Onan access cover May 12, 2024, 07:16:02 pm Hi all—newbie here. Tried to get the access cover off the Onan and when I tried to turn the handles to open, they both broke off in my hands! Guess they haven’t been moved in a long time. 2007 23 1/2’ twin king. Any ideas how I can get the access cover off so that I can work on the genny and replace the handles?? Thanks for any and all responses.
Re: Onan access cover Reply #1 – May 13, 2024, 09:29:50 am Hi, and welcome to the group! Perhaps a small vise grip tool could be clamped on the broken handle allowing it to be twisted off. Do you have a photo?
Re: Onan access cover Reply #2 – May 13, 2024, 01:01:14 pm Quote from: HiLola - May 13, 2024, 09:29:50 amHi, and welcome to the group! Perhaps a small vise grip tool could be clamped on the broken handle allowing it to be twisted off. Do you have a photo?I would follow Greg’s suggestion of using vise grips to turn shafts but first, spray the shafts with penetrating oil, to break up the accumulated rust and dirt. Spray several times for a day before attempting removal for best results. Tapping on the shafts with a small hammer can help the oil penetrate deeper and dislodge the debris. The cover should marked with the lock and open positions. showing the proper direction to turn. The handle assembly bolts on and should be repairable if you can find replacements.You must have the cover in place when using the generator to ensure the cooling airflow, is going to the correct parts of the generator and not out of the access door. Running under load for a long period without cover in place will eventually lead to engine overheating and damage.Good luckLarry 1 Likes
Re: Onan access cover Reply #3 – May 13, 2024, 04:25:54 pm I was able to find replacements for ours last fall on line. I think Yakima Generator had them in stock then.
Re: Onan access cover Reply #4 – May 13, 2024, 07:59:35 pm Unfortunately, the handles broke off flush with the cover so there is nothing to grab with vise grips. Any other ideas?
Re: Onan access cover Reply #5 – May 13, 2024, 10:05:29 pm "...the handles broke off flush with the cover..."Hmm, other ideas??Don't know if I've ever done a close examination of the subject area but in my imagination I picture the broken shaft/s as something other than round, perhaps square or hexagonal? Would a socket fit over the broken shaft? Is there clearance to do that? Grasping!
Re: Onan access cover Reply #6 – May 13, 2024, 10:22:22 pm At this point, a photo would be appreciated. This is a new one for me, I don’t know how the handle is connected to the back of the lock having never seen one break before.Both locks may need to be drilled out but until more information is available, I have no suggestions on how to proceed.Larry
Re: Onan access cover Reply #7 – May 13, 2024, 10:31:03 pm "A photo..."Not sure if this will help, but for what it's worth!!!Onan Microquiet 4000 COVER ASSY-ENCLOSURE 405−6383−01 | eBay
Re: Onan access cover Reply #8 – May 13, 2024, 11:36:15 pm You need to post a picture of the broken shaft still on the cover. Seems like a counter clockwise drill should release the cover. Harbor freight has them.https://www.harborfreight.com/left-hand-drill-bit-set-13-piece-61686.html
Re: Onan access cover Reply #9 – May 14, 2024, 09:41:24 pm "You need to post a picture of the broken shaft still on the cover."Take a look at the link I posted in reply #7. When the page opens for the Onan 4000 enclosure being offered by eBay, click once on the left arrow! That will show you what the inside cover fasteners look like. If the OPs cover is rusted like that illustration it's no wonder the shafts broke. Looking at the 'J' hooks it appears that there is a backing nut on each [broken] shaft and it's going tp be a bear to remove. 1 Likes
Re: Onan access cover Reply #10 – May 14, 2024, 11:40:01 pm I see what you mean. Well, here are a couple of long-shot ideas:1. For the lefthand latch (shown here), could you reach up through one of the big ventilation slots and finagle the latch to the open position? I'd try the slot to the right of the latch, reach in toward the left with a hooked coat hanger, and try to snag the latch and pull it open.2. For the righthand latch, could you drill a hole through the case just to the right of the end of the hook (use the molded-in rib as a guide), then reach in with a screwdriver and push the hook to the right until it's unlatched? 1 Likes
Re: Onan access cover Reply #11 – May 15, 2024, 12:49:54 am I took one of the latches apart this evening for a better look. The plastic knob is cast onto the shaft and is not made to be removed without destroying it. I will stay with my original idea to drill out the shaft, first center punching the remaining shaft and then drilling the shaft out with increasingly larger diameter drill bits until the shaft falls apart.We are here to help but we need as much information as possible and again, a photo would enable us to determine the best repair method. Work with us, please! No one here is getting paid to help you.Larry
Re: Onan access cover Reply #12 – May 16, 2024, 07:15:43 am Thanks to all for helping this newbie solve this problem! The handles broke off flush with the cover. I could see the shaft, so I drove it out with a hammer and center punch. New latches have been ordered so all will be well. Lesson learned—a picture is worth a thousand words—next time, post a photo to help explain what is going on!
Re: Onan access cover Reply #13 – May 16, 2024, 09:45:30 am Thanks for the update! It's always good to know how a problem was solved.
Topic: Onan access cover (Read 408 times)
previous topic - next topic
Topic: Onan access cover (Read 408 times)
previous topic - next topic