Champion Power Equipment 46505 Operator's Manual for All Serial Numbers in

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OWNER’S MANUAL & OPERATING INSTRUCTIONS

4000 Starting Watts/3500 Rated Watts
Wireless Remote, Electric Start

PORTABLE GENERATOR

MODEL NUMBER

46505

10006 Santa Fe Springs Road

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

MADE IN CHINA

REV 46505-20130218

www.championpowerequipment.com

Santa Fe Springs CA 90670

USA / 1-877-338-0999

AN IMPORTANT MESSAGE ABOUT TEMPERATURE:

Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to
40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -15°C (5°F) to
50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be
brought back within this range before operation. In any event, the product must always be operated outdoors, in a
well-ventilated area and away from doors, windows and other vents.

Have questions or need assistance?

Do not return this product to the store!

WE ARE HERE TO HELP!

Visit our website:

www.championpowerequipment.com

for more info:

• Product Info & Updates

• Frequently Asked Questions

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

• Tech Bulletins

• Product Registration

WARNING:

The Engine Exhaust from this product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

TABLE OF CONTENTS

46505

4000 Starting Watts/3500 Rated Watts

Wireless Remote, Electric Start

PORTABLE GENERATOR

Introduction ............................. 1

Introduction ........................... 1

Portable Power Generator .................. 1

Accessories ........................... 1

This Booklet ........................... 1

Manual Conventions. . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Rules ............................. 3

Controls and Features ...................... 5

Generator ............................. 5

Power Panel ........................... 6

Wireless Remote Control .................. 7

Remote Control Power Consumption ........ 7

Power Panel Load Management ........... 7

Parts Included ......................... 8

Wheel Kit .......................... 8

Other ............................. 8

Assembly ............................... 9

Remove the Generator from the Shipping Carton .. 9

Install the Wheel Kit ..................... 9

Install the Support Leg ................... 9

Install the Handles ...................... 9

Connect the Battery ..................... 9

Add Engine Oil ........................ 10

Add Fuel ............................ 11

Grounding ........................... 11

Operation .............................. 12

Generator Location ..................... 12

Grounding ........................... 12

Surge Protection ....................... 12

Wireless Remote and Electric Start .......... 13

Recoil Start .......................... 13

Connecting Electrical Loads ............... 14

Stopping the Engine .................... 14

Do Not Overload Generator ................ 15

Capacity .......................... 15

Power Management ................... 15

Operation at High Altitude ................ 15

Maintenance and Storage ................... 16

Engine Maintenance .................... 16

Oil .............................. 16

Spark Plugs ........................ 16

Air Filter .......................... 16

Spark Arrester ...................... 17

Cleaning .......................... 17

Adjustments ........................ 17

Maintenance Schedule ................ 17

Generator Maintenance .................. 17

Storage ............................. 18

Generator Storage .................... 18

Battery ........................... 18

Charge the Battery ................... 18

Disconnect the Battery ................ 18

Remote Control Battery ................ 18

Specifications ........................... 19

Engine Specifications ................... 19

Generator Specifications ................. 19

Fuel ............................... 19

Oil ................................ 19

Spark Plugs .......................... 19

Maintenance Valve Clearance .............. 19

FCC Statement for Remote Control Device ..... 19

Wiring Diagram ........................ 20

Parts Diagram ........................ 21

Parts List ............................ 22

Engine Parts Diagram ................... 23

Engine Parts List ...................... 24

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 25

Warranty .............................. 26

Warranty Qualifications .................. 26

Repair/Replacement Warranty .............. 26

Do Not Return The Unit To

The Place Of Purchase .................. 26

Warranty Exclusions .................... 26

Normal Wear ....................... 26

Installation, Use and Maintenance ........ 26

Other Exclusions ..................... 26

Limits of Implied Warranty

and Consequential Damage ............. 26

Contact Information. . . . . . . . . . . . . . . . . . . . . 26

Address ........................... 26

Customer Service .................... 26

Technical Service .................... 26

INTRODUCTION

ENGLISH 46505

Introduction

Congratulations on your purchase of a Champion

Power Equipment generator. CPE designs and builds

generators to strict specifications. With proper use and

maintenance, this generator will bring years of satisfying

service.

Portable Power Generator

This unit is a gasoline engine driven, alternating current

(AC) generator. It is designed to supply electrical power

for lighting, appliances, tools and similar equipment.

Record the model and serial numbers as well as date and place of purchase for future reference. Have this

information available when ordering parts and when making technical or warranty inquiries.

Accessories

Champion Power Equipment manufactures and sells

accessories designed to help you get the most from your

purchase. To find out more about our covers and power

cables, please visit our web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and

completeness of the information in this manual. We reserve

the right to change, alter and/or improve the product and

this document at any time without prior notice.

Champion Power Equipment Support

1-877-338-0999

Model Number

46505

Serial Number

Date of Purchase

Purchase Location

For O il Typ e see ‘Add Engine Oil‘ section. For Fuel Typ e see ‘Add Fuel‘ section.

1 REV 46505-20130218

46505 ENGLISH

MANUAL CONVENTIONS

This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol

is used with a key word to alert you to potential hazards in operating and owning power equipment.

Follow all safety messages to avoid or reduce the risk of serious injury or death.

DANGER

DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.

WARNING

WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.

CAUTION

CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, may result in property damage.

NOTE

If you have questions regarding your generator, we can
help. Please call our help line at 1-877-338-0999

REV 46505-20130218 2

SAFETY RULES

ENGLISH 46505

WARNING

Read this manual thoroughly before operating your
generator. Failure to follow instructions could result
in serious injury or death.

WARNING

The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm.

DANGER

Generator exhaust contains carbon monoxide, a
colorless, odorless, poison gas. Breathing carbon
monoxide will cause nausea, dizziness, fainting or
death. If you start to feel dizzy or weak, get to fresh
air immediately.

Operate generator outdoors only in a well ventilated
area.
DO NOT operate the generator inside any building,
including garages, basements, crawlspaces and
sheds, enclosure or compartment, including the
generator compartment of a recreational vehicle.
DO NOT allow exhaust fumes to enter a confined
area through windows, doors, vents or other
openings.
DANGER CARBON MONOXIDE: using a generator
indoors CAN KILL YOU IN MINUTES.

DANGER

Rotating parts can entangle hands, feet, hair,
clothing and/or accessories.
Traumatic amputation or severe laceration can result.

DANGER

Generator produces powerful voltage.

DO NOT touch bare wires or receptacles.
DO NOT use electrical cords that are worn, damaged
or frayed.
DO NOT operate generator in wet weather.
DO NOT allow children or unqualified persons to
operate or service the generator
Use a ground fault circuit interrupter (GFCI) in damp
areas and areas containing conductive material such
as metal decking.
Use approved transfer equipment to isolate generator
from your electric utility and Notify your utility
company before connecting your generator to your
power system.

WARNING

Sparks can result in fire or electrical shock.

When servicing the generator:

Disconnect the spark plug wire and place it where it
cannot contact the plug.
DO NOT check for spark with the plug removed.
Use only approved spark plug testers.

WARNING

Running engines produce heat. Severe burns can
occur on contact.
Combustible material can catch fire on contact.

DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least three feet of clearance on all sides
to ensure adequate cooling.
Maintain at least five feet of clearance from
combustible materials.

WARNING

Keep hands and feet away from rotating parts.
Tie up long hair and remove jewelry.
Operate equipment with guards in place.
DO NOT wear loose-fitting clothing, dangling
drawstrings or items that could become caught.

3 REV 46505-20130218

Medical and Life Support Uses.

In case of emergency, call 911 immediately.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical devices
or medical appliances.
Inform your electricity provider immediately if you
or anyone in your household depends on electrical
equipment to live.
Inform your electrical provider immediately if a
loss of power would cause you or anyone in your
household to experience a medical emergency.

46505 ENGLISH

SAFETY RULES

DANGER

Fuel and fuel vapors are highly flammable and
extremely explosive.
Fire or explosion can cause severe burns or death.
Unintentional startup can result in entanglement,
traumatic amputation or laceration.

When adding or removing fuel:

Turn the generator off and let it cool for at least two

minutes before removing the fuel cap. Loosen the

cap slowly to relieve pressure in the tank.

