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Old 07-31-2021, 07:11 PM   #1
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Onan 4000 Outside Starter Switch problem

I replaced the starter motor in my Onan 4000 Emerald generator. The parts supplier told my tech that the outside starter switch is the source of many of the starter gear failures. The high vibration while the genset is starting can cause the switch to repeatedly open and close, which then repeatedly slams the starter gear into the flywheel. Since that gear is plastic, it can’t handle any abuse.

The tech was told to firmly grip the back of the box when the outside switch is pressed to prevent the switch from opening due to vibration.

Thanks to Onan for providing another reason to baby what should be an industrial strength machine.
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Old 07-31-2021, 08:11 PM   #2
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I'd suggest a new Tech. Onan makes quality products.
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