ONAN 6.5 kw generator

[Trojan]

Well it finally happened. My 1973 6.5 KW Onan generator starter went south. Smoke and all. I don't know who installed my unit, but he should have his head checked out and his butt kicked. It took almost 3 hours to get the damn starter off. 3 bolts held it on. I had to cut the DC cable terminals off. I couldn't get the sound shield off. I have yet to figure out how I'm going to get it back together. The bolts inside the solenoid housing were just turning in the solenoid. After numerous cramps, back ache and many vulgar words. I got it off. I thought shit now I gotta find and buy a starter from ONAN. There goes my beer money. Well I took the starter over to my down the road starter and generator repair guy. I said Fred can you fix this? He looked at it, said YEP its an old Auto-lite starter. Then I told him it was for an old Onan. Give me a couple of days. Well I should know Friday. I didn't think Onan made all there own parts. Well maybe I'll have some beer money left since I don't have to go to Onan for parts. I can't think what the price from Onan would be. I don't even drink beer. BILL

 

[mobilemn1]

Have a coke, sit back and relax, and prepare for the cussing coming, while its going back in,,,,,

 

[Bob Bradley]

On my 7.5, I only used the 2 readily accessible bolts to re-mount my starter. As long as they're tight, it should hold fine. The starter housing sits tightly in the frame on the engine.

 

[REBrueckner]

Anytime you lose a 12volt ONAN starter, just take the old one to any alternator/starter automotive shop .....they will either recognize it and provide you another unit off the shelf or rebuild yours....My 1972 12 KW onan starter is a standard off the shelf Prestolite starter....the several starters I have come across over the years have all been standard automotive units....

And while I'm at it, faulty ONAN glow plugs can be replaced at 1/3 the cost with Champion brand....I posted the model equivalents (for my 12 volt, 12 KW onan) a few years ago but a good parts place will recognize equivalents....

 

[Trojan]

It's not that its going to be hard to put back in. It's just that they just drilled holes in the sound shield for the wires and the exhaust to go through. So you can't remove the shield without undoing all the wires from the batteries. That's 12 feet away. I was thinking about slotting the shield and making a plate with holes for the wires to feed through.

BILL

 

[Trojan]

Well I got my starter back. Looks great. $77. bucks. It just needed a cleaning and a new solenoid. I won't put it on until Monday.

BILL

 

[TedZ]

Use hex socket head cap screws and it will go back easily from the rear bolt perspective.

Ted

 

[Trojan]

Ill take a look at that. I think there is a ridge in the way of the Allen. I had to use an opened end wrench to get the bolts out and a box wrench to loosen them up.

BILL