Onan Marquis Gold 5500 Generator Carburetor Cleaning No More Surging Guaranteed, Fix Yours Today

okay the only way i can keep this on and running is a mini manipulated choke so we're going to take this cardboard apart and see what we can find okay first step is just take you can take loose four 10 millimeter screws here we got two screws and two nuts that's in the carburetor we'll take this loose pull this cover off and give it a little bit closer to the carburetor all right let's see so we just unplug this bottom wire here let's try to get this off electric choke pull off wires then back here we got our governor linkage let's follow the linkage slide it forward that's not so bad all right the wire got that off the cobra comes off pretty easy now we're going to see if we can't take it apart do a little further cleaning okay next step i'm gonna do i'm gonna take the cover off but i want to preserve this clamp because i think these are called ocular clamps they're a one time use but instead of like a spiral clamp that are prone to get loose these will not and i've already loosened this up so i'm going to spin the carburetor around and around until i get that filter completely off and then i'll take the carburetor to the bench and we'll take it apart all right the carburetor's on the bench and this is out of a 2002 winnebago uh with quite a few miles i believe it's been sitting a while now you need a 15 millimeter wrench to take this nut loose i already broke it loose it was pretty tight so i really held it firmly and and got got it broke loose and we'll take the bowl off together and see what we can find so that's already not a good sign saw that crud in there okay hoping to get this off and preserve the gasket see it trying to come loose if you don't stretch it too bad sometimes you can reuse it okay the bowl is off alrighty and you got a little washer in there make sure you don't want to lose that but our main problem is going to be right here i believe you see those little jets and get that thing to focus it's not focusing too good there we go let me clean my fingers a little bit here and get a better focus okay now we've got a little bit closer view and you see the the crud in there those little jets because all the fuel that goes up into the engine has to pass through these little holes first and you can see the crud it's not getting that's why the only way i could force it to run is keeping the choke on plus i want to explain also a little bit how how these work because you may wonder what's this what's this knob how's it working what's it do it's getting focused so when you're when you're 10 000 feet you turn this knob in so what that's doing it's shutting the fuel flow off slightly because of 10 000 feet you have less air if you have less air then you also need a little less fuel or you run rich and what's happening is all the fuel that enters the car enters the engine let's go ahead on the bottom side all right you see that little hole right there so when that's put together it's like this little washer i took out that makes a seal at the bottom of the of the bowl then you got all the gases laying in the bowl and it's all the fuel that passes before it gets the engine engine it's got to pass through this jet and i'm thinking let's keep it in focus when the fuel flows past this this jet here then it goes through that little opening right there and it enters this little chamber where these little holes are so then the fuel has to pass through these small holes goes up of course up into the main floor of the carburetor into the venturi now this here is a solenoid so when you turn off the key it electrically shuts the fuel off there's a valve in here it slides up and down that shuts the fuel off completely so we'll get cleaning this a little bit better get through it and see if we can't get this engine running okay i'm gonna go ahead and take this jet off the solenoid you'll need a 13 millimeter to hold the solenoid and 15 millimeter to break the nut loose and you'll see that little that little sunlight it's kind of crit it's kind of moving kind of slow so i'll get my carburetor cleaner on there and get it cleaned up but remember be mindful of all these little washers where they go to put them back in the right spot so i'm gonna get me some carb cleaner on that because i think that should actually a little bit quicker it's a little bit sluggish but i take that out so i can get in and clean these jets out better and flow my carburetor cleaner through it really good i'll probably let that soak a little bit because it's it's pretty dirty okay just to show you what i'm doing here spraying a little cover cleaner down in this you see it's working a whole lot better than what it was it was really sluggish getting all that varnish and stuff out there that's another reason why you want to start and exercise your generator every month and run it for at least 45 minutes but you know run it under load so that way you get all this old fuel out because it's going to evaporate on you over time when it evaporates it leaves behind all this slime and varnish and you end up having to clean your carburetor or buy a new carburetor or pay somebody to do this stuff but you watch this video now you can do it yourself this is nothing to it basic hand tools little patients also another reason that i was told is you want to run your