[CaptGregSTX]

Update on my leak generator situation...removing the top sound shield cover was the breakthrough I needed to get a look at the exhaust pipe, rubber elbow, and SS tube. It wasn't easy to remove. There is almost no clearance above the cover to lift the hinges that lock it to the read sound shield panel. I was able to wedge the right side of the shield forward enough to lift the hinge, but no luck with the left side...after a lot of pondering, I decided to sacrifice the hinge and pulled the rivets out. Next came the screws on the left that connected the top shield to the left side of the generator where the control box sits. Those screws were incredibly tight...PB blaster overnight didn't help much. Finally able to remove 5 of 8 with as much torque as I had in my wrists, 2 of the remaining 3 had to be drilled out and the last one (located in the far back corner) really tested my patience. Finally got a Dremel tool back there and cut off the head of the screw. So, with the top panel removed, I could stick my head back in there and get a look at the connections. I fired up the genset and felt along the hose connections, then down the SS pipe. That's when I felt the pinhole leak. So I removed everything and (incidentally) noticed that I broke one of the connectors to the hi temp cut out switch, which is not a cheap or easy part to replace. I think I was successful in epoxying the switch back together and tested it with a lighter...works (but I think I will buy a new one anyway). I got the SS pipe home, cleaned it up and looked for the pinhole leak, but couldn't find it; so I tried adding a little pressure though I really didn't do a proper test and still had no luck. I found a replacement kit at greatlakesskipper for about $90 (plus $40 to ship Priority Mail), so I'm hoping it gets here by the end of the week. This project has allowed me to clean up the sound shield panels, they were a complete mess with fragments of black foam falling everywhere, and install new sound dampening material. Wow, this has been quite the job...posting my experience in case someone like me comes along down the road with leaky Onan MDKAL. Thanks again ReelMagic, I would not have had the confidence in making it through this project without your guidance.

[ReelMagic]

Congratulations on getting it apart and on your way to fixing it. As I said it was no easy task. Your shield must be different from mine as I have an MDKAV unit (2003 ONAN).... Top was held in place by bolts and wasn't attached to the rear panel. The rear panel was connected the same as the front panel, using the 2 twist locks.... Oh well its great to hear your this far....Hopefully the leak was the SS tube as that was my problem.. The pin hole was about the size of a # 80 drill.... Really, really, small.. In any case glad to help... Have a great holiday and New Year