Service Manual - Champion Power Equipment
Contents
1. 4 Replace Control Unit 3 4 Generator 3 4 1 Low AC output 1 With Engine running check if the Overload light is ON a If Overload light is ON remove overload If light stays ON replace the Control Unit 2 Check Engine RPM a ECON ON less than 3000 rpm b ECON OFF 4300 rpm 3 Check Wire Harness Connector 4 Check Main Coil voltage 228 342 V AC a Low voltage Replace Rotor b No voltage Check Main Coil resistance 1 2 Ohm 0 24 i If resistance out of spec replace Stator 5 Check Sub Coil Voltage 228 342 V AC 20 degrees C a Low voltage Replace Rotor b No voltage Check Main Sub resistance 0 12 Ohm 0 02 i If Main Sub resistance is out of spec replace Stator ii If Main Sub resistance is OK replace Control Draft 08 23 2010 Page 9 4 0 Maintenance 4 1 Check Oil Level 1 Stopthe engine and place the unit on a level surface 2 Remove the Maintenance Cover 4 screws 3 Remove the Oil Filler Cap Dipstick 4 Checkthe oil level on the Cap Dipstick Add oil if the dipstick does not reach the oil level 4 2 Change Engine Oil 1 It is best to change the oil when it is warm Start the unit and let it run for 4 5 minutes to warm the oil 2 Stop the engine and place the unit above an appropriate oil collection pan 3 Remove the Maintenance Cover and remove the Oil Filler Cap Dipstick 4 Tiltthe unit towards its side to allow the oil to drain completely 5 Place the unit back in the upright pos2. damage and replace if needed 8 Install the removed parts in the reverse order of removal 4 9 Engine Switch Econ Switch 1 Check for continuity to determine if the switches are working properly a Switch ON continuity b Switch OFF No continuity Draft 08 23 2010 Page 13 4 10 Ignition Unit 1 Unplug the 10 Pin connector from the module 2 Measure the resistance by connecting one test probe to the metal case of the Engine and the other test probe to the pin on the 10 pin connector See Table 1 below for correct values Table 1 Resistance Values Color Circuit Name Resistance Blue Primary Ignition Coil 0 8 1 5 Ohm f No Continuity with proper Oil Yellow Oil Level Switch Level Green White Trigger Coil 80 132 Ohm Yellow Green Ground Wire Continuity Green Igniter Unit Power Coil Winding 0 5 0 9 Ohm No Continuity with Switch ON Black Engine Switch BR i Continuity with Switch OFF 4 11 Oil Level Switch 1 Place the oil alarm in the position shown below a There should be NO continuity between the Oil Level Switch and the Ground Wire 2 Rotate the oil alarm 180 degrees and check continuity a There should be continuity between the Oil Level Switch and the Ground Wire 3 Completely immerse the oil alarm in oil 4 Waittwo minutes 5 Check the continuity If working properly there should be NO continuity 4 12 AC Receptacle 1 Check the electrode c
3. Champion Power Equipment 2000 W Inverter Service Manual 735311 735921 Page 1 Table of Contents LO SPECT E LIONS ann A A ent dk vain 4 2 0 Service Informatica A Error Bookmark not defined 2 1 Maintenace Schedule u einen nebenbei iii 5 3 0 Troubleshooting EE 6 SNE 6 3 1 1 Engine Will Not Start ainia ae 6 3 1 2 Engine starts but will not run 7 3 1 3 Engine RPM are low or not steach saes sineera ssassn nares aara 7 3 2 lenition SyYStEM E 8 3 2 1 NO ET EE 8 3 3 Throttle Control System EE 8 3 3 1 Engine RPM ale Le HE 8 3 3 2 ECON Switch does NOt el 9 A A nennen e re benennen ENEE Ce energie 9 3 41 LOW AG output a casadas 9 GROEN 10 4 1 Check Oil Leve lirise e AAE a 10 4 2 Change Engine a E 10 4 3 Air Cleaner es Im AAA AAA yada ukas 10 e Ed TEE 11 4 5 Valve Claris 11 4 5 1 Measuring Valve Cle r nce uuuamiumninsieerniendnssmmdivejardsnediieidjani 11 45 2 Adjusting Valve Clearanc uaaarhmaadgauanunn m a A E AAA nee 12 4 6 Fuel Filter cono a 12 4 7 Fuel SM Aia 12 4 8 SPArk d LEE 13 Draft 08 23 2010 Page 2 4 9 Engine Switch Econ Switch visicss csccccciccccvdaavadessssscocssscdaascesaccssoes cavcaauddieuscceasedeaesucssassivedecesseeceadcacduanuaieeesss 13 O ne ea ea atte usant i aeai 14 4 11 Oil Level Witch cian a a Ren 14 410 AG Recept tle EE 14 4 13 Stepper MOtor u 0er s0c gras HeiseanctaccusddedsiancccecouciedsGuundere aii 15 4 14 General TEE 15 4 15 at 15 AUG 0 HON CO 15 4 17
