Champion Power Equipment 2000 User manual

Brand: Champion Power Equipment

Model: 2000

Category: Power generators

Type: User manual

Champion Power Equipment 2000 is a powerful and versatile inverter that provides clean, reliable power for a variety of applications. With its compact size and lightweight design, it's easy to transport and store, making it ideal for camping, tailgating, or powering small appliances and electronics on the go. The inverter features a fuel-efficient engine that delivers up to 3.8 hours of run time at rated load, and its low noise level ensures quiet operation.

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Champion Power Equipment



2000 W Inverter

Service Manual

73531i

73552i

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TableofContents

1.0Specifications.......................................................................................................................................................4

2.0ServiceInformation...............................................................................................Error!Bookmarknotdefined.

2.1MaintenaceSchedule.......................................................................................................................................5

3.0Troubleshooting...................................................................................................................................................6

3.1Engine...............................................................................................................................................................6

3.1.1Enginewillnotstart..................................................................................................................................6

3.1.2Enginestarts,butwillnotrun...................................................................................................................7

3.1.3EngineRPMarelowornot

steady............................................................................................................7

3.2IgnitionSystem.................................................................................................................................................8

3.2.1NoSpark....................................................................................................................................................8

3.3ThrottleControlSystem.......................................................................................................................................8

3.3.1EngineRPMnotsteady.............................................................................................................................8

3.3.2ECONswitchdoesnotwork......................................................................................................................9

3.4Generator.............................................................................................................................................................9

3.4.1LowACoutput...........................................................................................................................................9

4.0Maintenance......................................................................................................................................................10

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4.1CheckOilLevel...........................................................................................................................................10

4.2ChangeEngineOil......................................................................................................................................10

4.3AirCleaner..................................................................................................................................................10

4.4SparkPlug...................................................................................................................................................11

4.5ValveClearance..........................................................................................................................................11

4.5.1MeasuringValveClearance.....................................................................................................................11

4.5.2AdjustingValveClearance.......................................................................................................................12

4.6FuelFilter...................................................................................................................................................12

4.7FuelStrainer

...............................................................................................................................................12

4.8SparkArrestor............................................................................................................................................13

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4.9EngineSwitch/EconSwitch......................................................................................................................13

4.10IgnitionUnit.............................................................................................................................................14

4.11OilLevelSwitch........................................................................................................................................14

4.12ACReceptacle..........................................................................................................................................14

4.13StepperMotor..........................................................................................................................................15

4.14Generator.................................................................................................................................................15

4.15Trigger......................................................................................................................................................15

4.16IgnitionCoil..............................................................................................................................................15

4.17ValveStemOutsideDiameter

..................................................................................................................16

4.18ValveSpringFreeLength..........................................................................................................................16

4.19CamHeight...............................................................................................................................................16

4.20Cylinder‐InnerDiameter.........................................................................................................................16

4.21PistonSkirt–OutsideDiameter...............................................................................................................17

4.22PistonPin–OutsideDiameter.................................................................................................................17

4.23PistonRing–SideClearance....................................................................................................................17

4.24CrankshaftPin–OutsideDiameter

..........................................................................................................17

4.25CarburetorFloatHeight...........................................................................................................................17

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1.0Specifications

Overall Length 19.3 in / 490 mm

Dimensions

Overall Width 13.2 in / 335 mm

Overall Height 16.3 in / 415 mm

Dry Weight 48 lbs / 21.7 kg

Generator type Multi pole rotation

Generator

structure

Self-ventilation drip-proof

alternator

Excitation Self-excitation (Magnet type)

Frequency

regulation

AC-DC-AC conversion

Generator

AC output Frequency 60 Hz

Voltage 120 V

Rated output 1.6 kVA

Rated current AC 13.3A

Rated rotation

speed

4300 rpm

ECON no load

speed

3000 rpm

Engine type 4-stroke single cylinder OHV

Displacement 79.7mL

Bore x Stroke 48.6mm x 43.0mm

Compression

ratio

8.7

Ignition system T.C.I

Engine

Engine oil

capacity

13 fl oz / 0.4L

Carburetor Float type

Lubrication

system

Forced splash

Air cleaner Semi-dry type

Cooling system Forced air-cooled

Spark plug E6RTC (NHSP)

