Champion 100485 9200 W Electronic Fuel Injection Generator Instruction Manual (+ PDF)

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1 MODEL #100485

2 PARTS INFORMATION

3 GENERATOR PARTS DIAGRAM

4 GENERATOR PARTS LIST

5 ENGINE PARTS DIAGRAM

6 ENGINE PARTS LIST

7 CYLINDER HEAD DIAGRAM

8 CYLINDER HEAD LIST

9 ALTERNATOR PART DIAGRAM

10 ALTERNATOR PART LIST

11 CONTROL PANEL PART DIAGRAM

12 CONTROL PANEL PART LIST

13 FUEL TANK PART LIST

14 FRAME PART DIAGRAM

15 FRAME PART LIST

16 WIRING DIAGRAM

17 Documents / Resources

18 Related Posts

MODEL #100485

Champion Power Equipment, Inc., Santa Fe Springs, CA USA

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.

REV 20210415

100485 – 9200W ELECTRONIC FUEL INJECTION GENERATOR

GENERATOR PARTS DIAGRAM

Figure A

GENERATOR PARTS LIST

#	Part Number	Description	Qty.
1	2.06.006	Clamp Ø7 x Ø1	2
2	152.070014.05	Tube, Fuel Tank Vent	1
3	152.070013.03	Tube, Carbon Canister Vent, 135 mm	1
4	2.06.004	Clamp, Ø8 x Ø1	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	2.06.029	Clip Ø15	1
14	45.090006.20	Bracket, Air Cleaner Support	1
15	1.6177.1.06	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	46.101300.00	Spark Arrester Assembly	1
22	1.16674.0820	Flange Bolt M8 x 20	2
23	155.190000.06	Alternator Assembly, Al, Ø204 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	48.605	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 Ø6, Toothed	1
30	1.97.1.06	Washer Ø6	2
31	1.93.06	Lock Washer Ø6	1
32	1.62.06	Butterfly Type Nut M6	1
33	2.05.009	Clamp Ø12.5 x 7	2
34	65306.100485	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	9.1000.150	Battery 12V15AH	1
38	152.200904.00	Strap, Battery Hold Down	1
39	152.200013.02	Jacket, Wire, Blcak	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	100485.21	Control Panel Assembly, See Figure F	1
45	9.1700.009	Smart Charger, SAE	1

ENGINE PARTS DIAGRAM

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 Ø4 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	2.02.007	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	191.120100.00	Flywheel	1
21	191.091000.00.2	Air Cleaner Assembly	1
22	46.061000.00	Recoil Assembly	1
23	2.11.007	Oil Seal Ø35 x Ø52 x 8	2
24	2.05.050	Wire Clip, 100 mm	2
25	152.070031.01	Sheath, Wire	1
26	2.03.023	Washer Ø12.5 x Ø20 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	2.04.001	Dowel Pin Ø9 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	2.05.005	Clamp Ø6	1
44	1.6177.1	Flange Nut M5	6
45	47.050200.00	Connecting Rod	1
46	48.050005.00	Piston	1
47	2.09.004	Circlip Ø21 x Ø1	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	2.04.004	Dowel Pin Ø12 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	2.15.008	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
61	45.020001.03	Breather Tube	1
62	47.020100.00	Bolt, Cylinder Head Cover	1
63	2.08.039	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 Ø5	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 Ø6	2
82	22.040012.00	Screw, Valve Adjustment	2
83	1.6177.1.06	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

Figure C

CYLINDER HEAD LIST

#	Part Number	Description	Qty.
1	191.010100.00	Cylinder Head	1
2	2.01.010	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	2.01.008	Stud Bolt M6 x M8 x 105	2
12	191.030009.00	Gasket, Cylinder Head	1

ALTERNATOR PART DIAGRAM

Figure E

ALTERNATOR PART LIST

#	Part Number	Description	Qty.
1	1.6175.05	Nut M5	2
2	1.97.1.05	Washer Ø5	2
3	1.93.05	Lock Washer Ø5	2
4	2.08.071	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	153.190200.03	AVR	1
14	1.16674.0512	Flange Bolt M5 x 12	1
15	152.190002.00	End Housing	1
16	2.08.069	Flange Bolt/Washer Assembly M6 x 194	4
17	154.191002.00	Stator Cover	1
18	2.08.070	Flange Bolt/Washer Assembly M10 x 280	1
19	155.191200.06	Stator Assembly, Cu, Ø204 x 158 mm, CSA	1
20	155.191100.00	Rotor Assembly, Cu, Ø204 x 158 mm, CSA	1
21	155.191000.06	Alternator Assembly, Cu, Ø204 x 158 mm, CSA	1

CONTROL PANEL PART DIAGRAM

Figure F

CONTROL PANEL PART LIST

#	Part Number	Description	Qty.
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	2.06.048	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

Figure G

FUEL TANK PART LIST

#	Part Number	Description	Qty.
1	152.299.1.2	Control Panel	1
2	5.1000.007.3	Ignition Switch, Red	1
3	5.1440.011	Intelligauge	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	100485.21.10	Wire Harness	1
23	5.210400.00	Current Transformer	1
24	1.6177.1.05	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

Figure H

FRAME PART LIST

#	Part Number	Description	Qty.
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 Ø8	2
8	152.200703.02	Short Pin, Handle	2
9	152.100007.00	Heat Shield, Motor Mount	1
10	65306.0.10.2	Frame,700 x 541 x 600	1
11	1.6177.1.10	Lock Nut M10, Flange	4
12	152.201200.03	Vibration Mount 1	2
13	2.16.001.1	Pin Ø2 x 33, “R” Shape, Blcak	2
14	152.201701.13.48	9.5 in. Wheel, PU, Yellow	2
15	122.201501.25.1	Pin Roll, Wheel, Ø16 x Ø10 x 97, Blcak	2
16	122.201702.11.48	Wheel Cover, Tooth Profile 8-10 in, Yellow	2
17	152.201200.04	Vibration Mount 2	2
18	1.6177.1.08	Flange Lock Nut M8	6
19	1.6177.1.08.1	Flange Lock Nut M8, Blcak	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

WIRING DIAGRAM

COMBINATION SWITCH

	1	2	4	5	7	8	9	11	12
OFF
ON
ST

B	BLACK	Br	BROWN
Y	YELLOW	B/W	BLACK WHITE
L	BLUE	W/G	WHITE GREEN
G	GREEN	G/Y	GREEN YELLOW
R	RED	L/W	WHITE BLUE
W	WHITE	C	CARNATION
Gr	GREY	R/W	RED WHITE
O	ORANGE	R/B	RED BLACK
V	VIOLET	G/W	GREEN WHITE