Champ FX390 User manual

CHAMP MANUFACTURING
ENGINE OWNER’S MANUAL
MIDWEST EQUIPMENT MFG
5225 SERUM PLANT ROAD
THORNTOWN, IN 46071
765-436-2496
FX390
FX390E

TABLE OF CONTENT
ENGINE SAFETY ......................................................................................................................................... 1
INTRODUCTION .......................................................................................................................................... 2
Component Identification ............................................................................................................. 3
Specification................................................................................................................................. 4
OPERATIONS .............................................................................................................................................. 5
Pre-operation check ................................................................................................................ 5
1. Engine Oil ........................................................................................................................ 5
2. Air Cleaner ....................................................................................................................... 5
3. Fuel .................................................................................................................................. 6
Operation ................................................................................................................................... 7
1. Start the engine ............................................................................................................... 8
2. Stop the engine................................................................................................................ 9
TRANSPORTING & STORAGE ................................................................................................................. 10
SERVICE .................................................................................................................................................... 11
Maintenance............................................................................................................................ 11
1. Change Oil ..................................................................................................................... 12
2. Air cleaner service ......................................................................................................... 13
3. Sediment cup clearing ................................................................................................... 14
4. Spark plug service ......................................................................................................... 14
5. Spark arrester maintenance (Optional parts)................................................................. 15
Troubleshooting ....................................................................................................................... 16
Warranty Service ..................................................................................................................... 17
Champ FX390,FX390E Engine Parts Breakdown................................................................................... 18
Head Subassembly, Cylinder/Spark ......................................................................................... 19
Crankcase................................................................................................................................ 20
Gear Assembly ........................................................................................................................ 21
Crankshaft Rod ....................................................................................................................... 22
Camshaft Subassembly ........................................................................................................... 23
Starter ...................................................................................................................................... 24
Carburetor ................................................................................................................................ 25
Air Cleaner ............................................................................................................................... 26
Muffler Assembly ..................................................................................................................... 27
Fuel Tank ................................................................................................................................. 28
Starter ...................................................................................................................................... 29
Throttle Control ........................................................................................................................ 30

Thank you for purchasing an engine.
This manual covers the operation and maintenance of FX390, FX390E engines. All the
information in this publication is based on the latest product information provided at the time of
printing.
Our company reserves the right to make changes at any time without notice and without incurring
any obligation.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the engine and should remain with the
engine if it is resold.
READ THIS OWNER’S MANUAL CAREFULLY. Pay special attention to these symbols and any
instructions the following:
WARNING SYMBOLS
NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about your engine, consult
your engine dealer
Indicates serious injury or death will result if instructions are not
followed.
Indicates a strong possibility that serious injury or death could result if
instructions are not followed.
Indicates a strong possibility that serious injury or death could result if
instructions are not followed.
Indicates that equipment or property damage can result if instructions
are not followed.

ENGINE SAFETY
The engines are designed to give safe and dependable service if operated according to instructions.
Read and understand this Owner’s Manual before operating the engine. Failure to do so could result
in personal injury or equipment damage.
To prevent fire hazards and to provide ventilation, keep the engine at least 1 meter away from
buildings and other equipment during operation. Do not place flammable objects close to the engine.
Children and pets must be kept away from the operating areas due to the risk of burns from high
temperature engine parts or any equipment the engine may use for operation.
Know how to stop the engine quickly, and understand the operation of all controls. Never permit
anyone to operate the engine without proper instructions.
Gasoline is extremely flammable and is explosive under certain conditions.
Refuel in a well-ventilated area with the engine stopped. Do not smoke or swallow flames or sparks
in the area or where gasoline is stored.
Do not overfill the fuel tank. After refueling makes sure the tank cap is closed properly and securely.
Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may ignite. If any fuel is spilled,
make sure the area is dry before starting the engine.
Never run the engine in an enclosed or confined area. The exhaust contains poisonous carbon
monoxide gas; exposure may cause loss of consciousness and may lead to death.
1