generators for a good you know 45 minutes to an hour and under load to turn on your air conditioning units because it also heats up the those generator windings helps push out any moisture that they may have accumulated and uh i'm always sure that's a good thing too so i've got that going operating pretty good i've been letting this put sprayed cardboard cleaner in this cap i'm letting that soak try to get all those little little holes cleaned up really well and i got me a little torch uh i'll show you that here in just a second what i use to make sure those holes are are good and clean okay someone else like to use these little torch cleaning kits for cleaning these jets out because you want to have just the right size you don't want to make the holes any bigger but you can go around and at least make sure they're the they're cleaned out good get the varnish out of them that's a handy little tool to have just go around be patient get them all cleaned out you'll have a nice good running online generator or any cardboard you're working on all right next i want to pull the float in the needle valve if you look closely you'll see one pin has like a little flat spot on it's a little bit wider so you just take your pliers and give it a push that gets the pin off and you pull out your float there's needle valve looks pretty good but i always like to flush this out good because you can get a little get a little speck of crud in there and get on top of the needle and drive you crazy i've mentioned this before but whenever you pull like your fuel line off a fuel filter you got those little barbs i've had it tear off tiny slivers of rubber and that rubber will work its way up and get on on top and wiggle just on top of this needle valve sometimes stick it open and cause the flooding and all kinds of grief but by back flushing it this way and i'll hit it with my air pressure you see it coming out down here i'll blast that with air here in a second so i'll know it's it's perfectly clean now there's always a possibility this jet up in here could be clogged up but i'm they can be tricky to get out i'm hoping this cover is not that bad i think it's going to be okay so i'm going to take my chances and not try to remove it blast it good with carb cleaner let it soak a little bit and you can see i was careful about taking it apart i preserve this gasket and everything else are these aluminum brass washers so i can put this all back together without buying any parts uh i haven't torn any gaskets so just give it a good cleaning and you know these carburetors are expensive so uh we'll try to clean it up and get it back together and get it running [Music] stuff now you want to be careful some of these i don't know if no this one doesn't okay because this one has a rubber tip needle valve some of them have like a brass tip needle valve and then a rubber seat in the bottom and if you blow air in here you'll blow your rubber seat out and that'll ruin your day so you don't want to do that all righty so you may be wondering what's this little screw do is that adjustment or anything no that's just your drain screw so maybe you're in a situation where you're gonna be gone you can't get to your generator to start it every month so it's gonna sit still for a few months so open this up and drain all the fuel out of the bowl that's what that does all that does is opens up the passageway from right here to the there so it drains all the fuel out of the bowl so you're better off to leave the carburetor dry because if you leave fuel in there like i said before it will evaporate out over time leaving behind a varnish and sludge and making for a bad day later on when you're when your generator won't start but that's what that little screw does all right getting things pretty clean now um it's about to put it back together and i could think you know actually it's the first time i've rebuilt one of these carburetors i believe on my own and i dropped the bowl one time but i never did actually remove the carburetor but as you can see there's nothing to it but something i'm curious i don't know what's behind this plate so curiosity's getting to me so let's find out what is in here i just don't know i guess i could pull up this part schematic maybe but i'm already already here let's see what we can find out try not to hurt the gasket okay no more jets and passageways that's pretty cool that's a good thing open that up okay i see here so we got those little jets in there i mean they look clean and fine anyway because usually all your trash settles in the bottom that's what that's what gives you the grief you can't get your fuel this is going to be more for your idle circuit anyway these little screws but there's there's a jit there so uh i'll spray some clear on there and make sure everything flows good i can tell that right here see if you can see it in the throat of the carburetor or not yeah i saw it spray down through okay got that little jet so i'll blast that with a little bit of air too behind it put my hose so you just take your carbocarb cleaner wherever you see a hole you know just make sure it's clear all these little jets here like i said most this upper stuff is usually fine it's just the lower stuff that gives you the grief the fuel sits there and evaporates another tip is getting the carburetor cleaner down here on your throttle shafts because