Only fill or drain fuel outdoors in a well-ventilated area.

DO NOT pump gas directly into the generator at the

gas station. Use an approved container to transfer

the fuel to the generator.

DO NOT overfill the fuel tank.

Always keep fuel away from sparks, open flames,

pilot lights, heat and other sources of ignition.

DO NOT light or smoke cigarettes.

When starting the generator:

DO NOT attempt to start a damaged generator.

Make certain that the gas cap, air filter, spark plug,

fuel lines and exhaust system are properly in place.

Allow spilled fuel to evaporate fully before

attempting to start the engine.

Make certain that the generator is resting firmly on

level ground.

When operating the generator:

DO NOT move or tip the generator during operation.

DO NOT tip the generator or allow fuel or oil to spill.

WARNING

Rapid retraction of the starter cord will pull hand and
arm towards the engine faster than you can let go.
Unintentional startup can result in entanglement,
traumatic amputation or laceration.
Broken bones, fractures, bruises or sprains could result.

When starting engine, pull the starter cord slowly
until resistance is felt and then pull rapidly to avoid
kickback.
DO NOT start or stop the engine with electrical
devices plugged in.

CAUTION

Exceeding the generator’s running capacity can
damage the generator and/or electrical devices
connected to it.

DO NOT overload the generator.
Start the generator and allow the engine to stabilize
before connecting electrical loads.
Connect electrical equipment in the off position,
and then turn them on for operation.
Turn electrical equipment off before stopping the
generator.
DO NOT tamper with the governed speed.
DO NOT modify the generator in any way.

CAUTION

Improper treatment or use of the generator can
damage it, shorten its life and void your warranty.

When transporting or servicing the generator:

Make certain that the fuel shutoff valve is in the off

position and the fuel tank is empty.

Disconnect the spark plug wire.

When storing the generator:

Store away from sparks, open flames, pilot lights,

heat and other sources of ignition.

WARNING

Operation of this equipment may create sparks that
can start fires around dry vegetation.

A spark arrestor may be required. The operator
should contact local fire agencies for laws or
regulations relating to fire prevention requirements.

Use the generator only for intended uses.
Operate only on level surfaces.
DO NOT expose generator to excessive moisture,
dust, or dirt.
DO NOT allow any material to block the cooling slots.
If connected devices overheat, turn them off and
disconnect them from the generator.
DO NOT use the generator if:

– Electrical output is lost
– Equipment sparks, smokes or emits flames
– Equipment vibrates excessively

REV 46505-20130218 4

ENGLISH 46505

CONTROLS AND FEATURES

Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the

controls and features. Save this manual for future reference.

Generator

1

2

3

4

5

(1) Fuel Tank – 3.8 gallon (14.4 L) capacity fuel tank.

(2) Auto-Choke – Used to start the engine. No manual

adjustment required.

(3) Fuel Valve – Turn this valve to the “ON” position to

supply fuel to the engine.

(4) Air Cleaner – Protects the engine by filtering dust

and debris from the intake air.

8

6

(5) Recoil Starter – Used to start the engine.

(6) Oil Filler Cap – Check and fill engine oil level.

(7) Battery – Used to start the engine. Provides 12V

DC to the electric starter and receiver control

module.

(8) Power Panel – See “Power Panel” section.

7

5 REV 46505-20130218

46505 ENGLISH

Power Panel

CONTROLS AND FEATURES

1

2

4

5 6 7 8

3

(1) Intelligauge™ – Three mode digital meter for

running hours, voltage and hertz.

(2) Ignition Switch

(3) Circuit Breaker(s) – Protects the generator against

electrical overload.

(4) Battery Switch – Enables /disables starting

electrically – via remotely or by Ignition Switch.

(5) Ground Terminal – Consult an electrician for local

grounding regulations.

(6) 120 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L5-30R) –

power for the operation of 120 Volt AC, 30 Amp,

single phase 60 Hz electrical loads.

(7) 120 Volt AC, 30 Amp Receptacle (NEMA TT-30R)

May be used to supply electrical power for the

–

operation of 120 Volt AC, 30 Amp, single phase

60 Hz electrical loads.

(8) 120 Volt AC, 20 Amp Duplex (NEMA 5-20R) –

May be used to supply electrical power for the

operation of 120 Volt AC, 20 Amp, single phase

60 Hz electrical loads.

May be used to supply electrical

REV 46505-20130218 6

CONTROLS AND FEATURES

ENGLISH 46505

Wireless Remote Control

This generator is equipped with a wireless remote
control system for starting and stopping. The system
consists of (4) main components:

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

4. Ignition Switch
The Remote Control functions are enabled when:

1. The Ignition Switch is in the “ON” position, AND

2. The Battery Switch is in the “ON” position.
The Remote Control functions are disabled if either of
the above conditions is not met.
To start the generator by Remote Control, press the
“START” button on the Remote one time. The engine
will attempt to start (6) times. The RCM controls
the Auto Choke during each attempt to start. If the
generator does not start, call Champion Customer Care
team for assistance at 1-877-338-0999.
To stop the generator by Remote Control, press the

“STOP” button on the Remote one time.

Power Panel Load Management Cont’d.

The on/off voltage delay at startup and shut down only
happen when the Remote Control is used. There is no
voltage delay when the pushbutton electric start or recoil
start method is used.

When the pushbutton electric start or recoil start
method is used, the operator must be sure all electrical
loads (appliances) are turned OFF during startup and
shutdown. Damage to the generator or the attached
appliances can be caused by starting or stopping the
generator while appliances are plugged in and turned ON.

Remote Control Power Consumption

While the Ignition Switch is in the “ON: position, the
RCM is active and waiting for a remote signal. This
function requires electrical current from the battery.
If the Ignition Switch is left in the “ON” position for
extended periods (several weeks), the battery can be
completely drained.
Moving the Ignition Switch to the “OFF” position
disables the Remote functions, but the RCM still
consumes approximately 2 mA from the battery.
To prevent battery drain, press the Battery Switch to the
“OFF” position. This disconnects power to the RCM so

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no
voltage is supplied to the Power Panel for approximately
15 seconds. This allows the engine to reach full speed
before electrical loads are applied to the generator.
When the generator is stopped by the Remote, the
voltage to the Power Panel is immediately turned off.
Then the engine stops approximately 5 seconds after
the “STOP” button on the Remote is pressed. Turning
the Power Panel voltage off before the engine shutdown
protects connected appliances from being damaged by
non-60 Hz voltage while the generator coasts to a stop.

7 REV 46505-20130218

46505 ENGLISH

Parts Included

Your 46505 Gasoline Powered Generator ships with the

following parts:

Wheel Kit

– 8 in. Wheel ...........................2

– Bushing ..............................2

– Nut (M10 ) ............................ 2

– Flat Washer 10 ......................... 2

– Support Leg (w/vibration mounts) ............1

– Handle ..............................1

– Flange Bolt (M10x105 for Wheel) ............2

– Flange Bolt (M8x45 for Handle) .............2

– Flange Bolt (M8x16 for Support Leg) ..........2

– Nut (M8) ............................4

Other

– Oil Funnel ............................1

– Oil ............................ 0.63 qt.

– Spark Plug Socket ....................... 1

– Remote ..............................1

CONTROLS AND FEATURES

REV 46505-20130218 8

ASSEMBLY

ENGLISH 46505

Your generator requires some assembly. This unit ships

from our factory without oil. It must be properly serviced

with fuel and oil before operation.

If you have any questions regarding the assembly of your

generator, call our help line at 1-877-338-0999. Please

have your serial number and model number available.

Remove the Generator from the Shipping Carton

1. Set the shipping carton on a solid, flat surface.

2. Remove everything from the carton except the

generator.

3. Carefully cut each corner of the box from top to

bottom. Fold each side flat on the ground to provide a

surface area to install the wheel kit and support leg.

Install the Wheel Kit

CAUTION

The wheel kit is not intended for over-the-road use.

You will need the following tools to install the wheels:

• 17 mm wrench OR adjustable wrench (not included)

• Socket wrench with a 16 mm socket (not included)

• Pliers (not included)

Install the Support Leg

1. Attach the support leg to the generator frame with

cap screws (M8x16) and lock nuts (M8).