4. If Dry Check Carburetor port and nozzle 9 Check Spark strength a If weak See Ignition System trouble shooting 10 Check Compression 116 138 psi 1100 rpm and 58 72 psi 600 rpm a If pressure is high Check head cylinder carbon b If pressure is low Check Valve Clearance Draft 08 23 2010 Page 6 3 1 2 Engine starts but will not run 1 Check that the fuel level in tank is adequate 2 Check that the Fuel Valve is turned to completely to ON position 3 Check fuel filter clean or replace 4 Check Fuel Hose for blockage or damage Clean or replace if needed 5 Check Carburetor gasket for damage and confirm nuts are tight 6 Check Compression 116 138 psi 1100 rpm and 58 72 psi 600 rpm a If High Check head cylinder carbon b If low Check valve clearance 7 Check air gap of Pulser Coi 1 0mm 0 040 in gap a Adjust if needed 8 Check Pulser Coil Replace if needed 9 If engine will still not run see Throttle Control trouble shooting 3 1 3 Engine RPM are low or not steady 1 Check Air Filter element Clean or replace if dirty needed 2 Check Valve Clearance 0 1mm 004 in a Adjust if needed 3 Check Spark Plug clean or replace if needed 4 Check Main Jet Choke clean as needed 5 Check Carburetor Joint and Gasket for damage and confirm nuts are tight 6 Check Compression 116 138 psi 1100 rpm and 58 72 psi 600 rpm a If High Check head cylinder carbon b If low Ch
5. Valve Stem Outside Diameter Au 16 4 18 Valve Spring Free Length 16 4 19 Cam Height sos na eo no A 16 4 20 Cylind r Inner Diameter icine ses ea NEE EENEG DEER 16 4 21 Piston Skirt Outside Diameter u nennen nie 17 4 22 Piston Pin Outside Diameter 17 4 23 Piston Ring Side Clearance iii 22a aan 17 4 24 Crankshaft Pin Outside Diameter 17 4 25 Carburetor Float Height iii ER 17 Draft 08 23 2010 Page 3 1 0 Specifications Dimensions Generator Run Time Noise level Overall Length 19 3 in 490 mm Overall Width 13 2 in 335 mm Overall Height 16 3 in 415 mm Dry Weight Generator type Generator structure 48 Ibs 21 7 kg Multi pole rotation Self ventilation drip proof alternator Excitation Self excitation Magnet type Frequency regulation AC DC AC conversion AC output Frequency 60 Hz Voltage 120 V Rated output 1 6 kVA Rated current AC 13 3A Rated rotation speed ECON no load speed Engine type 4300 rpm 3000 rpm 4 stroke single cylinder OHV Displacement 79 7mL Bore x Stroke Compression ratio 48 6mm x 43 0mm 8 7 Ignition system TC Engine oil capacity 13 fl oz 0 4L Carburetor Float type Lubrication system Air cleaner Forced splash Semi dry type Cooling system Forced air cooled Spark plug Starting system E6RTC NHSP R
6. andard 4 948 4 960mm 1948 1953 b Service Limit 4 908mm 1932 2 Exhaust Valve a Standard 4 928 4 940mm 1940 1945 b Service Limit 4 908mm 1932 4 18 Valve Spring Free Length 1 Standard 27 4mm 1 078 2 Service Limit 24 4mm 961 4 19 Cam Height 1 Intake A a Standard height 20 490 20 590mm 8067 8106 b Service Limit 20 390mm 8028 2 Intake B a Standard height 16 139 16 239mm 6354 6393 b Service Limit 16 039mm 6315 3 Exhaust A a Standard height 20 490 20 590mm 8067 8106 b Service Limit 20 390mm 8028 4 Exhaust B a Standard height 16 139 16 239mm 6354 6393 b Service Limit 16 039mm 6315 4 20 Cylinder Inner Diameter 1 Standard 48 600 48 620mm 1 9134 1 9142 2 Service Limit 48 620mm 1 9142 Draft 08 23 2010 Page 16 4 21 Piston Skirt Outside Diameter 1 Standard 48 574 48 594mm 1 9124 1 9132 2 Service Limit 48 53mm 1 9106 4 22 Piston Pin Outside Diameter 1 Standard 11 996 12 000mm 4723 4724 2 Service Limit 11 950mm 7854 lt ask Yamashita to verify gt 4 23 Piston Ring Side Clearance 1 Top Ring a Standard 0 04 0 08mm 0016 0032 b Service Limit 0 12mm 0047 2 Second Ring a Standard 0 02 0 06mm 0008 0024 b Service Limit 0 10mm 0039 4 24 Crankshaft Pin Outside D