come sign varnish you get in all throttle shafts and they'll kind of bind and don't operate real smooth that'll get in there and dissolve that varnish off the shafts everything operating it's good good and smooth all right we're about ready for reassembly all right it's time to put this little carburetor back together so let's just follow me along and we'll see how it goes it would be nice if you ever been around these ultrasonic cleaners man they do a good job on the carburetors if it was really bad that's what i i do because i'm doing this at my home we've got one at the shop and uh man you can dip sit a carburetor in there let it run for a few hours and it just does an incredible job cleaning everything all right got the mystery cap put back on that done okay let me blast that one last time it's clean all right make sure in camera shot put needle valve in there drop it in remember one side's a little wider than the other put that in give it this little squeeze put some tension on it got that okay remember we got this little washer this guy has to go on first but before i do that let me and then put this on first remember how that sluggish that was working so nice it is now and we want to put this on first because seem like there's an issue when you put that together with this piece of aluminum hanging down it gets in the way sometimes getting everything good and snug so our 15 millimeter here get a 13 millimeter better position just a little bit there we go and they like these little sonos i was talking about a lot of lawn mowers have these too and i think their technical term on the long ones they call them after fire solenoids may remember i remember years ago when you shut your lawnmower off you'd walk about 10 foot away from it then boom and blow up what was doing is when you'd shut the engine off the engine would tenu to rotate a few more times sucking raw fuel into the combustion chamber but it wasn't getting ignited and burned because you've done turn the key off then it pumped all that raw fuel into the large muffler and then it sit there then it would pop make a big loud noise well in order in order to eliminate that problem they came up with this ideal so the moment you turn the key off or shut it off this plunger loses its 12 volt source it shuts the fuel off so even though the engine continues to rotate numerous times as it comes down to a full stop it cannot suck any more fuel up into the piston in the chamber and blow it into the muffler that hot exhaust muffler than to have it pop and explode and scare everybody so that doesn't happen anymore but years ago it used to all right where do we get to all right we have a little brass washer goes on here then we got a bowl then we got this little dude goes on there just like that see which way is front there's front like that so all there is to it see cardboard is not that complicated it's just a block of aluminum with a bunch of holes drilled in it you know getting the fuel to go in the right direction the correct amount looks pretty good okay i mean a lot a lot of engines i've actually cleaned carburetors with them on there this one you can't do so well because because of this big chunk of aluminum in your way there's really no way to get this nut off to drop the bowl but a lot of small generators different ones i'm able to just leave the carburetor mounted to the machine drop the bowl clean this lower jet really good that's when it gets all the crap in it clean it out put it back in there and good to go so if you can get that often and be easy and not break that gasket on the bowl you can a lot of times clean these carburetors without any buying any parts at all just just be careful take them apart put it back together so that's all there is to it we'll put it back on the onan and see if it'll run now during reassembly be mindful make sure you get that little spring put the little spring in that hole first and make sure the spring stays down in this hole it keeps the tension on your linkage there there we go plug up a few wires and a couple more screws just reverse process when you put the cover on make sure this gets connected i've seen these crack and get brittle yeah that one's getting cracked up some that's your positive crankcase ventilation right there got that rubber boot here so just when you put that on make sure that all that lines up that this don't get knocked sideways because if you did you'd be ingesting dirt into your engine if that got bumped out of the way because you can see that hole is a direct shot into the intake that would bypass the air filter so that's very important piece okay let's put it together okay moment of truth will it run will it be a do-over let's prime first all right here priming up pumping field into the bowl [Music] maybe not enough well as you can see we're back on the bench i failed miserably but i'm not done yet so now i talked about i didn't want to get into these other jets before but now i am so anyways it makes more for more thorough teardown but in doing this you can be very careful about the you gotta make sure you use the correct screwdriver make sure it's got a nice clean edge it fits the jet just right because you only got one shot at this if you slip and monkey up the slot on the jet you're kind of done so make sure you get a scooter that fits the jet really well i've already broke this loose so so