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Old 07-05-2016, 07:17 AM   #1
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Location: Olathe, Kansas
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Help Replacing Onan Starter

I've got an Onan 5BGE and I think the starter is out, it just makes an awful grinding sound when trying to start. Engine is not frozen up as I can turn it over with an allen wrench.

I've tried to remove the starter and got the top bolt out and found out that it has a captured nut on the backside that fell out when I removed the bolt instead of a tapped hole. I can get to the bottom bolt with a socket and extension but I can't reach the bottom nut on the back side to replace it when it would fall out.

I don't have the resources to remove the generator itself sitting in my driveway so unless I find a way to get to that lower nut, I'll have to take it into the Onan dealer.
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Old 07-05-2016, 08:16 AM   #2
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I have a different model but I suspect that the for replacing the starter the Genset would typically need to be removed. It's a pain to remove but not as bad as you would think.

Do you have the manual?
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Old 07-05-2016, 09:14 AM   #3
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yes I have the original owners and install manual. I was just wishing that there was an easier way than removing the whole generator. I've got an motorcycle jack that would work but my driveway is at a slight slope. I thought about cutting a hole through the back case mount to fit my hand through to get to the lower nut. I'll look at it again tonight to see.
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Old 07-05-2016, 09:16 AM   #4
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You could go over to Smokstak.com and do a search. I've gotten a lot of help from the old timers over there.
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Old 07-05-2016, 09:30 AM   #5
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Quote:
Originally Posted by jcgribks View Post
I've got an Onan 5BGE and I think the starter is out, it just makes an awful grinding sound when trying to start. Engine is not frozen up as I can turn it over with an allen wrench.

I've tried to remove the starter and got the top bolt out and found out that it has a captured nut on the backside that fell out when I removed the bolt instead of a tapped hole. I can get to the bottom bolt with a socket and extension but I can't reach the bottom nut on the back side to replace it when it would fall out.
jcgribks
Using a telescoping magnet I was able to place that nut back into the hex shape recess in the aluminum housing.
18" Telescoping Magnet
Mel
'96 Safari, 6.3 kw Onan
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Old 07-05-2016, 10:07 AM   #6
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I've got a telescoping magnet and that's how i retrieved the top nut when it fell behind the generator but with the starter being tilted so that the 2 mounting bolts are approx. 1:00 and 7:00 I didn't know if I could the lower nut back on. Not too much room on my coach to work around the generator. On the right side of the generator, I only have a small window maybe 3" tall that I can see the starter. From the front I've been using a mirror back in the right corner to try and see. I'll stick my magnet back in there to see if I might have room. I'd hate to get the starter out and not get it back in.
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Old 07-05-2016, 10:24 AM   #7
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just tried to register over at Smokstak.com and can't get the registration right. It keep popping up to "spell out your city, state and country" and I've done that, spelled out Olathe, Kansas,. Even tried USA, United States, United States of America and still get the same message.
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