2. Tip the generator slowly so that it rests on the

wheels and support leg.

Install the Handles

1. Place the handle over the mounting channel on the

frame.

2. Secure the handle to the frame using the two handle

bolts (M8x45).

3. Place a lock nut (M8) on the end of each bolt and

fasten securely. DO NOT over tighten the lock nuts.

1. Before adding fuel and oil, tip the generator on it’s side.

2. Slide the M10x105 wheel bolt through the washer,

sleeve and wheel.

3. Slide the bolt through the mount point on the frame.

4. Fasten securely with the M10 nut.

5. Repeat steps 2-4 to attach the second wheel.

Connect the Battery

1. Remove the protective cover from the red (+) lead on

the bat tery.

2. Attach the red (+) lead to the red (+) terminal on the

battery with the cap screw (M5x12) and secure with

the lock washer (M5).

3. Repeat steps 1-2 for the black (–) battery lead.

9 REV 46505-20130218

46505 ENGLISH

ASSEMBLY

Add Engine Oil

CAUTION

DO NOT attempt to crank or start the engine before
it has been properly filled with the recommended
type and amount of oil. Damage to the generator as
a result of failure to follow these instructions will
void your warranty.

NOTE

The recommended oil type is 10W-30 automotive oil.

1. Place the generator on a flat, level surface.

Add Engine Oil Cont’d.

NOTE

Check oil often during the break-in period. Refer to the
Maintenance section for recommended service intervals.

NOTE

The generator rotor has a sealed, pre-lubricated ball
bearing that requires no additional lubrication for
the life of the bearing.

2. Remove oil fill cap/dipstick to add oil.

3. Add 0.63 qt. (0.6 L) of oil (included) and replace oil

fill cap/dipstick. DO NOT OVERFILL.

4. Check engine oil level daily and add as needed.

CAUTION

The engine is equipped with a low oil shut-off and
will stop when the oil level in the crankcase falls
below the threshold level.

REV 46505-20130218 10

ASSEMBLY

ENGLISH 46505

Add Fuel

1. Use clean, fresh, regular unleaded fuel with a

minimum octane rating of 85 and an ethanol content

of less than 10% by volume.

2. DO NOT mix oil with fuel.

3. Clean the area around the fuel cap.

4. Remove the fuel cap.

5. Slowly add fuel to the tank. DO NOT OVERFILL.

Fuel can expand after filling. A minimum of ¼ in.

(0.64 cm) of space left in the tank is required

for fuel expansion, more than ¼ in. (0.64 cm) is

recommended. Fuel can be forced out of the tank as

a result of expansion if it is overfilled, and can affect

the stable running condition of the product. When

filling the tank, it is recommended to leave enough

space for the fuel to expand.

Add Fuel Cont’d.

NOTE

Our engines work well with 10% or less ethanol

blend fuels. When using blended fuels there are

some issues worth noting:

– Ethanol-gasoline blends can absorb more water

than gasoline alone.

– These blends can eventually separate, leaving

water or a watery goo in the tank, fuel valve and

carbur eto r.

– With gravity-fed fuel supplies, this compromised

fuel can be drawn into the carburetor and cause

damage to the engine and/or potential hazards.

– There are only a few suppliers of fuel stabilizer

that are formulated to work with ethanol blend

fuels.

– Any damages or hazards caused by using

improper fuel, improperly stored fuel, and/

or improperly formulated stabilizers, are not

covered by manufacture’s warranty.

It is advisable to always shut off the fuel supply,

run the engine to fuel starvation and drain the tank

when the equipment is not in use for more than 30

days.

6. Screw on the fuel cap and wipe away any spilled fuel.

CAUTION

Use regular unleaded gasoline with a minimum
octane rating of 85.

Do not mix oil and gasoline.
Fill tank to approximately ¼ in. (0.64 cm) below
the top of the tank to allow for fuel expansion.
DO NOT pump gas directly into the generator at the
gas station. Use an approved container to transfer
the fuel to the generator.
DO NOT fill fuel tank indoors.
DO NOT fill fuel tank when the engine is running or hot.
DO NOT overfill the fuel tank.
DO NOT light cigarettes or smoke when filling the
fuel tank.

WARNING

Pouring fuel too fast through the fuel screen may
result in blow back of fuel at the operator while filling.

Grounding

Your generator must be properly connected to an

appropriate ground to help prevent electric shock.

WARNING

Failure to properly ground the generator can result
in electric shock.

A ground terminal connected to the frame of the generator

has been provided on the power panel. For remote

grounding, connect of a length of heavy gauge

(12 AWG minimum) copper wire between the generator

ground terminal and a copper rod driven into the ground.

We strongly recommend that you consult with a qualified

electrician to ensure compliance with local electrical codes.

11 REV 46505-20130218

46505 ENGLISH

OPERATION

Generator Location

NEVER operate the generator inside any building,

including garages, basements, crawlspaces and sheds,

enclosure or compartment, including the generator

compartment of a recreational vehicle. Please consult

your local authority. In some areas, generators must

be registered with the local utility. Generators used at

construction sites may be subject to additional rules and

regulations. Generators should be on a flat, level surface

at all times. (Even while not in operation) Generators

must have at least five feet of clearance from all

combustible material. In addition to clearance from all

combustible material, generators must also have at least

three feet of clearance on all sides to allow for adequate

cooling, maintenance and servicing. Generators should

never be started or operated in the back of a SUV,

camper, trailer, in the bed of a truck (regular, flat or

otherwise), under staircases/stairwells, next to walls or

buildings, or in any other location that will not allow for

adequate cooling of the generator and/or the muffler.

DO NOT contain generators during operation. Allow

generators to properly cool before transport or storage.

Place the generator in a well-ventilated area. DO NOT

place the generator near vents or intakes where exhaust

fumes could be drawn into occupied or confined

spaces. Carefully consider wind and air currents when

positioning generator.

Failure to follow proper safety precautions may void

manufacturer’s warranty.

Grounding

The generator system ground connects the frame to the

ground terminals on the power panel.

– The generator (stator winding) is isolated from the

frame and from the AC receptacle ground pin.

– Electrical devices that require a grounded receptacle

pin connection will not function if the receptacle

ground pin is not functional.

Surge Protection

CAUTION

Voltage fluctuation may impair the proper
functioning of sensitive electronic equipment.

Electronic devices, including computers and many

programmable appliances use components that are

designed to operate within a narrow voltage range and

may be affected by momentary voltage fluctuations.

While there is no way to prevent voltage fluctuations, you

can take steps to protect sensitive electronic equipment.

1. Install UL1449, CSA-listed, plug-in surge suppressors

on the outlets feeding your sensitive equipment.

Surge suppressors come in single- or multi-outlet

styles. They’re designed to protect against virtually

all short-duration voltage fluctuations.

WARNING

Do not operate or store the generator in rain, snow,
or wet weather.

Using a generator or electrical appliance in wet
conditions, such as rain or snow, or near a pool or
sprinkler system, or when your hands are wet, could
result in electrocution.

WARNING

During operation the muffler and exhaust fumes
produced will become hot. If adequate cooling and
breathing space are not supplied, or if the generator
is blocked or contained, temperatures can become
extremely heated and may lead to fire.

REV 46505-20130218 12

OPERATION

ENGLISH 46505

Wireless Remote and Electric Start

Wireless remote starting is only possible within 80 feet

of the generator.

Do not attempt to adjust the carburetor choke. The

remote system will automatically close and open the

choke.

1. Make certain the generator is on a flat, level surface.

2. Turn the Fuel Valve to the “ON” position.

3. Press the Battery Switch to “ON”.

4. Press the Ignition Switch to “ON”.

5. WIRELESS REMOTE START: press and release the

“START” button on the handheld Remote Control

device. DO NOT hold the button down, only press

the button once. The engine will attempt to start six

times.

6. A safety feature is provided which delays the

electrical power availability during starting mode.

The delay lasts for approximately 15 seconds. The

delay is provided to prevent damage to the generator

if electrical loads are inadvertently turned on during

engine startup.

