CHAMPION 9200W Electronic Fuel Injection Generator 100485 User Guide

: June 7, 2024
: Champion

Champion Power Equipment, Inc., Santa Fe Springs, CA the USA
MODEl #100485

CHAMPION 9200W Electronic Fuel Injection Generator

PARTS INFORMATION
9200W ELECTRONIC FUEL INJECTION GENERATOR
SERIAL NUMBER RANGE: ALL

To order replacement parts please visit: shop.championpowerequipment.com or call 1-877-338-0999.

GENERATOR PARTS DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
A

GENERATOR PARTS lIST

| Part Number| Description| Qty.

---|---|---|---
1| 2/6/1906| Clamp 07 x 01| 2
2| 152.070014.05| Tube, Fuel Tank Vent| 1
3| 152.070013.03| Tube, Carbon Canister Vent, 135 mm| 1
4| 2/6/1904| Clamp, 08 x 01| 1
5| 1.5789.0608.1| Flange Bolt M6 x 8, Black| 2
6| 152.070018.03| Board, Heat Insulation| 1
7| 152.070702.06| Bracket, Carbon Canister Top| 1
8| 152.070700.02| Carbon Canister, 650 cc| 1
9| 1.16674.0812| Flange Bolt M8 x 12| 2
10| 152.070702.05| Bracket, Carbon Canister Bottom| 1
11| 152.070000.49.48| Fuel Tank, 29L, Yellow, See Figure E| 1
12| 2.08.143.1| Flange Bolt/Washer Assembly M6 x 20, Black| 4
13| 2/6/1929| Clip 015| 1
14| 45.090006.20| Bracket, Air Cleaner Support| 1
15| 1.61771.06| Lock Nut M6, Flange| 2
16| 1.6177.1.08| Lock Nut M8, Flange| 2
17| 46.100001.07| Gasket, Exhaust| 1
18| 191.100008.00| Oxygen Sensor| 1
19| 191.101000.00.2| Muffler Assembly| 1
20| 1.9074.4.0510| Screw/Washer Assembly M5 x 10| 3
21| 46101300.00| Spark Arrester Assembly| 1
22| 1.16674.0820| Flange Bolt M8 x 20| 2
23| 155.190000.06| Alternator Assembly, Al, 0204 x 158 mm, DC 12V, See Figure D| 1
24| 1.5789.0608| Flange Bolt M6 x 8| 2
25| 152.192300.01| Cover, Alternator Fan Inlet| 1
26| 49.| Engine, 459cc, See Figure B| 1
27| 5.1900.109| Wire Harness| 1
28| 5.1900.026| Grounding Line 150 mm| 1
29| 1.862.06| Lock Washer 06, Toothed| 1

| Part Number| Description| Qty.

---|---|---|---
30| 1.971.06| Washer 06| 2
31| 1.93.06| Lock Washer 06| 1
32| 1.62.06| Butterfly Type Nut M6| 1
33| 2/5/1909| Clamp 012.5 x 7| 2
34| 65306.| Frame, Wheel Kit, See Figure G| 1
35| 1.9074.3.0510| Screw/Washer Assembly M5 x 10| 2
36| 1.6177.1.05| Lock Nut M5, Flange| 2
37| 9.1000150| Battery 12V15AH| 1
38| 152.200904.00| Strap, Battery Hold Down| 1
39| 152.200013.02| Jacket, Wire, Black| 1
40| 152.200013.02.3| Jacket, Wire, Red| 2
41| 5.1900.127| Battery SAE Wire| 1
42| 152.200013.03| Sleeve, Connector| 1
43| 5.1900.129| Motor SAE Wire| 1
44| 100485.| Control Panel Assembly, See Figure F| 1
45| 9.1700.009| Smart Charger, SAE| 1

ENGINE PARTS DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
B

ENGINE PARTS LIST

| Part Number| Description| Qty.