7. eck valve clearance 7 If engine will still not run see Throttle Control trouble shooting Draft 08 23 2010 Page 7 3 2 Ignition System 3 2 1 No Spark 1 Check the Low Oil Sensor confirm crankcase is full Disconnect the Low Oil Sensor wire and check for spark a Ifthe Spark Plug sparks then the Low Oil Sensor needs to be replaced Install a new Spark Plug and check for spark Pull recoil starter and check if the Oil Warning Light flashes a Theflashing Oil Warning Light indicates that the Oil Level Sensor needs replacing Check Engine Switch for continuity a Replace if needed Check air gap and resistance of the Pulsar Coil lt need spec from Yamashita gt a Adjust air gap or replace Pulsar Coil if needed Check Ignition Coil lt need detail gt a Replace if needed Check Wire harness for damage a Replace if needed 3 3 Throttle Control System 3 3 1 Engine RPM not steady 1 2 3 Check Stepper Motor movement a Starting Full Open gt close b Stopping Full Open c Replace Stepper Motor if needed Check Stepper Motor Resistance 40 50 ohms a Replace if resistance is out of spec Check Wire Harness for damage a Replace if needed 4 Replace Control Unit Draft 08 23 2010 Page 8 3 3 2 ECON switch does not work 1 Check Stepper Motor Resistance 232 267 ohms 20 degrees C 2 Check ECON Switch for continuity a Replace if needed 3 Check Wire Harness for damage a Replace if needed
8. ecoil starter Fuel Draft 08 23 2010 Rated Automotive unleaded gasoline 3 8hr 1 4 Load Full Load 7m 9 5hr Fuel Tank Capacity 1 0 gal 3 8L 65 dBA 1 4 Load 7m 54 dBA 2 0 Maintenance Schedule Interval First 20 Hr Every 100 De Item Routine or First Hr or 6 12 Month Months Months Check oil level in engine Engine oil Replace engine oil e e Check fuel leakage Fuel system Clean fuel filter strainer e Check fuel hose for cracks or damage Air filter element Check and Clean Spark arrester Clean and replace if necessary Spark plug Clean and replace if necessary Valve clearance Check and adjust Note Perform each routine at the shorter of the two intervals whichever comes first Draft 08 23 2010 Page 5 3 0 Troubleshooting 3 1 Engine 3 1 1 Engine will not start 1 Check that the Engine Switch is in ON position 2 Check the Engine Oil level If low the Low Oil Sensor will ground the Spark Plug 3 Check that the Fuel Valve is turned to ON position 4 Check that the Choke is pulled completely out full choke 5 Check that the fuel level in tank is at adequate 6 Check that the Vent in the Fuel Cap is turned to ON 7 Check to see if there is fuel in the Carburetor a If no fuel in Carburetor check fuel line for blockage 8 Is the Spark Plug wet or dry a If Wet dry it off and try to start engine b
9. iameter 1 Standard 21 969 22 000mm 8649 8661 lt ask Yamashita to verify gt 2 Service Limit 21 985mm 8656 4 25 Carburetor Float Height 1 Standard 17mm 669 2 Replace the Carburetor if the Float Height is not correct Draft 08 23 2010 Page 17
10. ition 6 Add approximately 0 4 liter Use the Cap Dipstick to check for proper level 7 Replace the Maintenance Cover 4 3 Air Cleaner 1 Stop the engine and remove the Maintenance Cover 2 Remove the Air Cleaner Cover 1 screw 3 Remove the foam Air Cleaner element Wash foam element in warm soapy water rinse and dry 4 Saturate the clean element in clean engine oil Squeeze out any excess oil 5 Replace the foam element in the unit 6 Inspect the seals on the Air Cleaner Cover Clean as needed Replace and fasten Cover 7 Replace the Maintenance Cover NOTE H A dirty Air Cleaner will restrict airflow to the carburetor and reduce engine performance Clean the Air Filter more often if used in dusty conditions H Never run the unit without a filter element or with a damaged element Draft 08 23 2010 Page 10 4 4 Spark Plug 1 Stopthe engine and remove the Maintenance Cover 2 Remove the Spark Plug Maintenance Cap on top of the unit 3 Disconnect the Spark Plug Wire 4 Remove the Spark Plug The Spark Plug Maintenance Cap provides tool access 5 Remove carbon or other deposits with a wire brush 6 Measure the spark plug gap and adjust as needed 0 6 0 7mm 0 024 0 028 7 If needed replace spark plug with E6RTC NHSP or BPR6HS NGK 8 Install the new spark plug by until finger tight to seat the washer Then use a plug wrench and torque the new spark plug to 20 N m 14 4 ft lb 9 Replace the spa