ENGINE SAFETY
Pay attention to these labels before operate the engine.
GASOLINE WARNING LABEL
2

INTRODUCTION
3

SPECIFICATION
MODEL FX390,FX390E
Bore x Stroke (MM) 88X64
Displacement (CC) 389
Compression Ratio 8.5:1
Net Power (Kw/Rpm) 7.8/3600
Net Torque (N.m/Rpm) 25/2500
PTO shaft rotation Counter Clock wise
Ignition system Transistorized magneto ignition
Lubrication system Forced splash
Carburetor Flat suction valve carburetor
Governor system Centrifugal mechanical
Engine Type Forced air-cooling 4 stroke, OHV
Starting system Recoil/Electric start
Fuel Tank Capacity (L) 6.5
Engine Oil Capacity (L) 1.1
Fuel Consumption (g/Kw.h) ≤374
Dimension (LxWxH MM) 465x415x440
Net Weight (Kg) 30.5/33.5
4

OPERATION
Pre-operation Check
1. Engine Oil
Use 4 - stroke oil, or an equivalent high
-detergent, premium quality motor oil certified to
meet or exceed U.S automobile manufacturer’s
requirements for Service classification SG•SF/CC•CD.
(Motor oils classified SG•SF/CC•CD will show this
designation on the container.) SAE 10W-30 is
recommended for general, all-temperature in use. Other viscosities shown in the chart
may be used when the average temperature in your area is within the indicated range.
Remove the oil cap and wipe the dipstick clean. Insert the dipstick into the oil filler neck,
but do not screw it in. If the level is low, fill the top of the oil filler neck with the
recommended oil.
NOTE: The Oil Alert System will automatically stop the engine before the oil level falls
below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, it is
advisable to visually inspect the oil level regularly.
2. Air Cleaner
Never run the engine without the air cleaner. Rapid engine wear will result from
Contaminants, such as dust and dirt, being drawn through the carburetor and in
to the engine.
5

OPERATIONS
Check the air cleaner elements to be sure they are clean and in good condition. Clean
or replace the elements if necessary.
3. Fuel
Your engine is designed to use any gasoline that has a pump octane number of 86 or
higher, or that has a research octane number of 91 or higher. Gasoline pumps at service stations normally
display the pump octane number.
We recommend that you use lead-free fuel because it can reduce engine and spark
Plug deposits and extend the life of exhaust system components.
Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting
dirt, dust, or water in the fuel tank. Use of a lower octane gasoline can cause persistent
“pinging” or heavy “spark knock which, if severe, can lead to engine damage.
Occasionally you may experience a light spark
knock while operating under heavy loads.
This is not caused for concern, it simply
means your engine is operating efficiently.
If “spark knock” or “pinging” occurs at a steady engine speed under normal load,
change brands of gasoline. If spark knock or pinging persists, consult your authorized
Champ dealer. Failure to do so is considered misuse, and damage caused by misuse
♢ Gasoline is extremely flammable and is explosive under certain conditions.
Refuel in a well-ventilated area with the engine stopped. Do not smoke
or allow flames or spark in the area where the engine is refueled or where
gasoline is stored.
♢ Do not overfill the fuel tank (there should be no fuel in the filler neck).
After refueling, make sure the tank cap is closed properly and securely.
♢ Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite.
If any fuel is spilled, make sure the area is dry before starting the engine.
♢ Avoid repeated or prolonged contact with skin or breathing of vapor.
♢ KEEP OUT OF REACH OF CHILDREN.
6

OPERATIONS
Fuel Tank capacity
FX390 6.5 L
FX390E 6.5 L
GASOLINES CONTAINING ALCOHOL
If you decide to use gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that
recommended by our company There are two types of “gasohol”: one containing ethanol, and the other containing
methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol
(methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use
gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors.
Fuel system damage or engine performance problems resulting from the use of fuels that contains alcohol is not
covered under the warranty. Our company cannot endorse the use of fuels containing methanol since evidence of
their suitability is as yet incomplete.
Before buying fuel from an unfamiliar station, try to find the fuel that contains alcohol, if it does, confirm the type
and percentage of alcohol used. If you notice any undesirable operating symptoms while using that contains
alcohol, or one that you think contains alcohol, switch to gasoline that you know does not contain alcohol.
7

