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Old 08-02-2020, 09:40 PM   #1
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Default Need help with replacing generator muffler

We just got a 2001 Chinook Premier and the generator needs a new muffler. All the identification information for this Onan generator is worn off. Our local Cummings/Onan dealer said he can't help me unless he has that information. Any ideas from you seasoned RV veterans? Thanks!
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Old 08-02-2020, 11:17 PM   #2
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Welcome to the forum terance!

Is it truly the muffler (not visible and inside the generter housing) or the more common exhaust pipe that you need?
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Old 08-03-2020, 04:50 AM   #3
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Take the housing/clipped cover off, I think you can take a photo of that & send it to him. If the Chinook came with a manual, it should also be in there. By the way, Chinook has been resurrected as a going concern, you could call them.
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Old 08-04-2020, 02:50 PM   #4
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I believe it is the one that is wrapped behind the generator and exists below and out the side.
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Old 08-04-2020, 02:51 PM   #5
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I don't see any references in the owners manual as to the specific identification.
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Old 08-04-2020, 04:20 PM   #6
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That will require removing the generator. Something others here have done, but with the aid of a motorcycle lift or something similar to lower it down on if mounted underneath. If your genny is in a side compartment, it may be easier. Not easy, just easier.
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Old 08-04-2020, 05:10 PM   #7
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Mine is side mounted...I haven't found the bolts from the muffler to the down pipe yet. I'll keep looking. Thanks
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Old 08-04-2020, 05:34 PM   #8
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1/2 joke:


and onan running normally sounds like a busted muffler!


Good luck with the job, by the time you have it out, you'll not need the dealer.
The onan maunals are online ( most smaller RV's use the 2800) and have good tune up instructions



Mike


best quote ever,my nephew aged 7: "is that a race car, or is the muffler broken"
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Old 08-04-2020, 07:11 PM   #9
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MK is right.

If you can get it out, you don't need the dealer.

PS. I almost forgot: you don't need a Dealer or a Specialist, find a bigger lawn mower repair place - lawn mowers & generators are the same.

I had one quite of $800 from a quality RV Guy I trust & admire to replace a Bad Regulator but he said wait a minute, let me make a call.

He gave me the phone to a Hispanic guy who specializes in Lawnmower, Chainsaw, etc repair & his cost, with a $50 Regulator * we salvaged from a dead generator (normally $250), wss only $230!

Dealers don't want to go through the hassle & time of dropping the genny, making changes & then testing them in the workshop & then the process of putting them back in.

But your job sounds so much easier but for the drop & lift.

However I hope they mounted a junction box so you can unplug it or else I believe you have to cut the wires, etc - not good - Roadtrek didn't do at the factory on my 2005.

2 years ago I did have a Onan Specialist charge me $800 to completely overhaul the unit. When he did that, he installed a junction box.

Regulators go bad. Like Water Pumps.

Gave me a code of HIGH AC at the Magnum Remote. The Magnum effectively blocks the unregulated power from blowing everything up.
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Old 08-04-2020, 10:38 PM   #10
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Thanks for everyones help and jokes!
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Old 08-05-2020, 02:55 AM   #11
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Working on an RV, DEMANDS a sense of Humour
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Old 08-05-2020, 09:33 PM   #12
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Here are some extensive write-ups I did when I removed and overhauled my Onan 2800.

https://www.classbforum.com/forums/f...ator-8416.html

https://www.classbforum.com/forums/f...ator-8499.html
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Old 08-09-2020, 07:49 PM   #13
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You’ll need to remove the generator to get to the muffler. Four torx screws to remove the green box cover. Four bolts secure the muffler assembly to the engine block. Two bolts secure the muffler to the exhaust manifold.
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Old 08-09-2020, 07:53 PM   #14
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Default Pictures of our Onan 2800, Spec K muffler

Your muffler part number should be stamped right on your muffler.
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Old 08-09-2020, 08:11 PM   #15
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Nice one Tom.
Mike
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