1986 Onan 6.5KW Gas RV Genset Service Manual

The 1986 Onan 6.5KW Gas RV Genset is a reliable power generation unit designed for recreational vehicles, featuring a 6.5 kilowatt output capacity, gasoline-powered engine, 120V AC output, and comprehensive service requirements. This manual covers safety procedures, technical specifications, maintenance schedules, troubleshooting, and repair instructions for proper operation and longevity of your generator set.

1. Safety Precautions 2. Technical Specifications 3. Maintenance Schedule 4. Engine Components 5. Electrical System 6. Fuel System 7. Cooling System 8. Troubleshooting Guide 9. Repair Procedures 10. Parts List 11. Warranty Information

Safety Precautions

Always follow safety guidelines when servicing your Onan 6.5KW generator.

Hazard	Precaution
Electrical Shock	Disconnect battery and power sources before servicing
Fire Hazard	Keep away from flammable materials; no smoking near fuel system
Carbon Monoxide	Operate in well-ventilated areas only
Hot Surfaces	Allow engine to cool before servicing
Moving Parts	Keep hands clear during operation; disconnect spark plug

Technical Specifications

Model: Onan 6.5NH-3CR/16004P
Power Output: 6.5 KW (6500 Watts)
Engine Type: 4-cycle, single cylinder, air-cooled
Fuel: Regular gasoline
Voltage: 120V AC, 60Hz
Starting System: Electric start with 12V battery
Dimensions: 24" L x 18" W x 18" H
Weight: 185 lbs
Oil Capacity: 1.5 quarts
Fuel Consumption: 0.75 gallons per hour at full load

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Every 50 hours: Check oil level, inspect air filter
Every 100 hours: Change oil and filter, clean spark plug
Every 200 hours: Replace air filter, check valve clearance
Every 500 hours: Replace spark plug, clean carburetor
Seasonal: Stabilize fuel, check battery charge

WARNING! Always disconnect spark plug wire before performing maintenance.

Engine Components

Key engine components and their functions.

Component	Function
Cylinder	Single cylinder with cast iron sleeve
Piston	Aluminum alloy with two compression rings
Crankshaft	Counterbalanced for smooth operation
Valve System	Overhead valves with mechanical lifters
Ignition	Solid state electronic ignition
Governor	Mechanical governor for speed control

Electrical System

12V starting system and 120V AC output specifications.

Battery: 12V, minimum 35 AH capacity
Starter: 12V DC electric starter motor
Alternator: 12V DC charging system
Output: 120V AC, 54.2 amps maximum
Receptacles: Two 120V 20A duplex outlets

CAUTION! Always disconnect battery before working on electrical system.

Fuel System

Gasoline fuel system components and maintenance.

Fuel Pump: Mechanical diaphragm type
Carburetor: Float-type with manual choke
Fuel Filter: In-line paper element
Fuel Lines: Rubber hoses with clamps
Fuel Tank: Integrated 5-gallon capacity

Cooling System

Air-cooled system with flywheel fan.

Ensure cooling fins are clean and unobstructed
Check flywheel fan blades for damage
Verify proper air flow around generator
Clean debris from cooling air intake

WARNING! Operating with blocked cooling fins can cause engine damage.

Troubleshooting Guide

Problem	Possible Cause	Solution
Engine won't start	Empty fuel tank, dead battery	Add fuel, charge/replace battery
No power output	Blown fuse, faulty breaker	Check/replace 20A fuses, reset breaker
Engine runs rough	Dirty air filter, bad spark plug	Clean/replace air filter and spark plug
Overheating	Blocked cooling fins	Clean cooling fins and air passages
Excessive vibration	Loose mounting bolts	Tighten all mounting hardware

Repair Procedures

Step-by-step repair instructions for common issues.

Spark Plug Replacement: Remove wire, clean area, install new plug gap 0.030"
Oil Change: Warm engine, drain oil, replace filter, refill with SAE 30
Carburetor Cleaning: Remove bowl, clean jets, reassemble with new gasket
Valve Adjustment: Set intake and exhaust to 0.010" cold
Starter Replacement: Disconnect battery, remove mounting bolts, install new starter

Parts List

Common replacement parts for Onan 6.5KW generator.

Part Number	Description
160-1046	Spark Plug
122-0750	Oil Filter
140-1455	Air Filter Element
160-2150	Fuel Filter
191-2150	Starter Motor
160-3025	Carburetor Kit

Warranty Information

Original 1986 warranty details and current support options.

Original Warranty: 2 years or 2000 hours from date of purchase. Coverage includes defects in materials and workmanship. Normal wear items, improper maintenance, and accident damage not covered.

Current Support: For technical assistance and parts availability, contact Onan Customer Service at 1-800-888-ONAN or visit www.onanparts.com. Many original 1986 parts are still available through specialized suppliers.