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Old 08-28-2019, 04:47 PM   #1
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Default 1999 Popular Generator Exhauxt Pipe

Hi!
I have recently bought a 1999 Roadtrek Popular 190.
The Onan generator needs work (surging) and trying to clean the carb with Seafoam, making progress (day 2). The generator is missing it's access door and exhaust extension/pipe (It now exhausts straight down from the generator).
I have found an access door replacement online. I have seen exhaust pipe/extensions online also, but there are several part numbers and I want to get the right one.
Does anyone know which pipe is for a 1999 Roadtrek with an Onan Microlite 2800 (K series)generator. Which direction should it point, side or to the rear (which side?)
Thanks!, Ed
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Old 08-28-2019, 06:18 PM   #2
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On my 2003C190P, the generator exhaust comes out on the drivers side, behind the rear wheel. Even though the exhaust port is closer to the passenger side, there's a battery compartment behind the rear passenger side wheel, so I wouldn't want the gen exhaust pipe getting in the way of that.
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Old 08-28-2019, 07:55 PM   #3
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The generator exhausts on the driver's side because people tend to sit on the door side.

Cummins/Onan is one of the few sources of the rare 1 1/4" pipe. Pick one, order the exhaust hanger, and see if you can make it work.

I think it is stainless steel.
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Old 08-29-2019, 01:51 AM   #4
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Thanks for the response! I'll buy an Onanpipe and hanger and make it work. Drivers side makes sense.
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Old 08-29-2019, 05:12 AM   #5
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Quote:
Originally Posted by RedPanEd View Post
Hi!
I have recently bought a 1999 Roadtrek Popular 190.
The Onan generator needs work (surging) and trying to clean the carb with Seafoam, making progress (day 2). The generator is missing it's access door and exhaust extension/pipe (It now exhausts straight down from the generator).
I have found an access door replacement online. I have seen exhaust pipe/extensions online also, but there are several part numbers and I want to get the right one.
Does anyone know which pipe is for a 1999 Roadtrek with an Onan Microlite 2800 (K series)generator. Which direction should it point, side or to the rear (which side?)
Thanks!, Ed
Could the surging be the mechanical governor set too sensitive and it is "hunting" rather than holding a constant speed? There are several adjustments (incl. speed and governor sensitivity).

I think these instructions are for an early 2000's Onan
:

https://www.manualslib.com/manual/83...page=30#manual
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Old 09-01-2019, 05:37 AM   #6
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If you have to bend it you will find that most muffler shops do not have dies to bend 1 1/4 inch pipe. Perhaps a crude bend could be done with a torch.
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Old 09-01-2019, 11:31 PM   #7
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Originally Posted by rowiebowie View Post
Could the surging be the mechanical governor set too sensitive and it is "hunting" rather than holding a constant speed? There are several adjustments (incl. speed and governor sensitivity).

I think these instructions are for an early 2000's Onan
:

https://www.manualslib.com/manual/83...page=30#manual
I tried for several days to make it run smoother with Seafoam, no luck. Bought an aftermarket carburetor from Amazon for $69.89 delivered. Took down the generator (easier than I expected), replaced old carburetor and it started right up and ran like new! Checked the voltage and frequency per the service manual with no load and with A/C running, NO adjustments needed!
Ed
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Old 09-01-2019, 11:42 PM   #8
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Quote:
Originally Posted by RedPanEd View Post
I tried for several days to make it run smoother with Seafoam, no luck. Bought an aftermarket carburetor from Amazon for $69.89 delivered. Took down the generator (easier than I expected), replaced old carburetor and it started right up and ran like new! Checked the voltage and frequency per the service manual with no load and with A/C running, NO adjustments needed!
Ed
Awesome. Nice score on the new carburetor.
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Old 09-02-2019, 01:25 AM   #9
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Quote:
Originally Posted by RedPanEd View Post
I tried for several days to make it run smoother with Seafoam, no luck. Bought an aftermarket carburetor from Amazon for $69.89 delivered. Took down the generator (easier than I expected), replaced old carburetor and it started right up and ran like new! Checked the voltage and frequency per the service manual with no load and with A/C running, NO adjustments needed!
Ed
Ed, thank's for posting your follow-up. Not everyone does when the find a solution to a problem they posted. Congrats.
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Old 09-04-2019, 12:30 AM   #10
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Default Exhaust System Complete!

