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Old 09-13-2016, 10:14 PM   #1
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Stuck Spark Arrester Bolt on Onan 10kw

Went to do my annual Generator service on our 3 year old coach. This was the first time I had done it myself. Problem is getting the Spark Arrester Bolt out. It is a 11/16" Brass Bolt. It says to do it every year or 150 hours, I'm betting that when I had the generator serviced they definitely didn;t try to clean the spark arrestor. Should add that there is 260 hours on it.

I can't get it to budge, if I try any harder I think I'll round off the bolt.
I'm going to soak it for a few days with a penetrating oil. Was wondering if any of you have any other suggestions.
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Old 09-13-2016, 10:32 PM   #2
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Others may have another opinion--but didn't "service" the arrestor on my 7500QD for 12 years. Recently had the mufflers out for another reason so decided to remove plug--didn't find anything inside. Did I mention--1500 hrs on the genset????????
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Old 09-13-2016, 11:53 PM   #3
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Spray the plug with penetrating oil daily for a few days. If needed apply torch heat briefly to metal around the outside of the plug, then immediately apply torque.
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Old 09-14-2016, 12:33 AM   #4
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Spray the plug with penetrating oil daily for a few days. If needed apply torch heat briefly to metal around the outside of the plug, then immediately apply torque.
Yup.
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Old 09-14-2016, 03:20 AM   #5
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I have attended several Onan Seminars and was told never take it out!
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Old 09-14-2016, 05:04 AM   #6
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Run genset for a few heats up naturally Give it a try. I have 2400 hrs. No issues, don't think previous owner ever did this task. Let us know.


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Old 09-14-2016, 07:33 AM   #7
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Run genset for a few heats up naturally Give it a try. I have 2400 hrs. No issues, don't think previous owner ever did this task. Let us know.


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This might work, might try soaking it with penetrating oil for a week and then run the gennie.

As for heating up with torch, there's not enough room to comfortably do that. Could end up needing to replace the whole gennie
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Old 09-14-2016, 07:50 AM   #8
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As others have said if you really want to get it out spray it with a rust solvent. I've found PB Blaster works better than others. Also use an 8 or 12 point socket to remove it. They'll get a better grip and you won't round off the corners. When it's time to reinstall it use some high temp anti seize. It'll come out much easier the next time.
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Old 09-14-2016, 08:06 AM   #9
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PB Blaster. I put some on my 18 year old 454 engine exhaust manifold bolts. Each day I put on another coat, by the end of one week I was able to remove all bolts without breaking a single one. Stuff works!
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Old 09-14-2016, 08:24 AM   #10
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X2 for PB Blaster. Great stuff.
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Old 09-14-2016, 09:41 PM   #11
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Didn't find any PB Blaster today but did get a can of Seafoam Penetrating Lubricant, hopefully it will work as good as the PB Blaster
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Old 09-15-2016, 05:39 AM   #12
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We have a 4000 Onan and couldn't get the brass plug out of it even after trying everything listed above. I finally drilled a 13/32 hole through the existing brass plug and tapped it 1/8-27 NPT and used a new plug. Did the clean out procedure and didn't see anything blow out of the hole so maybe not really needed. Put high temp neversieze on the new plug so hopefully it will come out at the next service. Jim.
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Old 09-15-2016, 08:35 AM   #13
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I am afraid you maybe about to violate golden rule #2 of RV ownership "....if it ain't broke, don't fix it!...." Just saying.... as a certified member of the #2 club .....[smile]
PS--using #2 for this rule is not a coincidence....
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Old 09-15-2016, 10:34 AM   #14
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I am afraid you maybe about to violate golden rule #2 of RV ownership "....if it ain't broke, don't fix it!...." Just saying.... as a certified member of the #2 club .....[smile]
PS--using #2 for this rule is not a coincidence....
Since I have the oppurtunity to soak it and try over the next 2 weeks I will.

But if that fails I will adopt rule #2. Cause to get the muffler out is a lot more time and effort than i care to invest at this time. So I would let it go until it becomes a problem.
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