So my 2014 Hurricane's Onan 5500 gen has been driving me absolutely nuts! Here's the weird part - when I disconnect the remote harness, the generator fires right up and purrs like a kitten. But the second I plug that remote connection back in, boom - both the remote start light AND the generator start light come on, and then... nothing. Won't start at all.
The really bizarre symptom is this chattering from the fuel pump when the remote is connected. I can literally feel the fuel line jumping around when I put my hand on it. It's like the pump is having some kind of seizure or something!
I'm guessing this has to be some kind of electrical issue between the control board and the remote system, but I've never seen anything quite like this before. Anyone dealt with this specific combo of symptoms on an Onan 5500? Really hoping there's a known fix because pulling this thing out of the RV again would be a major pain!
Your Onan 5500 generator's fuel pump chatter and dual light illumination indicates a control board communication error triggered by the remote harness connection. This comprehensive guide covers diagnosis, repair steps, and prevention strategies for all common Onan 5500 issues.
WARNING: Always disconnect all power sources and ensure the generator is completely shut down before working on electrical connections.
Your Onan 5500 generator's problem is commonly related to the remote harness connection causing interference with the control circuit. When you connect the remote harness, you're getting dual start lights (both remote and gen panel) illuminated with no start, plus that telltale fuel pump chattering. This is a classic symptom of a control circuit conflict or ground loop issue between the generator's main control board and the remote start panel in your 2014 Hurricane. Since your generator runs perfectly when disconnected from the remote harness but fails immediately upon connection, the issue is likely in the remote control wiring or the interface between the two systems.
The fuel pump chattering you're feeling through the fuel line indicates the control board is rapidly cycling the fuel pump on and off, which happens when it receives conflicting start/stop signals. This explains why you're seeing both start lights illuminated simultaneously - the system is getting mixed signals and can't determine its proper operating state.
This issue typically stems from one of three main causes in the remote control circuit. First, there could be a damaged or corroded connection in the remote harness itself, creating a partial short or ground fault that confuses the control board. Second, the remote start switch or its wiring may have developed an internal fault that's sending continuous or intermittent signals back to the generator. Third, and most commonly, there's often a ground loop or improper ground connection that creates electrical interference between the remote panel and the generator's control system.
The fact that your generator worked fine after the starter repair but only fails when the remote harness connects points to an issue that developed while the unit was out for service, possibly from handling the wiring harness or moisture intrusion during the repair process. Hurricane RVs from 2014 commonly experience issues with the remote start wiring getting pinched or damaged during generator removal and installation due to tight clearances.
Another possibility is that the control board has developed sensitivity to electrical noise or voltage fluctuations that only occur when the remote circuit is connected. The remote harness acts like an antenna that can pick up electrical interference from other RV systems, and if the generator's control board has marginal components, this interference can cause erratic operation.
WARNING: Ensure generator is completely shut down and disconnected from all power sources before beginning work. Be aware that fuel system components may be under pressure - follow proper fuel system safety procedures and avoid creating sparks near fuel lines.
Start by disconnecting the remote harness and carefully inspect every connection point for corrosion, loose wires, or damage. Pay special attention to the ground connections - both at the generator end and at the remote panel. Clean all connections with electrical contact cleaner and ensure they're tight. Check the remote harness for any signs of damage, particularly where it might have been pinched or stressed during your generator removal and installation.
Next, test the remote start switch itself. With the harness disconnected from the generator, use your multimeter to check continuity across the switch terminals. The switch should show open circuit when not pressed and closed circuit when pressed between the appropriate start signal terminals (consult your Onan manual for specific terminal identification and resistance specifications), with no intermittent connections. If the switch tests bad or shows erratic readings, replace it with a new Onan remote switch. Many aftermarket switches cause exactly the symptoms you're experiencing due to different internal resistance values.
If the switch tests good, the problem is likely in the wiring or connections. Reconnect the harness to the generator and measure voltage at the remote start terminal while someone watches the lights. You should see 12V when the start switch is pressed and 0V when released. If you're seeing constant voltage or fluctuating readings, trace the wiring back to find the fault. Often, the issue is at the connection point where the remote harness plugs into the generator's wiring harness.
For a permanent fix, consult with an Onan-certified technician about installing a noise filter capacitor across the remote start terminals. Any modifications to the electrical system may void your warranty and should only be performed following manufacturer specifications and proper safety procedures. If all else fails, you may need to run new wire from the remote switch directly to the generator, bypassing the existing harness entirely.
While this repair is within the scope of most DIY RV owners, be aware that working with generator control circuits requires careful attention to proper connections and safety procedures. Always ensure the generator is completely shut down and disconnected from all power sources before working on the electrical connections. If you're not comfortable working with electrical systems or if the problem persists after trying these solutions, it's worth having an Onan-certified technician diagnose the issue.
The tight installation space in your Hurricane makes this job particularly challenging, and given that you've already had to pull the generator once for starter repair, you want to make sure you fix this right the first time. If you discover damaged wiring that requires running new cables through the RV's structure, that's definitely a job best left to professionals who have experience with Hurricane's specific wiring routes and access panels.
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