3100W Inverter Muffler Replacement

Updated 5 months ago by Juan Velez

This covers all Champion 3100W Inverter models.

Read instructions carefully and completely before performing service.
You will need the following tools: 

10mm wrench and socket, 7mm socket, pliers, and a Phillips screwdriver.
  1. Remove the three screws along both the right and left handles. This will allow you to snap these handle pieces out. Do not forget to remove the gas cap. Remove the 10 mm bolts and set aside the top yellow cover.

  2. Remove the maintenance panel and locate the fuel drain hose. Place the fuel drain hose into a safe fuel storage container and loosen the drain screw. Turn the fuel valve on to drain all the gas from the fuel tank. 

  3. Next, remove the rubber ventilation hose that can be seen from the top of the fuel tank as well as the fuel line from the fuel "ON/OFF" valve. 

  4. With the hoses disconnected, you can remove the 7 mm fuel tank bolts and set the fuel tank aside. 
  5. Remove the 10 mm bolts holding the handle side of the panel to the frame. Also, remove the two screws and the two 10 mm bolts from the outside of the side panel. 
  6. Once you remove the side panel, you can see the muffler and its housing. You will need to locate a ventilation hose from the exhaust pipe. 
  7. Remove all the screws holding the top of the muffler casing, then remove the top casing. 

  8. Remove the two 10 mm bolts holding the muffler to the cylinder head. 

  9. There is one additional muffler bolt found at the bottom left of the muffler assembly. 

  10. You can now remove the muffler and gasket.

  11. To complete the installation, replace the muffler gasket and muffler. Then reassemble the generator following these instructions in reverse. 

View and download the PDF version here.

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