7. ELECTRIC START: Turn off all electrical loads

connected to the generator. Never start or stop the

generator with electrical devices plugged in and

turned on.

8. Press and hold the ignition switch to the “START”

position. Release as the engine begins to roll over. If

the engine fails to start within five seconds, release

the switch and wait at least ten seconds before

attempting to start the engine again.

9. If the generator fails to start, check the battery

condition and cable connections.

Recoil Start

1. Make certain the generator is on a flat, level surface.

2. Turn off all electrical loads connected to the

generator. Never start or stop the generator with

electrical devices plugged in and turned on.

3. Turn the Fuel Valve to the “ON” position.

4. Press the Ignition Switch to “ON”.

5. Move the choke lever to the “CHOKE” position.

6. Pull the starter cord slowly until resistance is felt and

then pull rapidly.

7. Do not over-choke. As as soon as engine starts, move

the choke lever to the “RUN” position.

NOTE

Keep choke lever in “Choke” position for only 1
pull of the recoil starter. After first pull, move choke
lever to the “Run” position for up to the next 3
pulls of the recoil starter. Too much choke leads to
spark plug fouling/engine flooding due to the lack of
incoming air. This will cause the engine not to start.

NOTE

If the engine starts but does not continue to run
make certain that the generator is on a flat, level
surface. The engine is equipped with a low oil
sensor that will prevent the engine from running
when the oil level falls below a critical threshold.

NOTE

When the battery switch is in the “ON” position,
the switch will light up if the battery is sending
out a charge. If the switch does not light up while
in the “ON” position, check that the battery
connection is still good.

NOTE

The supplied 12V 9AH battery does re-charge while
the engine is running, but it is also recommended
that the battery be fully charged at least once per
month.

13 REV 46505-20130218

46505 ENGLISH

OPERATION

Connecting Electrical Loads

1. Let the engine stabilize and warm up for a few

minutes after starting

2. Plug in and turn on the desired 120 Volt AC single

phase, 60 Hz electrical loads.

– DO NOT connect 3-phase loads to the generator.

– DO NOT connect 50 Hz loads to the generator.

– DO NOT overload the generator.

NOTE

Connecting a generator to your electric utility
company’s power lines or to another power source
may be against the law. In addition this action,
if done incorrectly, could damage your generator
and appliances and could cause serious injury or
even death to you or a utility worker who may be
working on nearby power lines. If you plan to run a
portable electric generator during an outage, please
notify your electric utility company immediately
and remember to plug your appliances directly
into the generator. Do not plug the generator into
any electric outlet in your home. Doing so could
create a connection to the utility company power
lines. You are responsible for ensuring that your
generator’s electricity does not feed back into the
electric utility power lines.
If the generator will be connected to a building
electrical system, consult your local utility company
or a qualified electrician. Connections must isolate
generator power from utility power and must comply
with all applicable laws and codes.

Stopping the Engine

1. Turn off and unplug all electrical loads. Never start

or stop the generator with electrical devices plugged

in or turned on.

2. Let the generator run at no-load for several minutes

to stabilize internal temperatures of the engine and

generator.

3. Turn the Fuel Valve to the “OFF” position.

4. Let the engine run until fuel starvation has stopped

the engine. This usually takes a few minutes.

5. Press the engine switch to the “OFF” position.

6. Press the battery switch to the “OFF” position.

Important: Always ensure that the Fuel Valve and the

Engine Switch are in the “OFF” position when the engine

is not in use.

NOTE

If the engine will not be used for a period of two (2)
weeks or longer, please see the Storage section for
proper engine and fuel storage.

NOTE

When the stop button on the remote is pressed,
power to the receptacles is turned off and the
engine will stop after 5 seconds.

REV 46505-20130218 14

OPERATION

ENGLISH 46505

Do Not Overload Generator

Capacity

Follow these simple steps to calculate the running and

starting watts necessary for your purposes.

1. Select the electrical devices you plan on running at

the same time.

2. Total the running watts of these items. This is

the amount of power you need to keep your items

running.

3. Identify the highest starting wattage of all devices

identified in step 1. Add this number to the number

calculated in step 2. Surge wattage is the extra

burst of power needed to start some electric driven

equipment. Following the steps listed under “Power

Management” will guarantee that only one device will

be starting at a time.

Power Management

Use the following formula to convert voltage and

amperage to watts:

Volts x Amps = Watts

To prolong the life of your generator and attached

devices, follow these steps to add electrical load:

1. Start the generator with no electrical load attached

2. Allow the engine to run for several minutes to stabilize.

3. Plug in and turn on the first item. It is best to attach

the item with the largest load first.

4. Allow the engine to stabilize.

5. Plug in and turn on the next item.

6. Allow the engine to stabilize.

7. Repeat steps 5-6 for each additional item.

NOTE

Never exceed the specified capacity when adding
loads to the generator.

Operation at High Altitude

The density of air at high altitude is lower than at sea

level. Engine power is reduced as the air mass and air-

fuel ratio decrease. Engine power and generator output

will be reduced approximately 3½% for every 1000

feet of elevation above sea level. This is a natural trend

and cannot be changed by adjusting the engine. At high

altitudes increased exhaust emissions can also result

due to the increased enrichment of the air fuel ratio.

Other high altitude issues can include hard starting,

increased fuel consumption and spark plug fouling.

To alleviate high altitude issues other than the natural

power loss, Champion Power Equipment can provide a

high altitude carburetor main jet. The alternative main

jet and installation instructions can be obtained by

contacting Customer Support. Installation instructions

are also available in the Technical Bulletin area of the

Champion Power Equipment internet site.

The part number and recommended minimum altitude

for the application of the high altitude carburetor main

jet is listed in the table below.

In order to select the correct high altitude main jet

it is necessary to identify the carburetor model. For

this purpose, a code is stamped on the side of the

carburetor. Select the correct main jet part number

corresponding to the carburetor code found on your

particular carburetor.

Carburetor
Code

P19-3 -Z

P19-3-H

P19-3-R

Main Jet Part Number Altitude

Standard 26. 131 017.20. Z

Altitude 26.131017.20 .01.Z

Standard 26. 131 017.20. H

Altitude 26.131017.20 .01.H

Standard 26. 131 017.20. R

Altitude 26.131017.20 .01.R

3500 feet
(106 7 m eter s)

WARNING

15 REV 46505-20130218

Operation using the alternative main jet at elevations
lower than the recommended minimum altitude can
damage the engine. For operation at lower elevations, the
standard main jet must be used. Operating the engine
with the wrong engine configuration at a given altitude
may increase its emissions and decrease fuel efficiency
and performance.

46505 ENGLISH

0.7 - 0.8 mm

0.028 - 0.031 in.

MAINTENANCE AND STORAGE

The owner/operator is responsible for all periodic

maintenance.

WARNING

Never operate a damaged or defective generator.

WARNING

Tampering with the factory set governor will void
your warranty.

WARNING

Improper maintenance will void your warranty.

NOTE

Maintenance, replacement, or repair of emission
control devices and systems may be performed
by any non-road engine repair establishment or
individual.

Complete all scheduled maintenance in a timely manner.

Correct any issue before operating the generator.

Oil Cont’d.

NOTE

Once oil has been added, a visual check should show
oil about 1-2 threads from running out of the fi ll hole.
If using the dipstick to check oil level, DO NOT screw
in the dipstick while checking.

Spark Plugs

1. Remove the spark plug cable from the spark plug.

2. Use the spark plug tool that shipped with your

generator to remove the plug.

3. Inspect the electrode on the plug. It must be clean and

not worn to produce the spark required for ignition.

4. Make certain the spark plug gap is 0.7 - 0.8 mm or

(0.028 - 0.031 in.).

NOTE

For service or parts assistance, contact our help
line at 1-877-338-0999

Engine Maintenance

To prevent accidental starting, remove and ground spark

plug wire before performing any service.

Oil

Change oil when the engine is warm. Refer to the oil

specifi cation to select the proper grade of oil for your

operating environment.

1. Remove the oil drain plug with a 12 mm socket and

extension.

2. Allow the oil to drain completely.

3. Replace the drain plug.

4. Remove oil fi ll cap/dipstick to add oil.

5. Add 0.63 qt. (0.6 L) of oil and replace oil fi ll

cap/dipstick. DO NOT OVERFILL.

