Champion 4000W Portable Generator Model 200921 Parts Information and Diagrams

Generator Parts Diagram

Figure A shows an exploded view of the generator assembly. Key components include the fuel tank (1, 2, 3), frame assembly (4), various clamps and clips (5-12), air cleaner support (13), muffler assembly (18), spark arrestor (17), exhaust outlet gasket (22), engine (24), and alternator (25). Fasteners like bolts and nuts are also indicated by numbers. Specific sub-assemblies are referenced by additional figures (F, H, E, B, G).

Generator Parts List

#	Part Number	Description	Qty.
1	90007-0620-A301	Hexagon Flange Bolt, M6x20, Black Zinc	4
2	90408-Y020110-0005	Flat Washer, Ø6, Black Zinc	4
3	200921-YXZJ-F	Fuel Tank Assembly - See Figure F	1
4	200921-JJZJ-H	Frame Assembly - See Figure H	1
5	90684-Z250110-00A0	Clip,Ø8	2
6	90685-YJ30110-Q200	Clamp,Ø9.5 x Ø8	2
7	90685-Z030410-0G00	Clamp, Ø10.7 x 8 x 0.6	1
8	16805-YGK0110-0001	Tube, Carbon Canister Vent, Ø6 x Ø10 x 170	1
9	30351-YGK0110-00A0	Cover, Carbon Canister Vent	1
10	90685-Z030610-0G00	Clamp, Ø8 x 7 x 0.6	1
11	90685-Z020110-0G00	Clamp, Ø9.5 x 8 x 0.8	1
12	16801-YGK0110-00A0	Carbon Canister, 400cc	1
13	17003-Y110130-0001	Air Cleaner Support	1
14	90001-0612-0305	Hexagon Flange Bolt, M6 x 12, Black Zinc	2
15	90305-0600-0302	Hexagon Flange Nut, M6, Black Zinc	2
16	90106-0408-0000	Screw, M4 x 8, Black Zinc	3
17	18250-YJ30110-0000	Spark Arrestor	1
18	18100-YJ30110-H7A0	Muffler Assembly	1
19	90406-0600-E305	Flat Washer, Ø6.4 x Ø18 x 1.6, Black Zinc	1
20	18030-YJ30110-H7A0	Muffler Bracket	1
21	90001-0816-0305	Hexagon Flange Bolt, M8 x 16, Black Zinc	2
22	18001-Z950110-00A0	Exhaust Outlet Gasket	1
23	90303-0800-3305	Hexagon Nut, M8, Black Zinc	2
24	R225MV000FB-CMP308	Engine - See Figure B	1
25	200921-DJZJ-E	Alternator - See Figure E	1
26	90001-0625-0305	Hexagon Flange Bolt, M6 x 25, Black Zinc	1
27	90415-0600-Z301	Lock Washer, Toothed, Black Zinc	1
28	30009-Y910110-0001	Grounding Wire	1
29	90403-0600-0305	Spring Washer, Black Zinc	2
30	90408-0600-E305	Flat Washer, Black Zinc	3
31	90303-0600-3305	Hexgon Nut, M6, Black Zinc	1
32	90312-0600-0301	Wing Nut, M6, Black Zinc	1
33	35610-YJJ0110-H200	Control Panel Assembly - See Figure G	1
34	90007-0616-A305	Hexagon Flange Bolt, M6 x 16, Black Zinc	4

Engine Parts Diagram

Figure B illustrates the engine components. It includes the cylinder head assembly (1), carburetor assembly (2), various bolts, nuts, washers, and seals. Major engine sub-assemblies like the crankcase (44), flywheel (52), engine fan (53), and recoil starter assembly (50) are visible. Specific detailed diagrams are referenced as Figure C and Figure D.

