Ziggy - Generator Woes & a Fix
We've had trouble with the built in Cummings Onan 2800 generator since we purchased our Pleasureway. It would start and run OK but not carry the load of the air conditioner. That is the main, if not only, reason we need a generator. These older carburated Onan generators are nutorious for having problems. It seems they need to be run frequently to avoid fuel gumming up the carburator, along with other problems. Many YouTube DIY guides for working on them, but Onan "shops" are few and far between. Service is noted to be very expensive at these shops.
Hugh jumped through many hoops to get ours running well. This included a new carburator and external fuel pump. Those looked to be the most likely cause of our problems. Replacement Onan parts are available, and most parts can be had from after market sources. After market, Chineese, parts cost a fraction what new Onan branded do. For example a carburtor from Onan is pushing $500 while after market they run around $75. However, reviews are very mixed on these after market replacements. Hugh finally decided to pop for a Onan carburator "to avoid problems". For the fuel pump he installed a generic after market one. It's size doesn't fit inside the Onan case but can easily mount of the vehicle frame. Those fixes seemed to solve our problems.
On our fall 2025 Lost Coast trip it was hot enough to run the AC when we stayed overnight at Clear Lake, CA. We tried to start up the Onan and it failed us. It would not continue running and the starter eventually failed. After all the trouble we've had with it this was the last straw, no more money thrown into this Onan money pit. Say goodbye.
We looked into getting a new generator that fits the footprint of the Onan. Well, a replacement from Onan runs some $4300, plus installation. I did find ads for a similar generator from a start up company, but the cost is comparably high. That's it! All general purpose generators are too tall to fit the space the Onan is in.
Well, we fixed the whole problem. We purchased a Honda 3200 for about $2800 and a front receiver rack to carry it on, maybe $500. We're ahead by $1000 plus what a new Onan installation would be, I'm guessing we're $2000 ahead. There are cheaper alternative to a Honda, but we know Hondas to be reliable and we figure worth the extra cost.
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Hugh did move the spare tire from the front reciver to the rear of Ziggy, just in front of the rear bumper. This is the spares normal location but, to fit our larger spare, he had to cut off the existing tire "guides".
The only rack we found specifially for the Honda 3200 was a "Squatch Mount" from Fitting Designs in California. It's a good product and has worked very well for the few trips we've taken with it. The generator mounts on a plate which locks to the rack proper. We recommend this product. The plate seen attached to the rack is for a Rotopax fuel container. We'll need to order a Rotopax and mounting hardware before our next big trip. This seems a great way to carry gas for the Honda, ourside the living area.
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There are a few downsides to carrying the Honda over the built in Onan. The Onan starts up using a switch inside the coach (when it works), and automatically feeds 110V juice to the coach through a transfer switch. Pretty automatic. The Onan runs off the Ford's fuel tank so no need for extra gas cans. To use the Honda we have to uncover it, hood up the 30A shore power cable, and pull the starter. It will also need some form of gas can for refilling, like the Rotopax. Final downside is the extra foot of vehicle length.
But for us the upsides of the Honda ourweigh the negatives. The Honda can be easily removed from its rack. That makes it easy to take to a repair shop if needed. Or use the generator separate from the PW. With our set-up one could even replace the whole generator if needed. To work on the Onan it needs to be taken out of the coach, expensive and time consuming. There are far fewer Onan repair shops than Honda. As above, the cost of a new Onan is quite high. Finally, the Honda is way more reliable than a circa 2010 Onan. (Just search the Internet for horror stories.) I can't compare to new Onans, but my experience with our Onan gives us no fond memories. Honda generators are notorious for their reliability. Oh ya, and $2000 in our pocket.
So that's our solution to a dead Onan generator. Your milage may vary.