6. Dispose of used oil at an approved waste

management facility.

5. Refer to the spark plug recommendation chart when

replacing the plug.

6. Carefully thread the plug into the engine.

7. Use the spark plug tool to fi rmly install the plug.

8. Attach the spark plug wire to the plug.

Air Filter

1. Remove the snap-on cover holding the air fi lter to

the assembly.

2. Remove the foam element.

3. Wash in liquid detergent and water. Squeeze

thoroughly dry in a clean cloth.

4. Saturate in clean engine oil.

5. Squeeze in a clean, absorbent cloth to remove all

excess oil.

6. Place the fi lter in the assembly.

7. Reattach the air fi lter cover and snap in place.

REV 46505-20130218 16

MAINTENANCE AND STORAGE

ENGLISH 46505

Spark Arrester

1. Allow the engine to cool completely before servicing
the spark arrester.

2. Remove the two screws holding the cover plate which
retains the end of the spark arrester to the muffler.

3. Remove the spark arrester screen.

4. Carefully remove the carbon deposits from the spark
arrester screen with a wire brush.

5. Replace the spark arrester if it is damaged.

6. Position the spark arrester in the muffler and attach
with the two screws.

CAUTION

Failure to clean the spark arrester will result in degraded
engine performance.

NOTE

Federal and local laws and administrative requirements
indicate when and where spark arresters are required.
When ordered, spark arresters are required for operation
of this generator in National Forest lands. In California,
this generator must not be used on any forest- covered
land, brush-covered land, or grass- covered land unless
the engine is equipped with a spark arrester.

Maintenance Schedule

Follow the service intervals indicated in the following

maintenance schedule.

Service your generator more frequently when operating

in adverse conditions.

Contact our helpline at 1-877-338-0999 to locate the

nearest Champion Power Equipment certified service

dealer for your generator or engine maintenance needs.

Every 8 hours or daily

Check oil level

Clean around air intake and muffler

First 5 Hours

Change oil

Every 50 hours or every season

Clean air filter

Change oil if operating under heavy load or in hot
environments

Every 100 hours or every season

Change oil

Clean/Adjust spark plug

Check/Adjust valve clearance*

Clean spark arrester

Clean fuel tank and filter*

Every 250 hours

Clean combustion chamber*

Every 3 years

Replace fuel line

*To be performed by knowledgeable, experienced owners or
Champion Power Equipment certified dealers.

Cleaning

CAUTION

DO NOT spray engine with water.

Water can contaminate the fuel system.

Use a damp cloth to clean exterior surfaces of the engine.
Use a soft bristle brush to remove dirt and oil.
Use an air compressor (25 PSI) to clear dirt and debris
from the engine.

Adjustments

The air-fuel mixture is not adjustable. Tampering with the
governor can damage your generator and your electrical
devices and will void your warranty. CPE recommends
that you contact our service line at 1-877-338-0999 for
all other service and/or adjustment needs.

17 REV 46505-20130218

Generator Maintenance

Make certain that the generator is kept clean and stored
properly. Only operate the unit on a flat, level surface in
a clean, dry operating environment. DO NOT expose the
unit to extreme conditions, excessive dust, dirt, moisture
or corrosive vapors.

CAUTION

DO NOT use a garden hose to clean the generator.

Water can enter the generator through the cooling
slots and damage the generator windings.

Use a damp cloth to clean exterior surfaces of the generator.
Use a soft bristle brush to remove dirt and oil.
Use an air compressor (25 PSI) to clear dirt and debris
from the generator.
Inspect all air vents and cooling slots to ensure that they
are clean and unobstructed.

46505 ENGLISH

MAINTENANCE AND STORAGE

Storage

The generator should be started at least once every 14
days and allowed to run for at least 20 minutes. For
longer term storage, please follow these guidelines.

Generator Storage

1. Add a properly formulated fuel stabilizer to the tank.

2. Be sure all appliances are disconnected from the
generator.

3. Run the generator for a few minutes so the treated
fuel cycles through the fuel system and carburetor.

4. Turn the fuel valve to the “Off” position.

5. Let the generator run until fuel starvation has
stopped the engine. This usually takes a few minutes.

6. The generator needs to cool acompletely before
cleaning and storage.

7. Clean the generator according to the maintenance
section.

8. Change the oil.

9. Remove the spark plug and pour about 1⁄2 ounce
of oil into the cylinder. Crank the engine slowly to
distribute the oil and lubricate the cylinder.

10. Reattach the spark plug.

11. Store the unit in a clean, dry place out of direct

sunlight.

Generator Battery

This product is equipped with an automatic battery
charging circuit. The battery will receive charging
voltage when the engine is running. The battery will
maintain a proper charge if the unit is used on a regular
basis (about once every two weeks). If it is used less
frequently, the battery should be connected to a trickle
charger or battery maintainer to keep the battery
properly charged. If the battery is not able to start the
engine, it can be started by manually pulling the engine
recoil cord. If the battery voltage is extremely low,
the charging circuit may not be able to re-charge the
battery. In this case, the battery must be connected
to a standard automotive style battery charger for re­charging before it can be used.

Charge the Battery

For a generator equipped with batteries for electric

starting, proper battery maintenance and storage

should be followed. An automatic battery charger with

automatic trickle charging capability should be used to

charge the battery. Maximum charging rate should not

exceed 1.5 amps. Follow the instructions included with

the battery charger. The battery should be fully charged

at least once per month.

DANGER

Generator exhaust contains odorless and colorless
carbon monoxide gas.

To avoid accidental or unintended ignition of your
remote start generator during periods of storage,
the following precautions should be followed:

– When storing the generator for short periods of

time make sure that the Ignition Switch, the Fuel
Valve and the Battery Switch are set in the OFF
position.

– When storing the generator for extended periods

of time make sure that the Ignition Switch, the
Fuel Valve and the Battery Switch are set in the
the the OFF position and the battery leads have
been disconnected from the battery.

NOTE

A Float Charger will maintain the battery condition
over long storage periods.

Disconnect the Battery

1. Remove the protective cover from the black/negative

battery lead.

2. Disconnect the black/negative lead from the black/

negative terminal on the battery and store the cap

screw (M5x10) and lock washer (M5).

3. Repeat steps 1-2 for the red/positive battery lead.

4. Store the battery in a cool, dry place.

Remote Control Battery

NOTE

– Always purchase the correct size and grade of

battery most suitable for the intended use.

– Clean the battery contacts and also those of the

device prior to battery installation.

– Remove batteries from equipment which is not to

be used for an extended period of time.

– Remove batteries if consumed or if product is to

be left unused for a long time.

REV 46505-20130218 18

SPECIFICATIONS

ENGLISH 46505

Engine Specifications

– Model .....................YF168FD-2-210

– Displacement .......................196cc

– Typ e ........................4-Stroke OHV

– Start Type ..................Wireless Remote

Generator Specifications

– Rated Wattage ..................3500 Watts

– Starting Wattage .................4000 Watts

– AC Load ..........................120 V

– Phase ............................Single

– Frequency .........................60 Hz

– Fuel Capacity ................3.8 gal. (14.4 L)

– Gross Weight ...............138 lbs (62.6 kg)

– Net Weight ............... 124.8 lbs (56.6 kg)

– Height ................ 21.8 inches (55.4 cm)

– Width ................ 23.9 inches (60.6 cm)

– Length. . . . . . . . . . . . . . . . 26.3 inches (66.7 cm)

Fuel

Fuel capacity is 3.8 gal. (14.4 L). Use regular unleaded

gasoline with a minimum octane rating of 85 and an

ethanol content of less than 10% by volume.

Oil

Use 10W-30 automotive oil.

Oil capacity is 0.63 qt. (0.6 L).

Please reference the following chart for recommended

oil types for use in the generator.

Spark Plugs

OEM spark plug: NHSP F6RTC

Replacement spark plug: NGK BPR6ES or equivalent

Make certain the spark plug gap is 0.7 - 0.8 mm or

(0.028 - 0.031 in.).