Engine Parts List

#	Part Number	Description	Qty.
1	R225V-QGT-C000	Cylinder Head Assembly - See Figure C	1
2	200921-HYQ-D	Carburetor Assembly - See Figure D	1
3	90001-0612-0101	Hexagon Flange Bolt, M6 x 12, Blue White Zinc	4
4	12410-Z4A0110-0100	Cylinder Head Cover, Blue White Zinc	1
5	12004-Z950410-00A0	Cylinder Head Cover Gasket	1
6	12003-Z010310-0000	Cylinder Head Bolt, M8 x 60, Black Zinc	4
7	30010-Z010110-0000	Spark Plug, F6RTC	1
8	13200-Z390110-0000	Piston Ring Assembly	1
9	13122-Z010110-0000	Piston Pin Clip	2
10	13010-Z950110-00A0	Connecting Rod	1
11	17004-Z6X0110-0000	Tube, Breather, Ø8 x Ø12	1
12	90740-Z010810-01A0	Clampr, Ø11 x Ø14	1
13	90502-1114-00A0	Pin, Ø11 x 14	2
14	14071-Z950110-0000	Valve Lifter	2
15	14081-Z040110-0000	Valve Tappet	2
16	13111-Z4A0110-00A0	Piston	1
17	13121-Z010110-0000	Piston Pin, Ø18 x Ø54	1
18	16400-Z0X0110-00A0	Governor Gear Assembly	1
19	90547-0205-00A0	Bearing	2
20	37060-Z010410-0000	Engine oil Sensor, W/O Nut	1
21	90001-0614-01A0	Hexagon Flange Bolt, M6 x 14, Blue White Zinc	2
22	90305-Z010210-0300	Hexagon Flange Nut, M10, Black Zinc	1
23	14200-Z4A0210-00A0	Camshaft Assembly	1
24	13300-Z950111-00A0	Crankshaft Assembly	1
25	90502-0912-00A0	Pin, Ø9 x 12	2
26	11001-Z440110-00A0	Crankcase Gasket	1
27	15010-Z2M0110-L400	Oil Dipstick	1
28	11411-Z530111-0BA0	Crankcase Cover	1
29	90001-0832-03	Hexagon Flange Bolt, M8 x 32, Black Zinc	6
30	90682-Z300110-0001	Oil Seal, Ø25 x Ø41.25 x 6	2
31	16061-Z010110-0000	Governor Arm	1
32	90408-Z010210-00A0	Washer, Ø6.2 x Ø15 x 0.6	1
33	90501-Z010110-0001	Pin, Blue White Zinc	1
34	16070-Z010110-0001	Governor Linkage Bracket, Blue White Zinc	1
35	90305-0600-33	Hexagon Flange Nut, M6, Black Zinc	3
36	16012-Z010310-0000	Throttle Valve Returning Spring	1
37	16062-Z010210-0100	Governeor Rod, Blue White Zinc	1
38	16063-Z010310-0100	Spring, Governor	1
39	16072-Z010310-0000	Governor Support Bolt, M6 x 21, Black Zinc	1
40	16520-Z4A0110-0000	Throttle Control Bracket, Blue White Zinc	1
41	90001-0610-03	Hexagon Flange Bolt, M6 x 10, Black Zinc	4
42	90408-Z010510-00A0	Washer, Ø10 x Ø15.8 x 1.5	2
43	11007-Z010310-0000	Drain Plug Bolt, M10 x1.25 x15, Black Zinc	2
44	11310-Z4A0210-0BA0	Crankcase	1
45	19340-Z010810-0100	Air Deflector, Crankcase	1
46	19304-Z950120-0001	Air Deflector, Crankcase Cylinder	1
47	28110-Z010610-L400	Cover, Engine Fan	1
48	90001-0612-03	Hexagon Flange Bolt, M6 x 12, Black Zinc	4
49	28261-Z2M0110-0000	Retainer Ring, Recoil Starter	1
50	28200-Z141010-H200	Recoil Starter Assembly	1
51	90251-0618-03	Bolts With Washer, Black Zinc	3
52	13510-Z440410-0000	Flywheel	1
53	19352-Z440110-0001	Engine Fan	1
54	28002-Z1E0110-0000	Starter Pulley, Blue White Zinc	1
55	13501-Z010110-00A0	Flywheel Nut, M14 x 1.5, Blue White Zinc	1
56	30400-Z440410-0001	Ignition Coil	1
57	90001-0625-01A0	Hexagon Flange Bolt, M6 x 25, Blue White Zinc	2
58	17100-Z2M0110-0000	Air Cleaner Assembly	1
59	17151-Z300310-0000	Element, Air Cleaner	1
60	90001-0616-01A0	Hexagon Flange Bolt, M6 x 16, Blue White Zinc	1

Cylinder Head Part Diagram

Figure C details the cylinder head assembly. It shows components such as valve rocker assemblies (1), rocker shaft assembly (2), valve rotators (3), valve lock clamps (4), valve springs (6), seal guide (7), cylinder head (11), intake valve (14), and exhaust valve (13). Studs (10, 12) and bolts (8) are also depicted.

