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Remove broken bolts in muffler

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Remove remaining bolt if any then with smaller drill bit than bolt or bolts drill hole in center of one or each insert easy out into hole and spin easy out counter clock wise with wrench

Posted on Sep 13, 2013


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How to remove and replace the stator from a champion generator

You don't state what model you have. I just replaced the rotor on a Champion Model 41302 but removing the stator is the same process.

You will need to remove the muffler and muffler outer protection. Remove the bolts that hold the muffler outer protection. Remove the two bolts that hold muffler to the engine exhaust.

Take a block of wood and place it under the engine to support the generator. The supports on the generator head end will be removed so the generator will tip down and make it difficult to remove the stator.

Remove the generator end cover by removing two bolts.

Remove the two bolts that hold the muffler to the end cover.0834b898-460f-41f6-b0a0-6704ae605277.jpg

Remove the bolt that holds the ground from the generator to the frame.


Remove the two bolts that hold the end cover supports to the rubber supports to the frame.



Disconnect the quick connect electrical connectors and remove the 120/240 volt wiring from the terminal block. See second picture below.



Remove the ground from generator to wiring cable assembly by removing the bolt that connects it to the end cover. Yellow and green wire in picture above.

Remove the bolt from DC brush assembly and pull out of generator. Picture below shows assembly removed.


The stator and cover now can be removed from the generator. Take a rubber mallet to tap on the back of the brackets on the end cover to loosen it. The rotor bearing is seated in the end cover making it hard to remove by pulling by hand. Once lose pull straight out.

The stator can now be removed from the generator end by taking the four bolts out.

The installation process is the reverse.

Nov 27, 2013 | Electrical Supplies

1 Answer

Ford Escape with rusted, broken bolts/muffler hanging loose from catalytic converter estimate/fix

That is a pretty common issue with the escapes. Most of the time the broken bolts can be removed and new bolts along with a gasket can be installed and everything is fine. Sometimes the flanges are to rusted and the two pieces need to be replaced. Just depends on the vehicle.

Aug 13, 2012 | 2005 Ford Escape

1 Answer

Replace muffler on poulanpro 262 42cc

there is two bolts on the front of the muffler that hold it on remove the bolts and the muffler will come off most muffler problems are carbon build up inside the screen it is made to open to clean the screen

Jun 30, 2012 | Garden

1 Answer

One of the bolts that holds the muffler on broke off flush with the head. how do you remove the broken bolt from the clyinder block?

You need a screw extractor. Google it. There are several styles. They aren't expensive. Basically you drill a hole in the bolt (a little smaller hole than the bolt so you don't ruin the thread in the engine block), then you tap the extractor into the hole and turn it with a wrench. Good luck.

Apr 07, 2011 | Husqvarna Garden

1 Answer

How do i replace stud bolts that tighten the bar

if this is the plastic crankcase machine, the bar bolts are pressed into the case, start by removing the muffler, use a punch and drive the broken stud back through the case, it will have a square head on the rear, re fit the new stud, use a spscer and the bar nut to pull the new bolt fully back through.

Feb 11, 2011 | Poulan Pro 42CC 2 Cycle Chainsaw, 18"

1 Answer

On the right-side of my 3.9 liter Dakota, where the manifold comes-out of the engine, there is an aluminum heat-shield attached by a couple of bolts. the front bolt has either broken or whatever it was...

There is a tool you can buy for a few dollars that will turn out the broken bolt. Once removed replace it with a new bolt. This should solve your problem. Good luck

Nov 20, 2010 | 2002 Dodge Dakota Club Cab

1 Answer

Broken muffler mounting bracket

all bolts need to be heated very hot with a map gas torch or hotter get all the part around the bolt hot too. hit your wrench with a hammer ( JAR THE BOLTS LOOSE) The pipes mAY HAVE to be loosened at the engine first to get them to move around enough the heat and beat them loose. A good welder can just weld the bracket and grind it with it installed as long as it in a place that doesnt show and the place can be covered or painted to look OK. The welded bracket will be better than a new one and not removeing the bolts will make the bike stay together longer without any problems.

May 21, 2010 | 2003 Harley Davidson FLHTCUI Electra Glide...

1 Answer

1994 V6/AT Isuzu Trooper- Exhaust Manifold Bolt Studs stripped at muffler pipe connection. Can they be replaced without removing the passengers side manifold? What is best manual to cover this? Bob in...

there are several stud removers on the market and several broken bolt removers as well.
The best ones are the ones that have a reversed spiral inside them and tighten down on the stripped or broken bolt / stud as they are turned to remove it.
The Sears unit I use are about 1 inch tall and can be used with a wrench or socket.
Set over the bolt / stud , tap lightly as you slowly turn the tool with a small hammer to start it on the bolt, as soon as it catches switch to a wrench and remove as you would a regular bolt.

Jan 23, 2010 | 1994 Isuzu Trooper

2 Answers

Muffler strap broken on 2001 saturn sc1 series how to repair the easy way

Part is a dealer only part. There is 2 pieces to it. The strap is all you should purchase. The other part disconnects via a treaded bolt through the rubber mount above the muffler. Loosen the bolt/clamp on the muffler first this will give you the room to reach above the muffler with good lighting.

Sep 11, 2009 | 1993 Saturn SC1

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