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03-14-2012, 12:08 PM
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#1
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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1991 generac NP-66G genset
The gen was running perfectly after I changed the oil, filters and plugs and now I have a starter issue, I hit the starter button and the starter motor spins and makes an ugly sound but does not engage the flywheel to start the motor.
I removed 4 bolts on the starter cover and broke it free but it only swings out a few inch and strikes the heaVY STEEL BRACKET SUPPORTING THE MUFFLER. thru the opening I can see part of the starter
Looking around with a flashlight thru the gen access door I can see only 3 bolts holding the engine top housing down and about 6 bolts holding the air inlet screen to the housing, (yes I have an exploded view of the sheet metal and all other parts of this thing) I just want to raise the housing about a 1/2 inch or so to get it off the starter cover so I can get at the starter.
Has anyone any experienced changing a starter on one of these that can give me some advice here?? I just hate to unscrew something that does not need unscrewing,.
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03-14-2012, 03:59 PM
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#2
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by Bilito
The gen was running perfectly after I changed the oil, filters and plugs and now I have a starter issue, I hit the starter button and the starter motor spins and makes an ugly sound but does not engage the flywheel to start the motor.
I removed 4 bolts on the starter cover and broke it free but it only swings out a few inch and strikes the heaVY STEEL BRACKET SUPPORTING THE MUFFLER. thru the opening I can see part of the starter
Looking around with a flashlight thru the gen access door I can see only 3 bolts holding the engine top housing down and about 6 bolts holding the air inlet screen to the housing, (yes I have an exploded view of the sheet metal and all other parts of this thing) I just want to raise the housing about a 1/2 inch or so to get it off the starter cover so I can get at the starter.
Has anyone any experienced changing a starter on one of these that can give me some advice here?? I just hate to unscrew something that does not need unscrewing,.
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I removed the air screen and sure enough, under it were two more bolts holding the top cover in place. well after some struggling in tight places I finally have access to the starter, but not so fast, one of the two starter attach bolts is just a tad behind the counter weight on the starter shaft, I have tried everything to get a socket on that bolt and all to no avail. The plastic gear is toast, there was a plastic retainer deal with a spring and some other parts that stopped the bendix gear from going too far up the shaft and it broke and the gear went way up jammed and got destroyed by the flywheel gear
I think there is something called a wobble extension for sockets that might let me get in there to remove that darn bolt, anyone ever heard of that???
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03-14-2012, 04:37 PM
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#3
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Senior Member
Join Date: Nov 2010
Location: hanson ma
Posts: 234
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removing starter
you are correct there are socket extensions that alow a limited amount of flexability harbor freight sells them at a reasnoble price lee
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03-14-2012, 05:02 PM
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#4
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by hometool
you are correct there are socket extensions that alow a limited amount of flexability harbor freight sells them at a reasnoble price lee
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We got a harbor freight a few miles away I will check that out tomorrow, thanks
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03-14-2012, 07:47 PM
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#5
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Junior Member
Join Date: Feb 2012
Location: Fairfax, VA
Posts: 18
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You are going to want a spring extension not a wobbly.
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03-14-2012, 08:06 PM
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#6
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by blaster88
You are going to want a spring extension not a wobbly.
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spring extension, I don't think you can get the torque I need to break the bolt loose with a spring
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03-14-2012, 08:23 PM
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#7
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Senior Member
Join Date: Jun 2009
Posts: 1,528
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Flex sockets are available many places (Lowes, Home depot, Auto Supply, Sears, Farm stores, etc.). Come in both american and metric sizes. Single sockets or sets. 3/8 or 1/2 drive. They also make flexable joints that go between the ratchet and a standard socket
Dave
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03-15-2012, 05:56 PM
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#8
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by Dave78Chief
Flex sockets are available many places (Lowes, Home depot, Auto Supply, Sears, Farm stores, etc.). Come in both american and metric sizes. Single sockets or sets. 3/8 or 1/2 drive. They also make flexable joints that go between the ratchet and a standard socket
Dave
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I have some U joint sockets, they do not fit in the space allowed, I bought a 1/4 inch wobble extension, I will connect a 1/2 inch small socket and try to get it in there and get that bolt off
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03-16-2012, 01:39 AM
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#9
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Senior Member
Vintage RV Owners Club Fleetwood Owners Club
Join Date: Jun 2009
Location: Somewhere in the woods in Belfair, WA, WA
Posts: 1,250
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I suspect that most often the entire gennie has to be dropped to work on them with any ease. Ours will drop down and forward to access the back.
__________________
Life rocks when your house rolls
Senior Chief & the Cheese Queen
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03-16-2012, 04:46 PM
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#10
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by Senior Chief
I suspect that most often the entire gennie has to be dropped to work on them with any ease. Ours will drop down and forward to access the back.
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I made my own tool and it worked, I took a 1/4 inch drive by 1/2 inch socket and ground it down to almost half it's size, combined that with a 1/4 inch wobble extension from harbor frieght and I got that last bolt out. I took the starter to the Generac dealer and they fixed it for 31 bucks, now the issue is to get it back in. No one around here has a 1/4 drive by 1/2 inch flexible socket not even Sears, so I made it work.
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03-20-2012, 02:39 PM
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#11
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Senior Member
Join Date: Jan 2012
Location: Cutler Bay, Florida
Posts: 707
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Quote:
Originally Posted by Bilito
I made my own tool and it worked, I took a 1/4 inch drive by 1/2 inch socket and ground it down to almost half it's size, combined that with a 1/4 inch wobble extension from harbor frieght and I got that last bolt out. I took the starter to the Generac dealer and they fixed it for 31 bucks, now the issue is to get it back in. No one around here has a 1/4 drive by 1/2 inch flexible socket not even Sears, so I made it work.
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Got the starter back in,m I installed the easy to reach bolt and my wife with her small hands and my home made special tool got the hard to get at bolt in. ONLY TOOK HER ABOUT A MINUTE
It's starting and running good again
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03-20-2012, 03:11 PM
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#12
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Senior Member
Join Date: Jul 2011
Posts: 221
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Quote:
Originally Posted by Bilito
Got the starter back in,m I installed the easy to reach bolt and my wife with her small hands and my home made special tool got the hard to get at bolt in. ONLY TOOK HER ABOUT A MINUTE
It's starting and running good again
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Good work! There's an immense satisfaction to diagnosing a problem, overcoming difficulty and, in the end, fixing it. Be sure to place your unique self-made tool someplace special so should you need it again it's right at hand.
__________________
[B]BichonLover is a 100% California gal, driving a vintage Fleetwood in SoCal.
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03-20-2012, 07:42 PM
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#13
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Senior Member
Gulf Streamers Club
Join Date: Mar 2011
Location: Central Texas
Posts: 3,797
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Quote:
Originally Posted by BichonLover
Good work! There's an immense satisfaction to diagnosing a problem, overcoming difficulty and, in the end, fixing it. Be sure to place your unique self-made tool someplace special so should you need it again it's right at hand.
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That is not how it works. You place that special tool someplace special and 4 years later when you need it, it is right where you put it. But you don't remember where that is.
ronspradley
__________________
'95 Monaco Windsor DP 32' Cummins 5.9
Toads '96 Tracker 4x4, '06 Honda CRV AWD
Life's too short to drink diet soda.
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03-20-2012, 07:51 PM
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#14
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Registered User
Monaco Owners Club
Join Date: May 2009
Posts: 3,198
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Excellent, good work!
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