Gas Tank Replacement

Updated by Juan Velez

This covers gasoline powered Champion Power Equipment  generators.

Read instructions carefully and completely before performing service.

  • 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 followings tools to replace the gas tank: 10 mm wrench or socket, socket wrench with a 12 mm socket, 14 mm wrench, Phillips screwdriver, and pliers.

Remove the Tank 

  1. On the recoil end of the generator, remove the end bar held in place by two 10 mm bolts.
  2. Loosen the wire retaining clip on the fuel line and remove the fuel line at the petcock valve.
  3. Remove the four 10 mm bolts from the corners of the bank.
  4. Slide the fuel tank out of the chassis towards the recoil end of the generator. 
  5. Drain the tank completely into an approved container. 
  6. Loosen the lock nut on the petcock closest to the tank with a 14 mm wrench. When the lock nut is loosened, unscrew the petcock from the tank.
  7. Remove the fuel gauge by carefully peeling back the ends of the decal on the gauge and remove the two Phillips-head screws.

Install the Tank

  1. Insert the fuel gauge into the tank and attach with two Phillips head screws. 
  2. Insert the petcock valve into the tank and tighten by hand. Tighten the lock nut with a 14 mm wrench.
  3. Slide the tank into the generator chassis.
  4. Attach the tank to the chassis with the four 10 mm bolts.
  5. Attach the fuel line to the petcock and secure the wire retaining clip.
  6. Install the end bad and secure it with the two 10 mm bolts. 

View and download the PDF version here.

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