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I’m having trouble finding a YouTube video or any other link showing the specific process for removing an Onan Microlite 2800 from its side compartment in my 1990 Dolphin. Of course I could just wing it and go for it but I’d prefer to read a step by step description etc beforehand. Thanks?

doubt you'll find it. there are 4 bolts going up into the gen from below. you need to remove the exhaust pipe. there is the fuel line. wiring usually is long enough to disconnect after the unit is slid out onto a platform you provide. not really difficult
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rz

That’s excellent. The one gotcha I see is that wiring harness conduit is an inflexible sort of tubing. Appears to connect to the outer gen housing with a large ‘nut coupler’ so maybe once I loosen that up thereby opening that rigid conduit the harness will give me some slack. As long as that rigid conduit is connected to the gen the generator can’t be moved even 2 inches. I’ve pulled the engine and transaxle out of a VW using a stack of plywood as a jack in a chicken coop so I can get a bit.creative when need be. I just don’t want to wreck anything like a cable harness, complicating the job even more. Thanks for the tips. More confident now. The shops in this area are charging $280 per hour. Crazy.?

trying to post a?
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rz

i was wrong you have found it
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rz

It's been 20+ years since I removed the generator from my Dolphin, but I remember the task not being
very complicated. Only common hand tools are necessary. The biggest issue is it's quite heavy, so
be careful when trying to move it (try to have a second person help).

Otherwise, if you've pulled a VW engine, you have the mechanical skills needed to remove the
generator.

Good luck,

Buzz L.
Phoenix, AZ

post 207257 is a pdf of onan 2800 microlite service manual
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rz

Thanks for the pdf’d manual and thanks for the vote of confidence. Got the mounting bolts off and trying to disconnect the electrical connector that’s (of course) located in the rear left corner of the generator where it’s tough to reach. Don’t want to break it. Must be a latching tab of some sort on it. I made a Yankee screwdriver using a Philips bit and vice grips and got the top cover loose hoping I could lift it enough to get at the starter but no luck on avoiding removal. My intent is to swing/slide it out onto an equal height work surface, swap out the starter and get back to troubleshooting the oddball angle sensitive carburetor issue. Most of this hasn’t been touched in 33 years. The Dolphin is a neat package. Once the generator is repaired I’ll like it even better.?

Chuck

while mine was out i added connectors to the wires so if i need to remove it in the future i wont have a problem?
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rz

the flat connector has squeeze tabs on each end holding it on.? one toward you and one to the back
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rz

Well I suppose I just graduated from “Pull and Re-install Your RV Generator” college. Even used plywood scraps on a metal stand to support it, harkening back to the college days VW engine removal. What I learned was the starter must have had one armature spot where it lacks continuity because once I pulled it and tested it separately (also testing the solenoid relay) it spun up strongly. So to get back to carburetor testing where this all began, I reinstalled the generator with the same starter, for now. That was a good exercise. Thanks for the gen removal guidance. I’ll let you know how the carb troubleshooting goes, or whatever the gremlin is. ?Chuck?

i had a bad starter drive.? ?
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rz couldn't find a replacement so i bought a new starter.? still have the old one

The gremlin is really messing with me now. I suspect he’s monitoring this forum. After reinstalling the generator last night and then today restoring the new carburetor’s original float and plunger; two quick presses on the Start and it fired up and ran perfectly for 10 minutes until I killed it. So I’m baffled if this gremlin is actually dead. Wife’s comment “time will tell” is smart. This successful test was with the Dolphin parked on an upslope, front end higher. This has been the angle where its operation was marginal to dead. If the generator indeed proves itself reliable over the longer term then perhaps there was a restrictive kink in the fuel line or some other oddity that I luckily straightened out during my generator removal/reinstall exercise. We shall see. I’ll fire it up every few days and see how it goes. If it sputters again I might focus on the fuel pump. Thanks to your earlier coaching I now know how to yank the whole thing out the RV pretty quickly.?

Chuck