---|---|---|---
1| 21.061300.00| Handle, Recoil, Soft| 1
2| 1.5789.0608| Flange Bolt M6 x 8| 3
3| 46.061100.00.2| Cover, Recoil Starter, Black| 1
4| 45.060005.00| Spring, Recoil Starter| 1
5| 45.061102.00| Reel, Recoil Starter| 1
6| 2.10.003.1| Rope 04 x 1550, Black| 1
7| 45.060003.00| Spring, Ratchet| 2
8| 45.060002.00| Starter Ratchet, Steel| 2
9| 45.060009.00| Spring, Ratchet Guide| 1
10| 45.060007.00| Ratchet Guide| 1
11| 45.060008.00| Screw, Ratchet Guide| 1
12| 1.5789.0612| Flange Bolt M6 x 12| 13
13| 2.08.174| Flange Bolt M12 x 95| 2
14| 47.080100.01.48| Fan Cover, Yellow| 1
15| 2/2/1907| Nut M16 x 1.5| 1
16| 1.5789.0620| Flange Bolt M6 x 20| 2
17| 45.060001.00| Pulley, Starter| 1
18| 191.123000.00| Ignition Coil With RPM Sensor| 1
19| 48.080001.00| Cooling Fan| 1
20| 191120100.00| Flywheel| 1
21| 191.091000.00.2| Air Cleaner Assembly| 1
22| 46.061000.00| Recoil Assembly| 1
23| 2/11/1907| Oil Seal 035 x 052 x 8| 2
24| 2/5/1950| Wire Clip, 100 mm| 2
25| 152.070031.01| Sheath, Wire| 1
26| 2/3/1923| Washer 012.5 x 020 x 2, Drain Bolt| 1
27| 191.030100.00| Crankcase| 1
28| 45.127000.00| Oil Level Sensor| 1
29| 1.5789.0615| Flange Bolt M6 x 15| 2
30| 1.276.6202| Bearing 6202| 2
31| 48.050006.00| Weight Balancer| 1
32| 47.050100.51| Crankshaft| 1
33| 46.030008.00| Gasket, Crankcase Cover| 1
34| 2/4/1901| Dowel Pin 09 x 14| 2
35| 46.080600.00| Air Guide, Right Side| 1
36| 1.276.6207.9| Bearing TM6207| 1
37| 46.031000.01.48| Oil Dipstick Assembly, Yellow| 1
38| 191.030007.00| Cover, Crankcase| 1
39| 1.5789.0840| Flange Bolt M8 x 40| 7
40| 45.040013.00| Lifter, Exhaust Valve| 1
41| 45.125000.03| Starter Motor Assembly| 1
42| 46.040200.00| Rocker Arm Assembly| 1
43| 2/5/1905| Clamp 06| 1
44| 1.6177.1| Flange Nut M5| 6
45| 47.050200.00| Connecting Rod| 1
46| 48.050005.00| Piston| 1
47| 2/9/1904| Circlip 021 x 01| 2
48| 45.050003.00| Pin, Piston| 1
49| 48.050303.00| Ring, Oil| 1
50| 48.050302.00| Ring, Second Piston| 1
51| 48.050301.00| Ring, First Piston| 1
52| 2/4/1904| Dowel Pin 012 x 20| 2
53| 45.091002.20| Seal, Air Cleaner| 1
54| 46.080400.01| Air Guide, Lower| 1
55| 191.010000.00| Cylinder Head Assembly – See Figure C| 1
56| 5.1900.111| Sensor, Engine Temperature| 1
57| 2/15/1908| Spark Plug F7RTC| 1
58| 2.08.122| Flange Bolt M10 x 95| 2
59| 46.020002.01| Gasket, Cylinder Head Cover| 1
60| 47.021000.01| Cover, Cylinder Head| 1

| Part Number| Description| Qty.

