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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 us

ing 

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. 

Содержание 100204

Страница 1: ... 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 no...

Страница 2: ...ry 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 ...

Страница 3: ...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 ...

Страница 4: ... 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...

Страница 5: ...t 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 ...

Страница 6: ...est 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 ...

Страница 7: ... 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 ...

Страница 8: ...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 ...

Страница 9: ...t 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 ...

Страница 10: ...hieve 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 ...

Страница 11: ...ve single bolt with 10mm socket disconnect wires and install new Make sure cable routing is correct Reverse steps for reassembly If you have any questions regarding these recommendations please contact our technical department Monday Friday from 8 30 AM 5 00 PM PST at 877 338 0999 Champion Power Equipment Inc 12039 Smith Ave Santa Fe Springs CA 90670 Phone 1 877 338 0999 Email tech championpowereq...

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