How to fix a genset 6500 generators that stops when you turn starter switch loose?

You can buy a service and or operator manual from advanced-power-technologies.com

The transfer switch is responsible for starting / stopping the generator. Check your auto - start circuit. It is 2 wires that go between the genset and ATS. They are generally normally open. When the genset is to shut down this circuit needs to change state.

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

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Sounds like a flat battery.

Either you have a kill wire ( if I remember it is the brown wire) that is disconnected on one end or the other Or your in coach switch is bad.
Check the switch this way

Remove the switch from the dash/ mounting surface unplug the brown wire - start the genset - ground the brown wire - it should kill the motor
If it kills the motor your switch is bad

ONANS ARE PRETTY QUIRKY AS IT IS NOT CONSUMER FRIENDLY. THE GENSET IS DESIGNED FOR ROUTINE AND SIMPLE MAINTENANCE PERFORMED BY THE OWNER, AFTER THAT, U WILL NEED TO TAKE IT TO THE NEAREST DEALER OR CUMMINS DIESEL REPAIR SHOP.

a 10 year old genset with only 45hrs on it...sound like the carb may need replace. working with these rv units for 6+ years has taught me that you cannot clean one well enough to fix it. you will need a new carb. your local onan dealer can help. when new the warrenty makes known that 1hr per month under load will keep the carb clean and problem free. evaporating gas leaves deposits and eventualy plug fuel jets. no replacement parts are recommended. i've personaly worked on rv's with 200+ hous and no issues at all. hope this helps, good luck...

What I would do is isolate the starter from the switch and see if the starter turns without heating up any wires. If this works, then you have a loose connection going to the swich. Trace out the wires to the switch. As far as the ground, I would place it on the engine block or genset, where ever you can find a bolt.

When this happens, this usually means that your genset is not creating voltage. First thing I would do is disconnect your remote start wire from the genset, this will eliminate the start switch inside the RV. For a shorted remote start switch can cause you genset to shutdown. Second, place a volt meter at a spot where you will be able to read genset voltage. If no voltage is available and your voltage regulator is new, then the problem is with either the rotor or stator. The rotor is the easiest check. You need to reach the brushes. Take a resistance reading, which should be around 20 ohms. Clean the rings and make sure there is enough length on the brushes, at least over 1/2". Next, flash the fields using a 12Vdc battery. Use rubber gloves when doing this. Place the positive side to the ring closest to the bearing and negative goes to the back ring. This is done while genset is running so be careful with rotating parts. Have a volt meter on the output wires. Once you flash the fields the voltage should increase to over 50Vac. If it does then your stator is bad since you installed a new voltage regulator. If the voltage does not increase when flashing, then the rotor is bad.

1. Does the generator stay running when you start it the first time?

2. What color is the housing on this generator? Try to get the model number and serial number.

If the genset is shutting down on the first try, then your probably not creating voltage. However, if this is an older unit then the genset may stay running although no voltage is created. Place a volt meter on the genset to check for output voltage.