---|---|---|---
61| 45.020001.03| Breather Tube| 1
62| 47020100.00| Bolt, Cylinder Head Cover| 1
63| 2/8/1939| Drain Bolt M12 x 1.5 x 15| 1
64| 48.041000.00| Camshaft| 1
65| 48.040013.00| Lifter, Intake Valve| 1
66| 191.080300.00| Air Guide, Upper| 1
67| 1.16674.0516| Flange Bolt M5 x 16| 2
68| 46.040005.00| Push Rod| 2
69| 1.93.05| Lock Washer 05| 2
70| 45.125200.03| Relay, Starter, Three Gear| 1
71| 45.125100.00| Starter Motor| 1
72| 1.5789.0835| Flange Bolt M8 x 35| 2
73| 191.091200.00| Cover, Air Cleaner| 1
74| 45.091003.20| Element Air Cleaner| 1
75| 45.040008.00| Rotator, Exhaust Valve| 1
76| 46.040004.00| Guide Plate, Push Rod| 1
77| 46.040016.00| Shaft, Rocker Arm| 1
78| 46.040201.00| Retainer, Rocker Arm| 1
79| 46.040009.00| Rocker Arm, Intake Valve| 1
80| 46.040018.00| Rocker Arm, Exhaust Valve| 1
81| 1.97.1.06| Washer 06| 2
82| 22.040012.00| Screw, Valve Adjustment| 2
83| 1.61771.06| Flange Nut M6| 2
84| 21.040021.00| Nut M6 x 0.5, Lock| 2
85| 45.091001.20| Separator, Air Cleaner| 1
86| 46.130002.20| Gasket, Insulator| 1
87| 45.130001.00| Insulator, Throttle Body| 1
88| 46.130003.20| Gasket, Throttle Body| 1
89| 191.130000.00| Throttle Body| 1
90| 46.130004.20| Gasket, Air Cleaner| 1
91| 1.6177.06| Flange Nut M6| 2
92| 191.091100.00| Base, Air Cleaner| 1

CYLINDER HEAD DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
C

CYLINDER HEAD LIST

| Part Number| Description| Qty.

---|---|---|---
1| 191.010100.00| Cylinder Head| 1
2| 2/1/1910| Stud Bolt M8 x 35| 2
3| 47.040002.00| Valve, Intake| 1
4| 47.040006.00| Valve, Exhaust| 1
5| 45.040015.00| Retainer, Valve Spring| 2
6| 45.040017.00| Oil Seal, Valve| 2
7| 45.040003.00| Spring, Valve| 2
8| 45.040001.00| Retainer, Intake Valve Spring| 1
9| 45.040007.00| Retainer, Exhaust Valve Spring| 1
10| 23.040010.00| Bolt, Rocker Arm| 2
11| 2/1/1908| Stud Bolt M6 x M8 x 105| 2
12| 191.030009.00| Gasket, Cylinder Head| 1

ALTERNATOR PART DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
E

ALTERNATOR PART LIST

#	Part Number	Description	Oty.
1	1.6175.05	Nut M5	2
2	1.97.1.05	Washer 05	2
3	1.93.05	Lock Washer 05	2
4	2/8/1971	Bolt M5 x 229	2
5	152.190300.00	Carbon Brush Assembly	1
6	122.190004.01	Bracket, Carbon Brush Retaining	1
7	1.9074.15.0520	Bolt/Washer Assembly M5 x 20	1
8	1.16674.0512.1	Flange Bolt M5 x 12, Black	2
9	152.190003.00.48	Cover, End Housing, Yellow	1
10	1.9074.17.0516	Screw/Washer Assembly M5 x 16	2
11	122.190400.00	Terminal Block	1
12	1.16674.0516	Flange Bolt M5 x 16	2
13	153190200.	AVR	1
14	1.16674.0512	Flange Bolt M5 x 12	1
15	152.190002.00	End Housing	1
16	2/8/1969	Flange Bolt/Washer Assembly M6 x 194	4
17	154.191002.00	Stator Cover	1
18	2/8/1970	Flange Bolt/Washer Assembly M10 x 280	1
19	155.191200.06	Stator Assembly, Cu, 0204 x 158 mm, CSA	1
20	155.191100.00	Rotor Assembly, Cu, 0204 x 158 mm, CSA	1
21	155.191000.06	Alternator Assembly, Cu, 0204 x 158 mm, CSA	1

CONTROL PANEL PART DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
f

CONTROl PANEL PART LIST

| Part Number| Description| city.

