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Old 07-04-2022, 07:08 PM   #1
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Onan 2500 lp generator

Hello All
I have a 2019 arctic fox with an onan 2500 lp generator. I'm having a starting issue. It started with rapid clicking, like a car solenoid at low voltage. I checked voltage at the two cables leading in at the back and got better than 12 volts. I removed the brass washers and cleaned them anyways. Same issue, and when it would turn over I noticed an arc here and there. I removed the unit from its home and got the housing off. I checked all connections for a loose wire or something obvious.

When I turned it over, I noticed arcing and sparking and realized it was at places where there was metal to metal contact, like where the exhaust heat shroud meets the bottom of the generator tray, only noticeable when the cover was off.

Anyways, I think I have some sort of short going on, and to add to that, I installed two batteries and this problem might be something I did when I put the new batteries in. I have no block where the majority of wiring goes, just a cluster, which I will deal with later


I tried to remove one ground at a time at the battery but it turned over with all negative wires off, so I'm really confused. I don't think it's a mechanical issue, but the arcing is not cool and im about at my limit of knowledge with 12 volt.

I'm contemplating removing the two leads coming into the back of the generator and straight jumping it off of a battery to see if it's a wiring issue, but don't want to screw anything up unknowingly. Any suggestions?
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Old 07-05-2022, 08:00 AM   #2
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Originally Posted by tracy View Post
Hello All

When I turned it over, I noticed arcing and sparking and realized it was at places where there was metal to metal contact, like where the exhaust heat shroud meets the bottom of the generator tray, only noticeable when the cover was off.

Anyways, I think I have some sort of short going on, and to add to that, I installed two batteries and this problem might be something I did when I put the new batteries in. I have no block where the majority of wiring goes, just a cluster, which I will deal with later
If this only started after putting new batteries in, start with that. Did you mistakenly connect the generator leads to the batteries backwards?
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Old 07-05-2022, 08:12 AM   #3
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No. And I have correct voltage going into the generator
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Old 07-05-2022, 08:29 AM   #4
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You mention removing "one ground at a time" at the batteries. The generator only has two connections from the batteries, a "+" and a "-"

Internally the Neg should be connected to the generator frame, as is the Neg of the starter.

If you removed ALL wires from the Neg of the batteries, there is no return for the 12V and it should not work.
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Old 07-05-2022, 10:09 AM   #5
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Tha k you old web. I removed one ground at a time because there are multiple ground wires and I'm not sure which one goes to the generator, im still not sure.
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Old 07-05-2022, 03:18 PM   #6
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Tha k you old web. I removed one ground at a time because there are multiple ground wires and I'm not sure which one goes to the generator, im still not sure.
Typically the battery bank will have one Neg going to the RV chassis and the starter is shown to be grounded to the generator chassis, so the starter will have a return back to the batteries through the metal frame(s) and that may be causing the sparks if they are not tight.
So follow the two cables (Pos & Neg) from the generator, they should go directly to the batteries.
Good Luck!
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