Question about Watts Onan Portable Generator - 4000 , Model# 5500

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Onan generator making grinding noise while cranking

I have a 94 Onan 4000 microquiet generator that makes an intermittent grinding noise while turing over before starting. It is very loud and reminds me of a starter grinding on a flywheel but I'm not convinced that is what it is. Is there something else it could be?

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If it walks like a duck and quaxks like a duck?

If it grinds like a starter ?

Your alternator would hsve to be in absolutely unaerviceable condition to match a noise a starter makes.

Posted on Jun 14, 2009

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1 Answer

Onan 4000 won't turn over


check for bad battery, loose terminals ,dirty terminals , faulty starter relay
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Check the ignition circuit, and trigger coil for correct resistance on the trigger coil, and the ignition coil. The trigger coil is a small module on the engine shaft near the flywheel.

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It certainly sounds like you have damaged the control board. If you cranked it with reverse polarity, there is a good chance that you have rotor winding damage also. If not you still may have to flash the rotor windings to ensure a correct polarized field. That involves hooking a battery for a couple of seconds to the rotor brushes (with correct polarity) with rotor brush wires disconnected. Only do this if there is no output voltage after you replace the control boards. Bad mistake :)

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Check the pickup tube in the vehicle, the fuel pump is suspect. If you check the fuel pump pressure and it is ok, then try installing a test check valve between the fuel delivery hose to the generator. If it solves the problem the pump is losing it's prime internally, so replace the fuel pump.

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Onan Microquiet 4000 starter will spin but not turn engine


bendix is actual the spring that pushes the gear back out of the ring gears engagement your issue is more likely a rusted /corrodied incline engagemnt gear a little lube will probably bring ti right back (do not us WD_40) this is not a lubricant it is an anti lubricant any light oil will do Good Luck

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Remove the air cleaner and inside near the throat of the carb is two bolts holding the carb to the intake remove these. Unhook the fuel line and twist the carb to allow the linkages to remove.

Sep 14, 2009 | Watts Onan Portable Generator - 4000 ,...

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