that this is our idle circuit jet the flow comes up through the top and you see those little bitty holes down in there and that's the outside circuit so that's what that little jet controls all right then we've got this one down here we take out i believe this is called the emulsion tube i remember that years ago and then when that is in there where's my i believe i think it's this one here call it there's an air bleed i know there's a passageway that bleed bleeds air into this of course you've got low pressure it causes the the vacuum to pull the fuel up into the into the carburetor so the fuel passes through here so i did the same thing to my pipe cleaners cleaned everything didn't see anything obvious i was hoping i'd find something plugged i did clean them all up so then i got to thinking all right i think i know what what i can do to make this work because this is a non-adjustable carburetor and i got thinking okay what can i do to make it adjustable because the jets are fairly clean but i'm still running lean uh so i got to looking at looking at the floor fuel how it works remember how our flow is we've got our fuel comes up comes into the float bowl gets into this chamber the fuel settles down into the bottom find me saw a pointy stick here so all all the fuel that enters that engine sorry i got a phone call it must first pass this jet right here and then that once it passes this jet then it has to pass through these little holes then it has to go up through these little holes on and on on so i got okay so this is our first restriction point and this is our high altitude adjustment knob remember like for high altitude you can give it a little bit of a twist to make it a little bit leaner so i thought okay what if i just remove this knob so that's what i've done i've it's on a spline so i pulled it i'll hit it off there we go all right so i've removed that and i've marked it right here 12 o'clock position so my next step i'm going to take my dremel tool i'm going to slot this so i'm going to make this adjustable epa ain't going to like it so um so i'm going to make this adjustable i'll turn it in until it seats so i'll know where factory position is and then i'll back it out clean it but now i will have an ability to actually to adjust the mixture on this thing on the fly and i think that'll get us going so let me get my dremel tool out put my nice little slot here and then we'll go from there okay to show you what it did i just took a simple dremel tool and carefully went across the top of that after popping the plastic cap off of it maybe a nice little slot so now get me a screwdriver on it so i can take a non-adjustable carburetor and make it adjustable just don't tell epa so now i want to figure out the kind of from the factory where it was sitting at how many turns off the seat so there's one turn two turns but got about yep okay so we bottomed out all right so we're about two turns or so off the seat from the factory so let's take it completely out see what it looks like okay so i'll take some carb cleaner to that clean it up a little bit blow that up well and we'll start to reassemble this and we will try this again see if we can get this thing going the second time okay so it's reassemble time so i've cleaned it up spray some cardboard carburetor cleaner in it so put this back in little seats okay then someone from the factory was about two turns there's one and there's two all right so i'm gonna take it about two and a half i'm gonna make it rich we'll go three and i put that back together and then i can fine tune it adjust it and put the cap back on there all right now so reassembling these jets i got to remember there's certain order we got to do this yeah we've got to put this one in first it all looks good and clean i mentioned we you got to be sure you got a screwdriver that matches you want to make sure you got a screwdriver that catches both sides properly because if you slip and burger it up you're going to be done you may never get the jet out okay and i got this top jet that one was that was problematic is it very small remember that's the idle circuit you found what screwdriver would i use that fit in there i think i used something little wd-40 loop loop up those threads slightly to make my life a little easier okay now i need a smaller screwdriver because now i've lost reach where'd my other one go it's a little bit skinnier that's not it let me go find it okay i found it a little bit smaller okay snug all right one last blast okay now what we need the float bowl i mean the flute it's like deja vu isn't it but like i've mentioned this before the the art to fix and anything or troubleshooting anything is is to begin with understand actually how it works you know understanding the process understanding the fuel flow that's how i kind of figured out a way to to make this adjustable because like after running it through my head and say how's what's restricting what is a restriction because i'm not getting enough fuel then it dawned on me oh this is restricting it but uh then i thought well how can i make it unrestricted as well pop the cap off of it make it adjustable and i'm thinking this will work ain't 100 sure we can always buy a new cardboard but i'm trying to avoid that what else do i need okay we need our pieces parts let me put this on here where's my that's my tools oh and part of