tells me its the regulator what are your thoughts?

Hi I have a a 1991 onan emerald plus gen set. It runs fine and powers the rv for 5minutes. Then surges, the house power goes out, it stays running but makes a loud clanking sound like there are loose screws jumping around inside of it. When it calms down (idling) the house power comes back on.

My MEP003A is locked up, I bought it and it has been sitting outside with open exhaust. What's the best way to add oil to cylinders,too see if I can free it up. I have never worked on diesel engines. Where can I get manuals?

Hello. So I have a 90s Kohler 4500 ckm 21. I couldn’t get it to start with the start/stop switch. I removed it and left the wires disconnected and wired in a key switch. It starts fine now but no power. What did I do wrong

I got that cover off mine without unbolting it from the pan. 4KY P

I have an onan 4000 that fires right up but will only stay running if i hold the start switch down. It will run that way and throws a code 4 for overcrank and that is the only code. Any suggestions? Power is lost to the carb and i have swapped the control module with a known good one.

I've got a microlite 4000 spec B, trying to get the end bell off to remove the rotor seems the bearing is frozen where bell meets rotor shaft. Any way I can unfreeze/loosen this without causing damage to the bearing/rotor shaft?

how many hours was on the generator, and any idea why one brush was that much more worn. thanks as always.

back watching your video second time have you any experience with one of these starting with low-power say round 80 v over the let it run for around 10 minutes and it slowly builds up to normal 123 have you ever heard of this could have something to do with the brushes appreciate any thoughts 🦧 ✌️

Hey Hillbilly! I have a Onan Marquis 7000 in a 1997 Holiday Rambler. I changed the oil & filter, replaced spark plugs, replaced air filter, replaced fuel filter, replaced fuel pump, replaced fuel line, and checked all fuses. It now runs great, purrs like a kitten. However, it doesn't rev up when a load is applied. It will run fine under a small load but if I turn on one of air conditioners and another thing or two, it will bog down and shut off. It always starts right back up but when I repeat the process it has the same results. What would you check now?

The holes you use for the puller aren't tapped. you're going to have to tap them first and then use a puller to get the flywheel off

So a little verbose on the words. Showing the pin outs for the plugs would have been nice. Showing the wiring diagram would have been divine. Showing how to ohm out the brush block would have been made it a "super tech" video.

What is the part number for the muffler on the Onan 4000?

You need an impact to get that bolt out of the flywheel

Hello my friend I got a Jenni Rider Just like that What is a Six Thousand 32 watts I want to know how much horsepower Something About That things

Hi My onan generator start ok And power ok But no cranks Can you help me Thank you so much

I think you're supposed to tap those holes at like 8 mm if my memory serves me correctly..

Can I contact you about a generator issue I am having? Thanks

My onan 4000 watt generator the muffle it's running to hot.

high presser air in holes full of filings without eye protection ? silly boy

What a pain in the A I think I’ll keep my portable generator 🤬

I'm guessing you don't like working on generator's any more because...hmmm, I'm gonna take a guess...wait for it... they're a pain in the arse??!!!

!989