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Old 10-14-2013, 02:21 PM   #1
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Join Date: Oct 2013
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Onan 4000 Microquiet stalling

The generator in my 2005 Concord 270SS has started surging and stalling after about 15 to 30 minutes run time. The generator smelled heavily of gasoline and would restart only after repeated attempts. This has been occuring for the past year and getting progressivly worse. After performing the standard service items (new plug, new fuel filter,etc.) with only limited results, I decided to run some tests to find the problem. Fuel pressure was within limits (3 to 4 psi). Removing the carburetor bowl showed some small black specks. After cleaning, the generator would run perfectly for 30 minutes to hours before repeating the surging and stalling. Since it appeared to be flooding I attached a clear plastic tube to the carb drain port (photo 1) to see what the fuel level was in the carb. With the tube I could monitor fuel level as the generator was running. This can be seen in photo 2. CAUTION!! Watch the generator at all times with the tube in place as it could present a fire hazard. With the fuel level at the level shown in photo 2 the generator would run fine but after a while the level would rise well above the top of the bowl and the generator would surge and die. Obviously the float and needle valve were not closing the flow of fuel from the fuel pump. Suspecting rubber hose deterioration from ethanol 10 fuel I placed an additional 40 micron fuel filter which can also be seen in the photo just before the carb. So far the generator has performed perfectly. This was much easier than replacing the line from the fuel pump to the carburetor which is very well hidden. Maybe someone else can benefit from my experience. This is a lot less expensive than a new carburetor which would only temporarily solve the problem.

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Old 10-15-2013, 02:07 AM   #2
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Hello, and thank you for your post of the effects of ethanol on the generator. We are glad to have you join us here and we look forward to reading of your adventures and experiences. I am sure you will enjoy the website and forum. Good luck, stay safe and keep us posted.
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