I bought these parts from Amazon:
Cummins Onan 155-2845 (X) Tailpipe Kit
Cummins Onan 1552174 Exhaust Hanger
I still needed to extend the exhaust out from under the RV. 1 1/4" exhaust pipe is not readily available, so I went to Lowe's and bought this:
https://www.lowes.com/pd/Galvanized-...Rail/999989216
Galvanized top rail for chain link fence. One end is reduced about 3 inches from the end to allow connection to the next rail.The reduced end fits snugly into the Onan exhaust pipe and the clamp on the hanger is right at the joint. You could weld the pipes together, but with the 3 inch insertion and the snug fit I don't think it's needed. I cut the top rail pipe off so it sticks out from the drivers side about 2 inches.
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File Type: jpg exhaust 1.jpg (325.0 KB, 13 views)
File Type: jpg exhaust 2.jpg (346.5 KB, 13 views)
File Type: jpg exhaust 3.jpg (141.7 KB, 16 views)
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Old 09-05-2019, 05:02 PM   #11
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Hi
On my 1997RT.
The genie exhaust extends just past on the passenger side.
I have my original paperwork.
Might be able to find a part number?
Should be schematics on line?
Eddie
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Old 09-05-2019, 06:59 PM   #12
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Default Thi is my 1997 Roadtrek 190 Onan Exhaust

Very noisy though.
Let me know if you can fix the noisy exhaust
thanks
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Old 09-05-2019, 07:42 PM   #13
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Is that stock?
It looks almost like stainless , and rather new.
Mine is a simple straight pipe right over to the passenger side. Very simple .
I have contemplated putting a baffle on it?
Much like the ones on guns and sport motorcycles?
Just being careful not to cause much back pressure. Should work???
Maybe I will do it this weekend and report back if it works well.
Eddie
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Old 09-06-2019, 01:12 AM   #14
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Made mine out of electrical conduit and used pipe bender. I needed a new muffler to. Welded several times but got to bad. Went to Cummings dealer was very expensive. He told me to go to Sears and order one for one of their riding lawn mowers. More than half the price and was at fit. Unfortently, I do not remember which model it was for. Make sure you excercise your generator monthly with a load. This is one if the most important things you can do! On 2800 model fuel pumps seem to go bad often. Just replaced mine for second time. Have heard heat inside cabinet kills them. Have had many problems and solutions. Feel free to contact if need be.
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Old 09-06-2019, 01:29 AM   #15
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The fuel pump??
I think that might be what is wrong with mine at the moment?
What is the best way to test it?
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Old 09-06-2019, 03:00 AM   #16
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I think it is stock, I am third owner.
Not stainless just buffed it with steel wool, probably plated.
Let me know if you bring down the noise.
Onan vibrates alot.
Thanks
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Old 09-06-2019, 01:43 PM   #17
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Quote:
Originally Posted by Eraygunz View Post
The fuel pump??
I think that might be what is wrong with mine at the moment?
What is the best way to test it?
Pull fuel line off and carefully hit start. Should be a steady supply of gasoline. First pump just quit. Second one started making a knocking sound. At first I thought motor was going up. Then knocking was not consistent with engine RPM. Plus engine would die after 15 to 20 mineuts of operation. Woukd not restart until cooled off. Order an shop manual on line. Has much needed info.
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Old 09-06-2019, 02:27 PM   #18
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Quote:
Originally Posted by Joe View Post
Made mine out of electrical conduit and used pipe bender. I needed a new muffler to. Welded several times but got to bad. Went to Cummings dealer was very expensive. He told me to go to Sears and order one for one of their riding lawn mowers. More than half the price and was at fit. Unfortently, I do not remember which model it was for. Make sure you excercise your generator monthly with a load. This is one if the most important things you can do! On 2800 model fuel pumps seem to go bad often. Just replaced mine for second time. Have heard heat inside cabinet kills them. Have had many problems and solutions. Feel free to contact if need be.

I would remind everyone to be aware that conduit and galvanized pipe are zinc plated which can give off some quite dangerous fumes when welding, especially if you use a torch. The zinc will also mess up the welds and make them weak many times. If you are using a wire welder or TIG welder it is good to grind off the zinc about an inch back on each piece, a bit more if you use a torch. Spray can zinc works pretty well to touch up

the welded areas.
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Old 09-26-2019, 10:02 PM   #19
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Let me know if you can fix the noisy exhaust
They make a resonator that while the dB level doesn't go down, the harsher high pitched notes do making it seem less noisy. Unfortunately, they don't get quieter and don't meet current rules for national forests.
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Old 09-26-2019, 11:10 PM   #20
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They make a resonator that while the dB level doesn't go down, the harsher high pitched notes do making it seem less noisy. Unfortunately, they don't get quieter and don't meet current rules for national forests.
First off, welcome aboard.

That's the first I've heard of this, documentation, links, cites?


thanks.
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