Champion 100204 Service manual

11/8/18 1 Champion Power Equipment, Inc.
Technical Bulletin
Number: 181108-60-50-2
Date: 11/8/18
Recoil Install for 3KW Inverters
This covers the following models (Read completely before performing service):
•100204
•100158
•100387
•75537i
•100476
•100396
•100233
•100264
•100262
•100523
•75531i
•100477
•100263
•100269
•100261
•All similar body style inverters
1. Unscrew the screws and bolts for the left side
panel.

11/8/18 2 Champion Power Equipment, Inc.
2. Unscrew the bolts on the controller module and
take out the controller module.
(If using a remote start or electric start version,
unscrew the bracket with the controller module
and battery (4) bolts. Take out the battery and
unplug all connectors on the controller module and
remove the whole bracket)
Electric/Remote Start Unit:
3. Loosen the cable holder on the recoil cover.

11/8/18 3 Champion Power Equipment, Inc.
4. Unscrew (3) bolts of recoil assembly. Unscrew (2)
screws of handle orientation plate at the panel
side. Take out the recoil assembly with the handle
orientation plate.
5. Pull rope out for some length and secure a stop-
knot at the recoil cover end.

11/8/18 4 Champion Power Equipment, Inc.
6. Remove the recoil handle and orientation plate.
7. Unscrew the bolts of the recoil cover and remove
the recoil assembly
8. Put the new spring into the pulley if need to
replace a new spring.

11/8/18 5 Champion Power Equipment, Inc.
9. Put the new rope into the pulley and secure with
a stop-knot. And then rotate the rope clockwise
[spring side towards to you] (about 3.5 turns)
until the rope aligns with the open slot on the
outer edge of the pulley.
10. Apply lubricant or grease to the shaft of the
recoil cover and insert the pulley to the recoil
cover.
11. Pull the rope into the slot and take the loose part
of the rope inside the pulley and rotate the
pulley about 3 turns [counter-clockwise] until the
tension spring resists. Hold the pulley from
reversing until the rope is ready to wind back
onto the pulley. Feed the rope out to the hole of
recoil cover and pull it through the guide hole on
the outside of the recoil cover. Place the guide
plate / pull handle on the rope and secure with a
stop-knot.

11/8/18 6 Champion Power Equipment, Inc.
12. Place the (2) detent springs as shown
13. Put 2 detents into the spring positions with some
lubricant. Note the detents must press the springs
when install the detents.

11/8/18 7 Champion Power Equipment, Inc.
14. Put the bolt with some lubricant into the press
plate, and then put a spring to the bolt. The bolt
thread can have some locking glue. Put the press
plate assembly onto the detents, and then
tighten the bolt.

11/8/18 8 Champion Power Equipment, Inc.
15. Install the orientation plate with a new recoil
assembly.
16. Install the new recoil assembly. Tighten the cable
holder on the recoil cover.
17. Install the orientation plate.
18. Re-install the controller module. To check all wire
harness and connectors at the suitable position
after installation.

11/8/18 9 Champion Power Equipment, Inc.
19. Re-install the left panel.
If you have any questions regarding the previous procedure, please contact our technical department
Monday-Friday from 8:30 AM-5:00 PM PST at 877-338-0999.
If you have any questions, please contact Champion Power Equipment:
Champion Power Equipment, Inc.
12039 Smith Ave.
Santa Fe Springs, CA 90670
Phone: [phone]
Email: [email protected]