Champion 75537i User manual

Relay Starter Repair/Replace
Date: 5/8/2019
This covers the following models (Read completely before performing service):
•75537i, 100204, 100261, 100262, 100263, 100264, 100477 –Dual Fuel, Electric Start, or Wireless
Remote Start
*Specification, descriptions and illustrations are as accurate as known at the time of publication but are subject
to change without notice.
SAFETY PRECAUTIONS
• To reduce the risk of injury, user must read and understand the operator’s manual before using
this product.
• DO NOT make any adjustments to the generator without first stopping the engine, turning all
switches to the ‘OFF’ position, close fuel valve and disconnecting the spark plug wire.
• Burns from hot parts —let the engine cool for 30 minutes before touching hot parts.
• Injury from moving parts
• To reduce the possibility of fire or explosion, be careful when working around gasoline.
Keep cigarettes, sparks and flames away from all fuel‐related parts.
Tools Required
Tool
Size
Rachet
3/8
Sockets
7mm, 8mm, 10mm,
Pliers
Box nose
Phillips Screwdriver
#2
Crescent Wrenches
7mm, 8mm
Empty Gas Container
Minimum 2 Gallon
Nitrile Gloves
*3 –Containers or boxes for Parts
Small to Medium
*Containers or boxes will help organize/identify parts when reassembling.
Never store the machine with gasoline in the fuel tank in a confined area with improper ventilation. Gasoline
fumes could reach open flames, sparks and cigarettes etc.

1. Ensure that the Fuel Valve, Battery and
Start switches are all in the “OFF”
positions.
(panel illustrated is from model 75537i)
2. Remove the 2 Phillips screws from the
battery maintenance cover and pull on
the rubber tab to access the battery.
Unclip the pinch rubber and slide the
battery back to access cables.
Pull back on the protective boots to
expose the battery bolts and using a
10mm wrench or socket remove the
Black (-) negative cable first and then
remove the Red (+) positive cable.
*Put all battery parts into a tray and
label it “Battery Parts”

3. Remove the 2 Philips screws to remove
access panel.
4. Gently pull the spark plug cap by firmly
grasping the spark plug insulator at the
base. Leave disconnected while working
on unit.

5. Remove the clear or pink carburetor
drain hose from the drain hole in the
base of the enclosure and extend hose
to exterior and direct the hose into your
gasoline container. Turn main fuel valve
to the “ON” (“gasoline” position for Dual
Fuel) and with hose securely positioned
into your gasoline can loosen drain
screw only enough until you see gas
flowing. After fuel tank is completely
empty close drain screw, turn fuel valve
“OFF” and insert drain hose back into
the drain hole in the base of the
enclosure.
6. On the top handle on both sides, with a
Phillips screwdriver, remove the 3
Phillips screws facing toward the gas
cap.
7. Separate the handle along the center
seam and pull downwards toward the
top of the unit.
*Put all parts into a box and label it
“Top/Handle Parts”

8. Located on the right side of the metal
frame, remove the 2 bolts with a rachet
and 10mm socket.
*Put all parts into a box and label it
“Right Side Parts”
9. With a Phillips screwdriver, remove the 2
screws on each side and then with a
rachet with a 10mm socket, remove the
2 shoulder bolts at the bottom.
10. Remove the right-side cover (Handle
side).
*Place hardware into tray already
labeled “Right-Side Cover”.

11. Unscrew gas cap and remove the Phillips
screw. Place gas cap to the side.
*We suggest you thread the screw back
into the cap so as not to misplace.
12. Remove the top cover by removing the 4
bolts (2 on each side) with 10mm socket.
*Put all parts into box labeled
“Top/Handel Parts”
13. Gently push up on the top cover, the top
will unsnap out of place. Replace Gas
cap on tank.

14. Remove the 4 fuel tank bolts with 7mm
socket. Remove the rubber hose on the
top by gently twisting and pulling with
your fingers.
*Put all parts into a box labeled
“Top/Handle Parts”.
15. Gently lift-up on the gas tank and locate
the hose clamp securing the fuel line in
place. (Make sure the gas tank is empty
if you haven’t already done so in step #6
before removing fuel line). Using your
pliers, pinch the clamp to expand it and
gently wiggle the fuel line and clamp off.
Once removed, (gas cap on tank), place
tank in a safe location, away from
cigarettes, sparks and flames.

16. Loosen the choke cable clamp screw and
loosen the cable wire clamp using a
7mm and 8mm wrench. Remove choke
cable from Pinch bolt and allow cable to
lay loosely so we can remove front panel
in later step.
17. If unit is a dual fuel, take note of which
wires go to which terminals. We suggest
you take a picture then disconnect the
spade terminals. There are 6
connections and we only use 4 so we
recommend you Take a Picture!

18. Front panel remove the (5) screws as
indicated. Remove the center screw and
pull off fuel knob and place to the side.
DO NOT lose the small center screw.
*Put all parts into a box and label it
“Front Panel”
19. FOR DUAL-FUEL MODEL ONLY –
Remove the (5) front panel screws as
indicated. Holding the fuel knob in the
“OFF” position, remove the center screw
and pull off fuel knob and place to the
side. DO NOT lose the small center
screw.
*Put all parts into a box and label it
“Front Panel”
20. Once all screws are removed, gently pull
out on the top right-hand corner, and
swing out the panel slowly, DO NOT
FORCE.

21. Located on the inside left front panel
below the recoil cord, disconnect the
Molex connector from the Rectifier. This
will enable you to achieve more room to
open the front panel.
22. Directly in front of you, against the
engine block, you will see the starter
solenoid and starter motor. Inspect
black solenoid wire for damaged wire
insulator as shown in picture. Use
electric tape to cover the exposed
copper wire, wrap firmly with at least 3
to 4 layers.
Exposed starting solenoid wire