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Old 09-19-2015, 02:32 PM   #15
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Decided to check everything over again before seeking professional help. Pretty sure all wiring connections are good and where they belong. All the wiring diagrams I have seen indicate there is a 5-amp slo-blo fuse somewhere in the wiring, usually located near the start switch.

My genny (a 4KY, Spec J) has no fuse on the start panel nor a place for one.

Does anyone know where the 5-amp fuse might be physically located?????

I would at least like to check this before shelling out $350 for a new controller.

Thanks
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Old 09-20-2015, 09:41 PM   #16
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Final update (Thank goodness)

Went over the wiring once more and found that I did have a wire connected on the wrong starter solenoid terminal. Corrected that and found that the solenoid would click repeatedly, and the starter tried to engage twice but failed. Finally decided I had probably screwed up the solenoid (or it just picked this time to die), and replaced the solenoid. The old genny fired up and ran, under load, for three straight hours without missing a lick. Apparently the first problem was, in fact, the fuel pump; and the other problems were my fault. Glad to say she's starting and running fine now.

By the way, I looked for an Onan replacement solenoid and found prices anywhere from $32 to $65 for the same part. Went to the auto parts store and bought a $12.99 12-volt solenoid for a lawn tractor, and it works perfectly. Even mounted ok in the same location. If it doesn't last very long, I'll spring for the Onan part.

Thanks to everyone for your thoughts and suggestions.
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