A few months ago, I posted a message that my Onan DJE pictured here:
has developed starting problems. The problem is that when I flip the start switch, it makes a loud CLICK as the solenoid pulls back and pushes the gear forward, the the starter usually does not engage.
The problem got worse over time.
I finally found time to work on it (having torrential rains in the area and seeing our friend's basement flood due to 13 hour power outage also helped).
I took the enclosure apart a little.
My finding is as follows.
1. The contacts between positive and negative cable ends, and ther contacts on the genset, were corroded. I corrected that by taking them apart and applying sandpaper pads and using a copper conductive goo.
It did not help.
2. When I engage the starter switch and the gear pulling solenoid pulls back, there is no voltage on the other contact that it is supposed to close when it pulls back (the one leading to the main starter).
in other words, either the solenoid fails to pull back far enough, or the contact inside is bad.
I tried pulling it back by hand as far as I could and measuring ohms -- there is no difference.
So, to me, it is the inside contact that does not work.
I am going to take the starter off and try to open it up carefully in my garage. How can I do it (just take off the wires and the main bolts that bolt its flange to the body of the generator?)
Any words of wisdom?