Maintenance Valve Clearance

– Intake: 0.13 – 0.17 mm (0.005 – 0.007 in.)

– Exhaust: 0.18 – 0.22 mm (0.007 – 0.009 in.)

Note: Tech bulletin regarding the valve adjustment

procedure is on www.championpowerequipment.com.

FCC Statement for Remote Control Device

1. This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) This device may not cause harmful interference.

(2) This device must accept any interference

received, including interference that may cause

undesired operation.

2. Changes or modifications not expressly approved by

the party responsible for compliance could void the

user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to

comply with the limits for a Class B digital device,

pursuant to Part 15 of the FCC Rules. These limits

are designed to provide reasonable protection against

harmful interference in a residential installation.

This equipment generates uses and can radiate radio

frequency energy and, if not installed and used in

accordance with the instructions, may cause harmful

interference to radio communications. However, there

is no guarantee that interference will not occur in a

particular installation. If this equipment does cause

harmful interference to radio or television reception,

which can be determined by turning the equipment

off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.

– Increase the separation between the equipment and

receiver.

– Connect the equipment into an outlet on a

circuit different from that to which the receiver is

connected.

Consult the dealer or an experienced radio/TV technician

for help.

19 REV 46505-20130218

46505 ENGLISH

Wiring Diagram

SPECIFICATIONS

REV 46505-20130218 20

SPECIFICATIONS

Parts Diagram

45

46

47

48

50 49
51

253

5

13

58

59

ENGLISH 46505

21 22
0

7

26

2

28

29

0

3

1

3

27

32

43

44

42

39

40

41

54

55

6

5

7

5

60

6

5

1

6

62

63

4

33

3

35

38

64

36

37

2

1

7

2

8

7

7

5

6

66

9

7

7

4

7

3

7

7

6

68

9

6

0

7

23

24

25

4

3

5

7

16

2

2

14

3

1

12

1

1

0

1

9

8

7

6

5

80

81

828
38

48
5

6

8

87

6

7

6

5
2

7

1

7

8

8

2
9

1

17

8

1

17

16

15

8

0

1

7
10

5

0

1

0

91

9

7

2

89

06

1

104

103

102

1
10

100

8

9

7

9

9

9

9

7

92

39

9
4

5

9
6

9

21 REV 46505-20130218

46505 ENGLISH

Parts List

# Part Number Description Qty

1

26.601.78 Engine 1

122.190005.00 Rubber, Fore-Cover 1

2

122.190005.01 Rubber, Fore-Cover 1

3

123 .191100.19 Rotor Assembly 1

4

2.08.022 Flange Bolt M8×242 1

5

1.96.08 Washer Φ8 1

6

1.7244.08 Spring Washer Φ8 1

7

123 .1912 00 .19 Stator Assembly 1

8

123 .191002.01 Stator Cover 1

9

122.190002.00 End Housing 1

10

2.08.065 Flange Bolt M6×168 4

11

1.97.1.06 Washer Φ6 4

12

1.93.06 Lock Washer Φ6 8

13

122.190300.00 Carbon Brush Assembly 1

14

122.190004.01 Brush Holder 1

15

1.93.05 Lock Washer Φ5 3

16

1.5783.0516 Bolt M5×16 3

17

1.97.1.05 Washer Φ5 2

18

122.190200.05 AVR, Remote Start 1

19

1.16674.0 516 Flange Bolt M5×16 2

20

122.190003.00.78

21

1.166 74. 0512 .2 Flange Bolt M5×12 3

22

122.190400.00 Terminal Block 1

23

122.190018.00 Bracket, Muffler 1

24

1.166 74. 0 820 Flange Bolt M8× 20 3

25

122.190018.01 Bracket, Muf fler 1

26

1.5789.0 612 Flange Bolt M6×12 11

27

1.9074.4 M5×14

28

46 .101503.08 Plate, Spark Arrester 1

29

46 .101300.08 Arrester Assembly, Spark 1

30

26.101000.00 Muffler Assembly 1

31

23.102000.03.2 Muffler Cover 1

32

1.6175. 08 Nut M8 2

33

1.93.08 Lock Washer Φ8 2

34

1.848.08 Washer Φ8 2

35

26.100001.00 Gasket, Exhaust 1

36

23.090006.22 Holder, Air Cleaner 1

37

1.5789.06 08 Flange Bolt M6 ×8 1

38

23.070011.04 Pipe, Fuel (6.1in) 1

39

2.06.007 Clamp 2

40

122.070400.03 Fuel Cock 1

41

122.071000.05.78 Fuel Tank (Silver) 1

42

122.070 015.01

43

2.03.004 Washer Φ6 4

44

1.5789.0620.2 Flange Bolt M6×20 4

45

23.070301.00 Fuel Filter 1

46

24.070100.00 Fuel Tank Cap 1

47

24.070014.03 Pipe, Revers al Valve 1

48

24.070030.00 Hole, Breather Tube 1

49

2.06.006 Clamp 1

50

24.070800.00 Reversal Valve 1

51

1.819.0510 Screw M5×10 2

52

122.072000.00 Fuel Meter Assembly 1

53

152.200702.00 Cover, Handle 1

54

Generator End Cover
(Gray)

