Muffler Replacement (3100-watt Inverters)

Updated 2 years ago by Juan Velez

This bulletin covers the following models: Champion 3100-watt inverters.

Read instructions carefully and completely before performing service.

SAFETY PRECAUTIONS

To reduce the risk of injury, user must read and understand the operator’s manual before using this product.
DO NOT make any adjustments to the generator without first stopping the engine and disconnecting the spark plug wire.
Burns from hot parts — let the engine cool completely 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.

You will need the following tools:

10mm wrench and socket, 7mm socket, pliers, and a Phillips screwdriver.

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.
Visual
See below.
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.
Visual
See below.
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.
Visual
See below.
With the hoses disconnected, you can remove the 7 mm fuel tank bolts and set the fuel tank aside.
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.
Visual
See below.
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.
Visual
See below.
Remove all the screws holding the top of the muffler casing, then remove the top casing.
Visual
See below.
Remove the two 10 mm bolts holding the muffler to the cylinder head.
Visual
See below.
There is one additional muffler bolt found at the bottom left of the muffler assembly.
Visual
See below.
You can now remove the muffler and gasket.
Visual
See below.
To complete the installation, replace the muffler gasket and muffler. Then reassemble the generator following these instructions in reverse.