Starting system Recoil starter

Fuel Automotive unleaded gasoline

Run Time

Rated 3.8hr

1/4 Load 9.5hr

Fuel Tank Capacity

1.0 gal / 3.8L

Noise level

Full Load /7m 65 dBA

1/4 Load @ 7m 54 dBA

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2.0MaintenanceSchedule

Interval

Item Routine

First 20 Hr

or First

Month

Every 100

Hr or 6

Months

Every

300 Hr or

Months

Engine oil

Check oil level in engine

Replace engine oil ● ●

Fuel system

Check fuel leakage

Clean fuel filter / strainer ●

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 ●

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Note:Performeachroutineattheshorterofthetwointervals–whichevercomesfirst

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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. 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

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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

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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–Checkvalveclearance

7. Ifenginewillstillnotrun,seeThrottleControltroubleshooting

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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. IftheSparkPlugsparks,thentheLowOilSensorneedstobereplaced

2. InstallanewSparkPlugandcheckforspark

3. Pullrecoilstarterandcheck

iftheOilWarningLightflashes

a. TheflashingOilWarningLightindicatesthattheOilLevelSensorneedsreplacing

4. CheckEngineSwitchforcontinuity

a. Replaceifneeded

5. CheckairgapandresistanceofthePulsarCoil<needspecfromYamashita>

a. AdjustairgaporreplacePulsarCoilifneeded

6. CheckIgnitionCoil<needdetail>

a. Replaceifneeded

7. CheckWireharnessfordamage

a. Replaceifneeded

3.3ThrottleControlSystem

3.3.1EngineRPMnotsteady

1. CheckStepperMotormovement

a. Starting:FullOpenclose

b. Stopping:FullOpen

c. ReplaceStepperMotorifneede d

2. CheckStepperMotorResistance:40‐50ohms

a. Replaceifresistanceisoutofspec

3. CheckWireHarnessfordamage

a. Replaceifneeded

4. ReplaceControlUnit

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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

4. ReplaceControlUnit

3.4Generator

3.4.1LowACoutput

1. WithEnginerunning,checkiftheOverlo ad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

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4.0Maintenance

4.1CheckOilLevel

1. Stoptheengineandplacetheunitonalevelsurface

2. RemovetheMaintenanceCover(4screws)

3. RemovetheOilFillerCap/Dipstick

4. Checkthe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. Tilttheunittowardsitssidetoallowtheoiltodraincompletely

5. Placetheunitbackintheupright position

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:

 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.

 Neverruntheunitwithoutafilterelementorwithadamagedelement.

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4.4SparkPlug

1. Stopthe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

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spark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12



a. Torqueto11N‐M(7.9ft‐lb)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.

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Cap

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13



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.

CleanthecarbonfromthesteelmeshoftheSparkArrestorusingastiffwire brush.

7. Checkforany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14



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

Yellow OilLevelSwitch

NoContinuitywithproperOil

Level

Green/White TriggerCoil 80–132Ohm

Yellow/Green GroundWire Continuity

Green IgniterUnitPowerCoilWinding 0.5–0.9Ohm

Black EngineSwitch

NoContinuitywithSwitchON,

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. Waittwominutes

5. Checkthecontinuity.Ifworkingproperly,thereshouldbeNOcontinuity.

4.12ACReceptacle

1. Checktheelectrodecontactdiskinsidethereceptacle.Ifitisburnedordiscolored,replacethereceptacle.

Draft,08‐23‐2010 Page15



4.13StepperMotor

1. MeasuretheresistanceoftheStepperMotorlead‐outwires

a. Between1and3:45–55Ohm

b. Between2and4:???<ne edspecfromYamashita>

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. DCCoil

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. ACCoil

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pri mary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termi nalofthe

primarycoil

plugsoftheIgnitionCoil.Theresistanceshouldbe12.2KOhm2.4K

Draft,08‐23‐2010 Page16



4.17ValveStemOutsideDiameter

1. IntakeValve

a. Standard: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17



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”)<askYamashitatoverify>

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Diameter

1. Standard:21.969–22.000mm(.8649–.8661”)<askYamashitatoverify>

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



Champion Power Equipment 2000 User manual

Brand: Champion Power Equipment

Model: 2000

Category: Power generators

Type: User manual

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Champion Power Equipment 2000 User manual

Champion Power Equipment 2000 User manual

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