Bolt and Washer
As s embly M5 ×14

Vibration Mount, Fuel
Tan k

1

2

4

# Part Number Description Qty

122.200700.03.2 Handle 1

55

1.6177.1.08 Nut M8 14

56

1.5789.08 45 Flange Bolt M8×45 2

57

6.2.243.318.2 Frame 1

58

2.05.001 Clamp 2

59

122.201200.05 Motor Mount 1 2

60

122.201200.0 4 Motor Mount 2 2

61

1.6182.10 Nut M10 2

62

122.201701.05.2 8in Wheel (Black) 2

63

122.20 0016.01 Bush Φ16×Φ10.5×58.5 2

64

1.96.10 Washer Φ10 2

65

1.57 82.10105 Bolt M10 ×105 2

66

122.200904.00 Strap, Battery 1

67

9.1000.090 Battery 12V9AH 1

68

152. 20 0013.01 Jacket 1

69

5.19 00.010 Red Wire, Battery 1

70

122.20 0013.01 Jacket 2

71

5.190 0.011 Black Wire, Battery 1

72

1.5789.0816 Flange Bolt M8×16 2

73

152.200002.00.2 Support Leg 1

74

152.201400.00 Rubber, Support 2

75

1.5789.0825 Flange Bolt M8×25 2

76

5.19 00.0 26 Grounding Line 1

77

1.6177.1.06 Nut M6 1

78

1.862.06 Lock Washer Φ6 2

79

122.210003.00 Plug 2

80

1.9074.1.0538.2

81

122.210002.20 Control Box 1

82

5.1460.003 Indicator Light 1

83

5.1040.004 Switch 1

84

5.1830.000 Remote Control 1

85

1.8 23 .0514 Screw M5×14 4

86

5.1820.000 Charger 1

87

5.12 80 .0 03 Fus e (10 A) 1

88

122.159.006.2 Control Panel 1

89

5.14 30 .0 01 Intelligauge 1

90

5.1000.001.3 Switch 1

91

5.1000.000.3 Switch, Battery 1

92

1.5783.0622.3 Bolt M6×22 1

93

1.6175. 06 .3 Nut M6 2

94

1.97.1.06.3 Washer Φ6 2

95

1.93.06.3 Lock Washer Φ6 2

96

5.11 20 .0 0 8 Receptacle L5-30R 1

97

1.9074.4.0414.1

98

1.6177.1.04 .1 Nut M4 6

99

5.11 20 .0 3 4 Receptacle T T-30R 1

100

5.11 20 .010 Receptacle 5-20R 1

101

5.1210.925 AC. 25A Breaker 1

102

5.1210.920 AC.20A Breaker 1

103

5.1810.0 01 Over Voltage Protector 1

104

122.210002.14 Control Box 1

105

122.210003.01 Plug 1

106

5.13 30 .0 01 Sheath, Wire 1

107

122.210003.03 Plug 1

108

Bolt and Washer
Assembly M5×38

Bolt and Washer
As s embly M4×14

5

6

REV 46505-20130218 22

SPECIFICATIONS

Engine Parts Diagram

ENGLISH 46505

6

9

5

9

94

93

0

9

1

8

8

87

86

5

8

84

3

5

4

1

1

11

1

1

1

5

16

1

9

1

1

81

83

82

0

8

9

7

8

7

77

111

110

112

109

7

9

2

9

1

75

4

7

76

105

106

7
10

8
10

6

5

5

5

73

72

1

7

70

69

8

103

104

59

7

5

58

6

7

6

66

63

2

6

61

0

6

4

6

25

7

4

6

1

8
1，2

46

5

6

44

43

42

41

40

12

38

3

9

3

8

4

4

5

9

1

102

101

00

1

99

5

4

98

8

1

08

89

1

7

3

9

2

5

5

51

504

11

54

24

3

2

2

2

21

34

3

1

3

0

2

37

6

3

35

32

0

3

9

2

27

26

5

2

4

1

3

1

2

1

0

1

9

5

1

8

7

6

5

4

3

2

17

23 REV 46505-20130218

1

46505 ENGLISH

# Part Number Description Qty

1.5789.060 8 Flange B olt M6×8 6

1

22.061100.00.2 Recoil Starter C over 1

2

21.061005.00 Recoil Starte r Spring 1

3

2.10. 00 3 RopeΦΦ5×1550Φ 1

4

21.0610 01.01 Recoil Star ter Reel 1

5

45.060003.00 Spring, Ratchet 2

6

45.060002.00 Starter Ratchet (Iron) 2

7

45.060009.00 Spring, Ratchet Guide 1

8

45.060007.00 Ratchet Guide 1

9

45.060008.00 Screw, Ratchet Guide 1

10

24.040004.00 Guide Plate, Push Rod 1

11

1.578 9.061 2 Flange Bolt M6 ×12 8

12

24.080100.00.78 Fan Cover (Silver) 1

13

2.05.005 ClampΦΦ6Φ 2

14

21.061300.00 Handle (soft) 1

15

23.125200.01 Relay, Starter (Remote Control) 1

16

22.061000.00 Recoil Assembly 1

17

24.091000.21 Air Cleaner Assembly 1

18

1.5789.0629 Flange B olt ΦM6×29Φ 1

19

2.03.016 Wash er, Drain BoltΦΦ10×Φ16×1.5 2

20

2.02.006 Nut (M14×1.5) 1

21

21.06 00 01.01 Pulley, Starter 1

22

23.080001.00 Cooli ng Fan 1

23

24.120100.03 FlywheelΦElectric Star t EPAΦ 1

24

2.11. 00 1 Oil Se alΦΦ25×Φ41.3×6Φ 2

25

2.03.020.1 Washer ΦΦ6.2×Φ15× 0.5Φ 1

26

21.110100 .00 Gear, Governor 1

27

1.93.0 5 Lock Washer Φ5 2

28

21.110013.00 Shaft, Governor Gear 1

29

21.110 011. 00 Clip, Governor G ear 1

30

1.16674 .0516 Flange Bolt M5 ×16 2

31

21.110012. 01 Bushing, Governor Ge ar (Iron) 1

32

45.121000.00 Coil, Charging 1

33

23.030006.00 Plate, Coil 1

34

23.080600.02 Air Guide, Right Side 1

35

45.030032.0 0 Sheath, Wire 1

36

26.030100.00 Crankcase ( 200cc) 1

37

21.127000.01 Oil Level Sensor 1

38

23.125100.00 Starter Motor A ssembly 1

39

23.050200.0 0 Connecting Rod 1

40

25. 05 010 0.11

41

1.276. 6205 Be aring 6205 2

42

24.030008.00 Gasket, Crankcase Cover 1

43

22.031000.00 Oil Dipstick Ass embly 1

44

23.070011.04 Pipe, Fuel (6.1in) 1

45

23.030007.01

46

1.5789.0832.0.8 Flange Bolt 8 ×32 6

47

2.04.005 Do wel Pin (Φ8×10) 2

48

23.110006.00 Rod Governor 1

49

21.110003.00 Arm, Governor 1

50

1. 61 77. 06 Nut ΦM6Φ 3

51

21.110001.00 Shaft, Governor Arm 1

52

22.123000.02 Ignition Coil (Shield EPA ) 1

53

1.5789.0625 Flange Bolt 6 ×25 5

54

23.110005.01 Spring, Throttle Return 1

55

23.110007.00 Spring, Governor 1

56

2.08.040 Bolt, Governor ArmΦM 6×21Φ 1

57

21.110008.00 Pin, Shaft 1

58

23 .11100 0. 20

59

Crankshaf t (A 200 Engine For

Equipment)

Cover, Crankcas e (Engine For

Equipment)

Control Assembly (Engine For

Equipment)

# Part Number Description Qty

25.040013.00 Lifter, Valve 2

60

2.04.001 Do wel PinΦΦ9×14Φ 2

61

26.041000.00 CamshaftΦ2 00 EPAΦ 1

62

2.14. 012 Semi- Circula r Key( 4×7.5×19) 1

63

2.08.037 Bolt, Drain (M10×1.25×25Φ 2

64

26.050005.00 Piston 1

65

23.050003.00 Wrist Pin 1

66

2.09.001 Circlip (Φ18×Φ1) 2

67

26.050303.0 0 Ring, O il 1

68

26.050302.0 0 Ring, Second Piston 1

69

26.050301.00 Ring, First Piston 1

70

26.030009.00 Gasket, Cylinder H eadΦ168-2Φ 1

71

2.04.003 Do wel Pin (Φ10×14) 2

72

23.040002.00 Valve, Intake 1

73

23.040006.00 Valve, Exhaust 1

74

26.0804 00.00 Air Guide, Lower (200cc G) 1

75

2.15.002ΦF6RTCΦ Spark PlugΦF6R TCΦ 1

76

1.5789.085 5 Flange B olt M8×55 4

77

23.040017.00 Oil Seal, Valve (Iron) 2

78

21.040003.00 Spring, Valve 2

79

21.040007.00

80

21.040001.00

81

21.040008.00 Rotator, Ex haust Valve 1

82

24.040202.0 0 Shaft, Rocker A rm 1

83

22.040009.00 Rocker Arm, Intake Valve 2

84

22.040 012.00 Scr ew, Valve Adjustment 2

85

21.04 0021.00 Nut,Lo ck 2

86

1.97.1.06 Washer Φ6 2

87

1.6177.1.06 Nut M6 2

88

26 .131 01 7.20 Standard Main Jet 1

89

26.131017.20 .01 Altitude Main Jet /

22.040201.00 Retainer, Rocker Arm 1

90

23.040010.00 Bolt, Rocker Arm 2

91

23.040005.00 Push Rod 2

92

21.020002.01 Gasket, Cylinde r Head Cover 1

93

24.021000.00 Cylinder Head Co ver (CPE) 1

94

23.020001.02 Breather Tube 1

95

1.578 9.0 615 Flange Bolt ΦM 6×15Φ 4

96

2.01.010 Stud. BoltΦM8×35Φ 2

97

2.06.007 Clamp 2

1

1

1

98

24.09120 0.20 Cove r, Air Cleaner 1

99

23.091003.21 Element, Air Cleaner 1

100

23. 0910 01.21 Separ ator, Air Cleaner 1

101

23. 0910 02. 21 Seal, Air Cle aner 1

102

26. 010100. 00 Cylinder He ad (168-2) 1

103

2.01.003 Stud B olt 6×90 2

104

24.130002.00 Gasket , Insulator 1

105

23.130001.00 Insulator, Carburetor 1

106

22.130003.00 Gasket , Carburetor 1

107

26.131000.24 Carburetor, Remote Start 1

108

81.130010.00 Spring, Connecter 1

109

26.13 0015. 24 Connecter, Choke Valve A xis 1

110

24.130004.20 G asket, Air Cleaner 2

111

26.130005.24 Support, Stepper Motor 1

112

45.132200.01 Stepper Motor 1

113

1.823.04 08 Screw M4×8 2

114

81.132001. 00 Cover, Stepper Motor 1

115

24. 091100 .21 B ase, Air Cleaner 1

116

2.03.021.1 WasherΦΦ6.4×Φ13 ×1Φ 1

117

Retainer, Exhaust Valve Sp ring

(up)