11. ontact disk inside the receptacle If it is burned or discolored replace the receptacle Draft 08 23 2010 Page 14 4 13 Stepper Motor 1 Measure the resistance of the Stepper Motor lead out wires a Between 1and3 45 55 Ohm b Between 2 and4 lt need spec from Yamashita gt 4 14 Generator 1 Ignition Coil a Measure the resistance between the Blue terminal and Yellow Green terminal It should measure 0 1 0 2 Ohm 2 DCCoil a Measure resistance between the two green terminals It should measure 0 1 0 2 Ohm 3 Sub Coil a Measure resistance between yellow terminals It should measure 0 1 0 2 Ohm 4 ACCoil a Measure resistance between red terminals It should measure 1 5 2 0 Ohm 4 15 Trigger 1 Attach the two test probes to the Trigger and measure the resistance It should measure 120 Ohm 24 2 Measure the clearance between the Trigger and the Projection Part of the Rotor The clearance should be 0 3 0 5mm 0 012 0 020 4 16 Ignition Coil 1 Check the Primary Resistance a Attach the two test probes to the primary coil plug of ignition coil The resistance should measure 1 1 Ohm 0 22 2 Check the Secondary Resistance a Attach one test probe to the Spark Plug Cap and the other probe to each terminal of the primary coil plugs of the Ignition Coil The resistance should be 12 2K Ohm 2 4K Draft 08 23 2010 Page 15 4 17 Valve Stem Outside Diameter 1 Intake Valve a St
12. p 2 Remove the wire mesh Fuel Filter 3 Clean the Fuel Filter to remove any obstructions 4 Inspect for damage Replace if needed 5 Install the Fuel Filter and Fuel Cap 4 7 Fuel Strainer Danger Gasoline is highly flammable It can cause serious burns Keep heat flame and sparks away Clean up any spills immediately 1 Turn Fuel valve OFF Draft 08 23 2010 Page 12 2 Remove the Knob of the Fuel Valve 3 Remove the Handle 4 Remove the Top Cover 5 Remove the 3 screws that hold the Fuel Tank in place 6 Lift the Fuel Tank and disconnect the fuel line from the Fuel Tank 7 Drain the Fuel tank into an appropriate container 8 Remove the Fuel Strainer from the Fuel tank Fuel Strainer is connected to the Fuel Valve 9 Remove any obstructions Inspect for damage Replace if damaged 10 Clean the Fuel Tank with a cleaning solvent and let it dry completely 11 Install the Fuel Valve in the Fuel Tank 12 Connect the fuel line to the Fuel Valve 13 Install the removed parts in the reverse order of removal 4 8 Spark Arrestor 1 Make sure Muffler has cooled completely before servicing the Spark Arrestor 2 Remove the Handle 3 Remove the Corner Cover 4 Remove the Side Cover panel on the Muffler side of the unit 5 Remove the Spark Arrestor from the Muffler by loosening the clamp around the muffler pipe 6 Clean the carbon from the steel mesh of the Spark Arrestor using a stiff wire brush 7 Check for any
13. rk plug wire 10 Replace the Spark Plug Maintenance Cap 11 Replace the Maintenance Cover 4 5 Valve Clearance NOTE Valve clearance MUST be checked while the engine is cold 4 5 1 Measuring Valve Clearance 1 Remove the Maintenance Cover 2 Remove the Handle 3 Remove the Top Cover 4 Remove the Fuel Tank 5 Disconnect the spark plug wire 6 Remove the Spark Plug a Torque to 20 N M 14 4 ft lb when putting the unit back together 7 Remove the Breather 8 Remove the Clip 9 Remove the Cylinder Head Cover Draft 08 23 2010 Page 11 a Torque to 11 N M 7 9 ft Ib when putting the unit back together 10 Remove the Cylinder Head Cover Gasket 11 Remove Air Shroud 12 Rotate the Rotor clockwise until the Piston is at top dead center 13 Measure the Valve clearance by inserting a feeler gage between the Rocker Arm and the Valve a Both Intake and Exhaust Valves must be 0 1mm 0 004 clearance 4 5 2 Adjusting Valve Clearance 1 Loosen the Adjusting Screw Lock Nut 2 Turn the Adjusting Screw in or out as needed 3 Hold the Adjusting Screw with a wrench and torque the Lock Nut to 7 N m 5 1 ft lb 4 Measure the Valve clearance to verify it is correct Repeat as needed 5 Assemble the unit by performing steps 1 11 of section 4 5 1 in reverse order 4 6 Fuel Filter Danger Gasoline is highly flammable It can cause serious burns Keep heat flame and sparks away Clean up any spills immediately 1 Remove the Fuel Ca
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