OPERATIONS
Start The Engine
♢ Turn the fuel valve to the ON position.
The choke may not need if the engine is warm or the air temperature is high
♢ Move the choke to the CLOSE position.
♢ Move the throttle lever slightly to the left.
♢ Start the engine.
• With recoil Starter: Turn the engine switch to ON position
• Full the starter grip lightly until resistance is felt, then pull briskly.
♢ As the engine warms up, gradually move the choke lever to the OPEN
position.
♢ Position the throttle lever for the desired engine speed
8

OPERATIONS
Stop The Engine
To stop the engine in an emergency, turn the engine switch to the OFF position.
Under normal conditions, use the following procedure:
Move the throttle lever fully to the right.
Turn the engine switch to the off position.
Turn the fuel to the off position.
9

TRANSPORTING & STORAGE
To avoid severe burns or fire hazards, let the engine cool before transporting
It or storing it indoors. When transporting the engine, turn the fuel valve to the off
position and keep the engine level to prevent fuel spillage. Fuel vapor or spilled fuel
may ignite.
To avoid severe burns or fire hazards, let the engine cool before transporting It or storing it indoors.
When transporting the engine, turn the fuel valve to the off position and keep the engine level to
prevent fuel spillage. Fuel vapor or spilled fuel may ignite.
Before storing the unit for an extended period;
1. Be sure the storage area is free of excessive humidity, and dust.
2. Drain the fuel
Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke
Or allow flames or sparks in the area.
3. Change the engine oil.
4. Remove the spark plug and pour about a tablespoon of clean engine oil in-to the cylinder.
Crank the engine several revolutions to distribute the oil, and then reinstall the spark plug.
5. Pull the starter rope slowly until resistance is felt. Continue pulling until the notch on the starter
pulley aligns with the hole on the recoil starter (see illustration below). At this point, the intake
and exhaust valves are closed, and this will help to protect the engine from internal corrosion.
6. Cover the engine to keep out dust.
10

SERVICE
Maintenance
Periodic maintenance and adjustment are necessary to keep the engine in good operating condition.
Perform the service and inspection scheduled in the following table.
Shut off the engine before performing any maintenance. If the engine must be run, make
sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas;
exposure can cause loss of consciousness and may lead to death.
Use only genuine Our company parts or their equivalent. The use of replacement parts
that are not of equivalent quality may damage the engine.
♢ Maintenance Schedule
NOTE:
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by an authorized dealer, unless
the owner has the proper tools is mechanically proficient. See the
Our company, Shop Manual.
ITEM PERIOD Each use 25Hours 50Hours 100Hours 300Hours
Check Oil Level Check lever ●●
Change
Reduction gear oil Check lever ●
Change ●●
Air Cleaner Check lever ●
Change ●
Sediment cup Clean ●
Spark Plug Clean ●
Spark Arrester Clean ●
Valve Clearance Check ●
Fuel Tank Strainer Clean ●
Fuel Line Check Every 2 Years
11

SERVICE
1. Change Oil
Drain the oil while the engine is still warm to assure rapid and complete draining.
1. Remove the oil filler cap and drain plug to drain the oil.
2. Install the drain plug, and tighten it securely.
3. Refill with the recommended oil, and check the oil level.
4. Install the oil filler cap.
FX390,FX390E
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely unless you handle used oil on a daily
basis, it is still advisable to thoroughly wash your hands with soap and water as
soon as possible after handling used oil.
NOTE: Please dispose of used motor oil in a manner that is compatible with the
environment. Do not throw it in the trash or pour it on the ground.
12

