520h onan starter

[Denis L Goulet 22]

i have a wheelhorse 520h 1996,i have an issue with starter,it clicks a few times before starting,i replaced starter with new one and i have same problem,i checked all connections,all grounding wires,charged battery,replaced ignition,but have same problem,i tried to acces start relay under battery but cant acces because of cab,any ideas on what else i should verify before removing cab.

[ri702bill 10,085]

If you jump +12 volts to the starter connection - the one with the cable from the solenoid, and it spins right over 3 or for times, I'd be looking at the solenoid as the cause.

Secondly, pull the dreaded 9-pin connector apart & inspect for evidence of corrosion and / or overheating.... It may not be sending full voltage to the solenoid....

[gwest_ca-(File Mod) 11,752]

3 relays are all the same part number.

The wire colors going to each will be the way to identify what each does.

You need the kill relay to have ignition. You could borrow it to try in place of the switching relay and start relay as both are needed for the starter. It just won't run because of no ignition.

[lynnmor 8,091]

It is possible that your battery is bad, connect jumper cables from your car and try to start.

[Handy Don 14,697]

On 11/2/2025 at 4:31 PM, lynnmor said:

It is possible that your battery is bad, connect jumper cables from your car and try to start.

Seconding this. A dying battery can easily read 12v or more with no load but drop down a lot once connected to a load. 

[Denis L Goulet 22]

ok i will check battery, and ckeck the 9pine connection

[953 nut 62,227]

You should also take a look at the fuse holder for the 25 Amp fuse, if it is corroded that can reduce the voltage going to your solenoid to activate it.