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Onan Emerald Plus Genset Starter


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  #1  
Old 12-24-2017, 09:14:09 PM
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Default Onan Emerald Plus Genset Starter

Hello all. The starter on my Onan Emerald Plus Genset just kicked the bucket. The starter just spins so maybe it could be fixed by replacing the plastic gear, but it might just be easier to replace the whole starter. Regardless, I am having a hard time figuring out which starter to order and was wondering if anyone could point me in the right direction. The model number is 4BGEFA26100P and the serial number is G990946531. Thanks for your help.
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Old 12-24-2017, 09:26:51 PM
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Billy J Shafer Billy J Shafer is offline
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Default Re: Onan Emerald Plus Genset Starter

I believe there was an update to that starter. I will check my files.
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Old 12-24-2017, 10:05:15 PM
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Default Re: Onan Emerald Plus Genset Starter

The starters have a crappy plastic drive pinion on them and they can strip out. The machine you have is a Spec "P" and the complete starter number is 191-1667.
They sell a pinion kit 191-2129 is just the gear and some various parts. The more complete pinion kit is 191-2187.
I would remove the starter first and take it apart and check the condition of brushes and commutator FIRST, then decide whether to fix just the drive or replace the complete starter.
I bought a starter as a spare for my 4BGE off of ebay. Be careful as many are China junk.
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Old 12-24-2017, 10:06:59 PM
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Default Re: Onan Emerald Plus Genset Starter

Thanks for the part numbers. I am going to see what I can find out and I will report back.
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Old 12-24-2017, 10:10:48 PM
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Default Re: Onan Emerald Plus Genset Starter

Do you have an hour meter on the generator?
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Old 12-24-2017, 10:40:06 PM
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Default Re: Onan Emerald Plus Genset Starter

I do. The generator has 938.5 hours on it.
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Old 12-24-2017, 10:44:15 PM
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Default Re: Onan Emerald Plus Genset Starter

Starter may be corroded/froze in engine. Don't pry on starter ears or they may snap off. I heated engine aluminum casting, then broke starter free by tapping on starter ears to make it ROTATE. Came right off fine.

Also if have not run gen for few months clean slip rings before making AC to protect $$$ Ac voltage reg.
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Old 12-24-2017, 10:52:22 PM
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Default Re: Onan Emerald Plus Genset Starter

I have only had the RV for a month, but it has been working fine. I have been remodeling the RV and I have been starting the generator at least a few times a week since I bought it. We were installing some new Bilstein shocks on Friday and I tried to start the generator so we could use the power to run the air wrench, and that is when the starter went out. It was doing fine before then though.
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Old 12-24-2017, 11:41:51 PM
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Default Re: Onan Emerald Plus Genset Starter

As Len said, the starter can corrode (the aluminum) where it slips in to the engine housing. If you can't heat it, use some good penetrant such as Kroil or PB Blaster and spray the junction where the starter fits. Loosen the bolts and tap around the starter front flange to break it loose. The brushes are behind the rear cover. When you take the starter out, you undo the two long bolts that hold the starter together. Be careful to NOT let the starter armature slide forward as the brushes will come off of the motor commutator.
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Old 12-25-2017, 12:10:11 AM
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Default Re: Onan Emerald Plus Genset Starter

Don't hit it with a hammer, magnets inside will break and then you will need a new one.

If you do break an ear off you can solder it back together with these cheap zink rods from bernzomatic and think they are great.
https://www.youtube.com/watch?v=3SBfP4_i1Go
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Old 12-25-2017, 04:04:36 PM
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Default Re: Onan Emerald Plus Genset Starter

Check the back end bearing if you are taking the starter out. If that bearing (bushing?) is worn, the armature will soon eat the magnets.
I had one go bad in a 6.5NHE that had spent most of its life getting rusty and otherwise oxidized in an RV. Starter came out with little trouble.

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Old 01-02-2018, 09:58:28 PM
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Default Re: Onan Emerald Plus Genset Starter

Finally got around to pulling the starter today. The black gear was split in half. The starter sounded pretty bad when I spun it, so I decided to order a new one rather than try and rebuild the broken one. I ordered a cheap one that got good reviews on Amazon from people who claim to have had it installed for over a year, so we will see how it goes. Gotta love that free next day shipping though.
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Old 01-02-2018, 11:55:06 PM
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Default Re: Onan Emerald Plus Genset Starter

The starters have permanent magnets in them so they won't spin freely by hand. I would suggest taking apart the old one and rebuilding it, especially if it is an OE Onan starter. Then carry it with you as a spare. I carry a spare for my 4BGE because having my generator to run my AC in my 5th wheel is a must for my wife in hot weather if we have to stop. She has a med condition and over-heating is not a good thing for her. They are easy to take apart and re-assemble. The hard part is getting the spring clip on and off at the end of the motor shaft that holds the starter pinion gear on.
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Old 01-06-2018, 01:04:32 AM
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Default Re: Onan Emerald Plus Genset Starter

Good idea Motorhead. I think I could rebuild the original and keep it as a backup. Hopefully this new one will last but better safe than sorry.

While I had the generator pulled, I decided to check the exhaust really good because the generator was abnormally loud when I bought the RV. As I suspected, the exhaust manifold was cracked. I am going to see if I can get a muffler shop to weld it tomorrow, but I might need to replace it. Do any of you have a copy of the parts manual for this model? My email is precycled@gmail.com. Thanks in advance.
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Old 01-06-2018, 01:09:49 AM
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Default Re: Onan Emerald Plus Genset Starter

Look here for the manuals. Once you open it hold control key then hit F, at the top left will be a search box, type in BGE then hit enter, after that scroll down and BGE should be highlighted. I believe yours is a spec. P.

http://www.twinslan.net/~n0nas/manuals/onan/
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Old 01-11-2018, 10:01:47 PM
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Default Re: Onan Emerald Plus Genset Starter

Thanks for all of the help everyone. This case is closed for now. The new starter is in and I was able to get the exhaust manifold welded up ok. I am going to rebuild the original starter and keep it on hand in case the cheapo model craps out on me. So far so good though. The generator starts fine and sounds much quieter. Now I get to go fix some leaks that this week's rainstorm exposed. Yay! These RV's sure are good fun!
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