Retainer, Intake Valve Spring

(up)

1

1

REV 46505-20130218 24

TROUBLESHOOTING

Problem Cause Solution

Generator will not start No fuel Add fuel

Faulty spark plug Replace spark plug

Unit loaded during start up Remove load from unit

Generator will not start;
Generator starts but runs roughly

Generator shuts down during operation Out of fuel Fill fuel tank

Generator cannot supply enough power or
overheating

No AC output Cable not properly connected Check all connections

Generator gallops Engine governor defective Contact the help line

Repeated circuit breaker tripping Overload Review load and adjust. See “Power

Low oil level Fill crankcase to the proper level

Place generator on a flat, level surface

Choke in the wrong position Adjust choke

Spark plug wire loose Attach wire to spark plug

Low oil level Fill crankcase to the proper level. Place

generator on a flat, level surface

Generator is overloaded Review load and adjust. See “Power

Management”

Insufficient ventilation Check for air restriction. Move to a well

ventilated area

Connected device is defective Replace defective device

Circuit breaker is open Reset circuit breaker

Faulty brush assembly Replace brush assembly (Service Center)

Faulty AVR (auto voltage regulator) Replace AVR (Service Center)

Loose wiring Inspect and tighten wiring connections

Other Contact the help line

Management”

Faulty cords or device Check for damaged, bare or frayed wires.

Replace defective device

ENGLISH 46505

For further technical support:

Technical Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]

25 REV 46505-20130218

46505 ENGLISH

WARRANTY

WARRANTY

CHAMPION POWER EQUIPMENT

2 YEAR LIMITED WARRANTY

Warranty Qualifications

Champion Power Equipment (CPE) will register this
warranty upon receipt of your Warranty Registration Card
and a copy of your sales receipt from one of CPE’s retail
locations as proof of purchase.
Please submit your warranty registration and your proof
of purchase within ten (10) days of the date of purchase.

Repair/Replacement Warranty

CPE warrants to the original purchaser that the
mechanical and electrical components will be free of
defects in material and workmanship for a period of
one year (parts and labor) and two years (parts) from
the original date of purchase (90 days (parts and
labor) and 180 days (parts) for commercial & industrial
use). Transportation charges on product submitted
for repair or replacement under this warranty are the
sole responsibility of the purchaser. This warranty only
applies to the original purchaser and is not transferable.

Do Not Return The Unit To The Place Of Purchase

Contact CPE’s Technical Service and CPE will
troubleshoot any issue via phone or e-mail. If the
problem is not corrected by this method, CPE will, at its
option, authorize evaluation, repair or replacement of the
defective part or component at a CPE Service Center.
CPE will provide you with a case number for warranty
service. Please keep it for future reference. Repairs
or replacements without prior authorization, or at an
unauthorized repair facility, will not be covered by this
warr anty.

Installation, Use and Maintenance Cont’d.

Normal maintenance such as spark plugs, air filters,
adjustments, fuel system cleaning and obstruction due
to buildup is not covered by this warranty.

Other Exclusions

This warranty excludes:

– Cosmetic defects such as paint, decals, etc.
– Wear items such as filter elements, o-rings, etc.
– Accessory parts such as starting batteries, and

storage covers.

– Failures due to acts of God and other force majeure

events beyond the manufacturer’s control.

– Problems caused by parts that are not original

Champion Power Equipment parts.
This warranty does not apply to generators used for
prime power in place of a utility.

Limits of Implied Warranty and Consequential Damage

Champion Power Equipment disclaims any obligation to
cover any loss of time, use of this product, freight, or
any incidental or consequential claim by anyone from
using this generator. THIS WARRANTY IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
A unit provided as an exchange will be subject to the
warranty of the original unit. The length of the warranty
governing the exchanged unit will remain calculated by
reference to the purchase date of the original unit.
This warranty gives you certain legal rights which may
change from state to state. Your state may also have
other rights you may be entitled to that are not listed
within this warranty.

Contact Information

Warranty Exclusions

This warranty does not cover the following repairs and
equipment:

Normal Wear

Generators need periodic parts and service to perform well.
This warranty does not cover repair when normal use has
exhausted the life of a part or the equipment as a whole.

Installation, Use and Maintenance

This warranty will not apply to parts and/or labor if this
generator is deemed to have been misused, neglected,
involved in an accident, abused, loaded beyond the
generator’s limits, modified, installed improperly or
connected incorrectly to any electrical component.

Address

Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
www.championpowerequipment.com

Customer Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
Fax no.: 1-562-236-9429

Technical Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]
24/7 Tech Support: 1-562-204-1188

REV 46505-20130218 26

Champion Power Equipment, Inc. (CPE),

United States Environment Protection Agency (U.S. EPA)

Emission Control System Warranty

Your Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations.

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2013 small
off-road engine and engine powered equipment. New engines and equipment must be designed, built and
equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE warrants the emission
control system on your small off-road engine and equipment for the period of time listed below, provided there has
been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.

Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system,
catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other emission related
assemblies. Where a warrantable condition exits, CPE will repair your small off-road engine at no cost to you
including diagnosis, parts and labor.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

This emission control system is warranted for two years, subject to provisions set forth below. If, during the
warranty period, emission related part on your engine is defective in materials or workmanship, the part will be
repaired or replaced by CPE.

OWNER WARRANTY RESPONSIBILITIES:

As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in
your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small off­road engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance.

As the small off-road engine owner, you should however be aware that CPE may deny you warranty coverage if
your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.

You are responsible for presenting your small off-road engine to an Authorized CPE service outlet or alternate
service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact:

Champion Power Equipment, Inc.

Customer Service

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

[e-mail]

EMISSION CONTROL SYSTEM WARRANTY

The following are specific provisions relative to your Emission Control System (ECS) Warranty Coverage.

1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines. The ECS

Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use
purchaser, and shall continue for 24 consecutive months thereafter.

2. GENERAL EMISSIONS WARRANTY COVERAGE

CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent
purchaser that each of its small off-road engines is:
a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited
engines at or below 19 kilowatts.
b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical
in all material respects to the part as described in the engine manufacturer’s application for certification for a period
of two years.

3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS:

a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it
shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under
the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the
Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the
effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or
replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in
the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that
part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE
according to Subsection “d” below. Any such emissions-related part repaired or replaced under the ECS Warranty,
shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for
such emissions-related part.
d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be
performed at no charge to the owner at a CPE Authorized Service Outlet.
e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered
by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized
Service Outlet.
f. CPE shall pay for covered emissions warranty repairs at non-authorized service outlets under the
following circumstances:
i. The service is required in a population center with a population over 100,000 according to U.S.
Census 2000 without a CPE Authorized Service Outlet AND
ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile
limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska,
Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.
g. CPE shall be liable for damages to other original engine components or approved modifications
proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty.
h. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts
sufficient to meet the expected demand for such emission-related parts.
i. Any CPE Authorized and approved emission-related replacement part may be used in the performance of
any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not
reduce CPE’s warranty obligation.
j. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable
hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or
modified part.

EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the
engine)

Systems covered by this
warranty

Parts Description

Fuel Metering System

Fuel regulator, Carburetor and internal parts

Air Induction System

Air cleaner, Intake manifold

Ignition System

Spark plug and parts, Magneto ignition system

Exhaust System

Exhaust manifold, catalytic converter

Miscellaneous Parts

Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed
systems.
Evaporative Emissions

Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps, Pressure
Relief Valves, Control Valves, Control Solenoids, Electronic Controls,
Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge
Valves, Vapor Hoses, Liquid/Vapor Separator, Carbon Canister, Canister
Mounting Brackets, Carburetor Purge Port Connector

TO OBTAIN WARRANTY SERVICE:

You must take your CPE engine or the product on which it is installed, along with your warranty registration card or
other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is
authorized by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business
hours. Alternate service locations defined in Section (3)(f.) above must be approved by CPE prior to service. Claims
for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because
the engine was not properly maintained and used.

If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty
service, please write or call Customer Service at Champion Power Equipment, Inc.

Champion Power Equipment, Inc.

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

Attn.: Customer Service

[e-mail]