my testing i don't think i show this there's always another possibility that if you don't not get enough fuel this solenoid could be bad or if you're not getting no fuel at all so i did check that earlier i don't know if you can see or not but you probably can't pick it up but when you push that down these little jets open up and i did plug up the wire to it it put it in start mode and notice it did the plunger did operate because if that plunger doesn't go all the way down to open up those jets that can also cause a fuel restriction it's okay i need another little washer all right let me find it okay we found all of our pieces parts okay we found all of our pieces parts put you on the bottom here get the little washer here saw all right remember so far we've done all this with no new parts so if we can get this running that would be pretty cool okay all right well this part's pretty boring i'll just finish tighten these screws up we'll go out there to the rv bolt it up and see what happens all right i want to go in a little bit more detail of what we're trying to accomplish and what's happening inside the carburetor so hopefully i can convey it of course here's a fuel fuel bowl there's that little adjustment knob remember it only gives us a quarter turn that's all we got and if you if it doesn't help it doesn't help and we're trying to explain why it doesn't help so here's a kind of a poor schematic so of course there's a third of a carburetor and here's our fuel bowl we of course have fuel laying in the bowl constantly fuel pumps maintaining that level at all times through your float into your needle valve well that fuel before it gets gets metered and up into the throat of the carburetor and into the engine all that fuel must pass this needle valve if it doesn't get past that needle valve it's not going to get in the engine so over time what happens when we let our rv sit for a couple months because this carburetor is vented to the atmosphere it slowly evaporates so the fuel will evaporate down to nothing and just disappear but it disappears but it leaves behind a varnish and so that varnish will make every orifice slightly smaller so it's gonna instead of having this somewhat large gap to allow fuel to flow through it's gonna make it just a little bit more narrow now if you had a conventional carburetor we could actually adjust the screw an adjustable carburetor you could compensate for that by turning the screw out just a little bit more allowing more fuel to flow through and make up to the engine and keep make the surgeon go away but because we're limited with only a quarter inch turn we can't do that but with that little modification that i did you can get around it and hopefully make your surgeon go away you know and maybe even do it without taking the carburetor apart that just depends on how dirty the carburetor is now if you've got a whole bunch of crud in there you know this adjusting the screw out may or may not be enough in case you have some debris further up or down here in the bottom with all those other uh little orifices are so anyway that's that and i just want to show you a little bit about prices on these carburetors check it out let me get back here where i was at here we go because you can see here here's one for the oh the oem carburetors are like 400 bucks um so even amazon 3 81. um now you get you can get the china knockoffs for about 52 or so but i have seen some poor reviews and people were warning about them they put them on there and they surge and give trouble so uh and i did think it kind of funny remember when i was cleaning that on that cleaning video i made i was using tools like this to clean the jets and everything so why on earth would you need something like that shipped with a brand new carburetor that was kind of a little bit confusing unless they figure you're going to have trouble with it and you're going to go in there and clean the jets out anyway i thought i'd just point those few things out and hopefully that's what will help you with your troubleshooting and repair i also meant to mention um the fact that these cardboards they have no rebuilt rebuild kits available the only individual parts they offer is the the fuel solenoid at the bottom but all they offer is that solenoid and the complete carburetor no no internal parts whatever so um so when you take it apart be careful don't lose anything or you'll be binding your carburetor so i thought i'd mention that all right let's try this again see what happens try to get a prime going on don't that sound good try it again all right so we got it took care of now remember i talked about the from earlier we was about two turns off the seat so now we're running about three turns off so i'll just put this cap back on here put that on there well there she goes all right i'll get something to tap it on all the way and i think we're gonna have a working generator so so we still have a little bit of adjustment here high and low let's see if you'll so now you can see we got a perfectly running good onan and with zero cost no parts at all just take it apart clean things adjust things make things and we're back on the road now you can too thanks for watching bye

Channel: Kevin Caudill

Views: 27,031

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Id: xvBJeX2o2Ik

Length: 37min 40sec (2260 seconds)

Published: Sun Sep 05 2021