SERVICE
2. Air Cleaner Service
A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor
malfunction, service the air cleaner regularly. Service more frequently when operating
The engine in extremely dusty areas.
Never use gasoline or low point solvents for cleaning the air cleaner element. A fire
or explosion could result.
1. Unscrew the wing nut, remove
the air cover and remove the
Element.
2. Wash the element in a solution of household
detergent and warm water, then rinse thoroughly, or
wash in nonflammable or high flash
point solvent. Allow the element to
dry thoroughly.
3. Soak the element in clean engine
oil and squeeze out the excess oil.
The engine will smoke during initial start-up if too
much oil is left in the element.
4. Reinstall the air cleaner element and the cover.
Never run the engine without the air cleaner. Rapid engine wear will result from
Contaminants, such as dust and dirt, being drawn through the carburetor, into
the engine.
WARNING
NOTICE
13

SERVICE
3. Sediment Cup Cleaning
Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow
flames or spark in the area.
After installing the sediment cup, check for leaks, and make sure the area is dry
before starting the engine.
Turn the fuel valve to OFF. Remove the sediment cup and O-ring and wash them
In nonflammable or high flash point solvent. Dry them thoroughly, and reinstall
securely. Turn the fuel valve ON, and check for leaks.
4. Spark Plug Service
Use only the recommended spark plug or equivalent. Spark plugs which have an
Improper heat range may cause engine damage.
To ensure proper engine operation, the spark
plug must be properly gapped and free of deposits.
♢ Remove the spark plug cap, and use a spark
plug wrench to remove the plug.
♢ Visually inspect the spark plug. Discard it if the
Insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.
♢ Measure the plug gap with a feeler gauge. The
gap should be 0.7-0.8 mm (0.028-0.031 in).
♢ Check that the spark plug washer is in good
condition, and thread the spark plug in by hand
to prevent cross-threading.
♢ After the spark plug is seated, tighten with a
spark plug wrench to com- press the washer.
WARNING
WARNING
14

SERVICE
If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
NOTE: If installing a new spark, tighten ½ turn the spark plug seats to compress
the washer. If reinstall a used spark plug, tighten 1/8-1/4 turn after then
spark plug seats to compress the washer.
The spark plug must be securely tightened. An improperly tightened spark plug can become very hot may damage
the engine.
5. Spark Arrester Maintenance (Optional Part)
The muffler is come very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffler while it is hot allow
it to cool before preceding.
Be Careful not to damage the spark arrester screen.
1. Remove the two 8 mm nuts 1 and remove the muffler from the cylinder.
2. Remove the three 4 mm screws 2 from the exhaust deflector 3, and remove the deflector
3. Remove the four 5mm screws 4 from the muffler protector 5, and remove the muffler protector
4. Remove the 4 mm screw 6 from the spark arrester (optional)7, and remove the spark arrester
from the muffler 8
15

SERVICE
Troubleshooting
PROBLEM POSSIBLE CAUSE PROBABLE SOLUTION
Engine will not start Out of fuel
Engine Flooded
Add fuel to tank
Gasoline engine; set chock( if
equipped to OPEN/RUN
position and continue to pull
starter handle.
Engine stops suddenly
Low oil shutdown
Fuel tank empty or full of im-
pure of low quality gasoline
Fill engine oil to proper level.
Fill fuel tank with fresh 90+
gasoline.
Engine Knocks Engine overload. Do not exceed equipment’s
load rattling.
16

SERVICE
Warranty Service
Owner Satisfaction
Your satisfaction and goodwill are important to us. All warranty details are explained in the
Distributor’s Limited Warranty.
Warranty Service is available at the dealership you bought the equipment from.
Normally, any problem concerning the engine will be handled by the dealer’s service depart-
ment. If you have a warranty problem that has not been handled to your satisfaction, we suggest
you take the following action:
·Discuss your problem with a member of a dealership service department. Often complaints
can be quickly resolved at that level. If the problem has already been reviewed with the Ser-
vice Manager, contact the owner of the dealership or the General Manager.
·If your problem still has not been resolved to your satisfaction.
We still need the following information in order to assist you:
Name:
Address:
Telephone Number:
Engine Model:
Date of Purchase:
Dealer name and address if applicable:
Nature of the Problem:
17