Question about Watts Onan Portable Generator - 5000 , Model# 6500

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I have a 1997 onan emerald series GenSet 6500 I have been thru 4 starters it keeps breaking the drive gear assmbly WHAT CAN I DO PLEASE ITS ALREADY COST ME 400.00

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  • Robert Schumann Apr 12, 2012

    What I rellized was that the spring was behing the gear took it out went to a hardware store bout the sae size spring and put it in front of gear now its working fine

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Have you replaced the solinoid too? If not, maybe the solinoid is staying engaged, which keeps your starter, well starting. If the starter stays energised the flywheel WILL tear up the starter gear.


hope this helps

If you need further help, I’m available over the phone at https://www.6ya.com/expert/matt_8dbc24bf722649ac

Posted on Nov 04, 2010

  • Robert Schumann Nov 05, 2010

    roadtech7 thankyou i havent but i dont hear it staying engaged the gear is getting chewed up to the rear of it (1) could it be that the gear is traveling to far or is there shims im missing

  • Matt Olenzek
    Matt Olenzek Nov 05, 2010

    Good thinking, but there are no shims in this starter. it could be that you have the wrong starter on the generator. Did you replace the whole starter or just the starter gear assembly?

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