---|---|---|---
1| 122.070100.09| Fuel Tank Cap| 1
2| 122.070300.03| Fuel Filter| 1
3| 24.070800.00| Reversal Valve| 1
4| 1.9074.4.0512.1| Screw/Washer Assembly, M5 x 12, Black| 2
5| 152.070008.03| Cover, Fuel Pump| 1
6| 2.08.068.2| Flange Bolt, M5 x 13| 6
7| 191.070046.00| Plate, Fuel Pump Retainer| 1
8| 191.075000.00| Fuel Pump| 1
9| 152.071000.49.48| Fuel Tank, 29L, Yellow| 1
10| 122.070015.01| Mount Vibration, Fuel Tank| 4
11| 191.070600.00| Connect, Fuel Pump| 1
12| 2/6/1948| Clamp, Oil Hose| 1
13| 191.070011.00| Tube, Fuel Supply, 850 mm| 1
14| 2.08.172| Flange Bolt Assembly M10 x 15| 1

FUEL TANK PART DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
G

FUEL TANK PARTLIST

#	Part Number	Description	QTY.
1	152.2991.2	Control Panel	1
2	5.1000.007.3	Ignition Switch, Red	1
3	5.1440.011	Intelligence	1
4	5.1240.380	38Amp Circuit Breaker, Double Pole	1
5	5.1870.024	Receptacle Cover, Receptacle 14-50R	1
6	5.1120.044	Receptacle 14-50R	1
7	1.6177.1.04.1	Lock Nut M4, Flange, Black	8
8	5.1870.020	Receptacle L14-30R	1
9	5.1120.009	Receptacle Cover, Receptacle L14-30R	1
10	5.1120.050	Receptacle 5-20R, Duplex GFCI	2
11	5.1870.022	Receptacle Cover, Receptacle 5-20R, Duplex GFCI	2
12	5.1870.014	Circuit Breaker Cover, Push Button	4
13	5.1210.920	20Amp Circuit Breaker, Push Button, CSA	2
14	1.845.4216	Screw, ST4.2 x 16	2
15	5.1820.011	Charger, 5A	1
16	5.1280.003	Fuse, 10A	2
17	1.5789.0615.1	Flange Bolt M6 x 15, Black	4
18	152.210002.43	Control Panel Housing	1
19	122.210003.01	Wire Jacket, Control Box	1
20	5.1330.116	Sheath, Wire	1
21	152.210003.02	Plug, Control Box	1
22	100485.2110	Wire Harness	1
23	5.210400.00	Current Transformer	1
24	1.61771.05	Flange Lock Nut M5, Black	6
25	5.1830.026	CO Module	1
26	1.845.4213	Screw, ST4.2 x 13	2
27	1.818.0514.2	Screw M5 x 14	1
28	5.1810.008	OVP Diode	1
29	5.1210.930	30Amp Circuit Breaker, Push Button, CSA	2
30	1.9074.4.0306.1	Screw/Washer Assembly M3 x 6, Black	4
31	5.1460.019	Module, CO Shutdown LED	1

FRAME PART DIAGRAM

CHAMPION 9200W Electronic Fuel Injection Generator - Figure
H

FRAME PART LIST

| Part Number| Description| city.

---|---|---|---
1| 1.818.0414.1| Screw M4 x 14, Black| 2
2| 122.200702.13| Cover, Handle, Upper| 1
3| 122.200702.14| Cover, Handle, Lower| 1
4| 152.200703.03| Long Pin, Handle| 2
5| 11.110008.00| “R” Shape| 2
6| 152.200701.23.2| Handle, U Shape| 1
7| 1.894.1.08| Circlip 08| 2
8| 152.200703.02| Short Pin, Handle| 2
9| 152.100007.00| Heat Shield, Motor Mount| 1
10| 65306.010.2| Frame,700 x 541 x 600| 1
11| 1.61771.10| Lock Nut M10, Flange| 4
12| 152.201200.03| Vibration Mount 1| 2
13| 2.16.001.1| Pin 02 x 33, “R” Shape, Black| 2
14| 152.201701.13.48| 9.5 in. Wheel, PU, Yellow| 2
15| 122.201501.25.1| Pin Roll, Wheel, 016 x 010 x 97, Black| 2
16| 122.201702.11.48| Wheel Cover, Tooth Profile 8-10 in, Yellow| 2
17| 152.201200.04| Vibration Mount 2| 2
18| 1.61771.08| Flange Lock Nut M8| 6
19| 1.6177.1.08.1| Flange Lock Nut M8, Black| 2
20| 1.5789.0816.1| Flange Bolt M8 x 16, Blcak| 2
21| 152.200002.01.2| Support Leg 84 mm| 1
22| 152.201400.00| Rubber, Support| 2
23| 1.5789.0825| Flange Bolt M8 x 25| 2