Cylinder Head Part List

#	Part Number	Description	Qty.
1	14310-Z950110-00A0	Valve Rocker Assembly	2
2	14318-Z950110-0000	Rocker Shaft Assembly	2
3	12104-Z4A0110-00A0	Rotator, Valve, Ø5 x Ø8 x 3.6	2
4	12109-Z810110-0000	Valve Lock Clamp	4
5	12112-Z810210-0000	Valve Spring Retainer	2
6	12103-Z010110-0000	Valve Spring	2
7	12101-Z810210-0000	Seal Guide	1
8	90001-0610-03	Hexagon Flange Bolt, M6 x 10, Black Zinc	1
9	12419-Z950210-0000	Pin Stopper Plate, Cylinder Head Cover	1
10	90203-Z010110-0000	Stud, M8 x 34, Black Zinc	2
11	12140-Z4A0110-0BA0	Cylinder Head	1
12	90204-Z010210-0000	Stud, M6 x 96, Black Zinc	2
13	12121-Z4A0110-00A0	Exhaust Valve	1
14	12111-Z4A0110-00A0	Intake Valve	1
15	12131-Z4A0110-00A0	Cylinder Head Gasket	1

Carburetor Part Diagram

Figure D displays the carburetor assembly. Key parts include the carburetor itself (4), insulator gaskets (1, 2), carburetor gasket (3), air cleaner gasket (5), fuel supply tube (7), and various seal rings (8, 10). Main jets for different altitudes are also listed (9).

Carburetor Part List

#	Part Number	Description	Qty.
1	16002-Z950110-0000	Carburetor Insulator Gasket	1
2	16003-Z950110-0000	Carburetor Insulator Plate	1
3	16001-Z010110-0000	Carburetor Gasket	1
4	16100-Z4A0110-00M0	Carburetor	1
5	17001-Z010210-0000	Air Cleaner Gasket	1
6	90685-Z030610-01A1	Clamp, Ø8 x 7 x 0.6	1
7	90686-Z010710-00M1	Tube, Fuel Supply, Ø4.5 x Ø8.5 x 160	1
8	16112-Z010110-0000	Seal Ring, Float	1
9	16161-Z152010-00A2	Main Jet (79#), Standard	1
	16161-Z151810-00A1	Main Jet (77#), Altitude 3000-6000 Feet	/
	16161-Z151610-00A4	Main Jet (75#), Altitude 6000-8000 Feet	/
10	90681-Z010610-0000	Seal Ring, Carburator, Ø9.5 x 1.6	1

Alternator Part Diagram

Figure E illustrates the alternator components. This includes the rotor (1), stator (2), terminal block (3), end housing (5, 9), AVR (7), and carbon brushes (14). Various bolts and fasteners are also shown.

Alternator Part List

#	Part Number	Description	Qty.
1	31330-YGK0210-0000	Rotor, AL, Ø160 x 130	1
2	31310-YGK0310-0000	Stator, AL, Ø160 x 130	1
3	31303HY020110-0000	Terminal Block	1
4	90001-0516-01A1	Hexagon Flange Bolt, M5 x 16, Blue White Zinc	6
5	30021-YJ30110-00A0	End Housing	1
6	30048-YE30110-0900	Bolt, M6 x 174, Stator, White Zinc	4
7	30060-YGK0110-0000	AVR	1
8	51124HYJ30110-0100	Mounting Bracket, Blue White Zinc	1
9	30022-YJ30110-L400	Cover, End Housing, Yellow	1
10	90007-0508-A301	Hexagon Flange Bolt, M5 x 8, Black Zinc	1
11	90001-0612-0305	Hexagon Flange Bolt, M6 x 12, Black Zinc	1
12	30023-Y020110-0900	Stopper, Motor Right Cover, White Zinc	1
13	31300-YGK0210-0000	Alternator Assembly, AL, D160 x 130	1
14	31320-YGK0110-0000	Carbon Brushes	1
15	90408-Y020210-0001	Flat Washer, Black Zinc, Ø8.3 x 23 x 3	1
16	30049-YE30110-0001	Bolt, M8 x 230, Rotor, White Zinc	1
17	90005-0512-01A1	Hexagon Flange Bolt, M5 x 12, Blue White Zinc	2

Fuel Tank Part Diagram

Figure F shows the fuel tank assembly. Components include the fuel tank cap (1), fuel filter (2), fuel gauge (5), the fuel tank itself (6), a one-way valve (7), fuel valve with filter (10), and various tubes and clamps (8, 9, 11, 12).

Fuel Tank Part List

#	Part Number	Description	Qty.
1	16730-YGM0110-00A0	Fuel Tank Cap	1
2	16652-YGM0110-00A0	Fuel Filter	1
3	90683-Y020210-0100	Bushing, Blue White Zinc	4
4	16601-Y020210-0001	Vibration Mount, Fuel Tank	4
5	37200-YJ30110-00A0	Fuel Gauge	1
6	16620-YGK0210-L4A0	Fuel Tank, 4.7 L, PMS 109 C	1
7	15150-YGK0110-00A0	One Way Valve	1
8	90740-Z010610-00A1	Clamp, Ø9	1
9	16804-YJ10110-0000	Tube, Tank Vent, Ø4.5 x Ø8.5 x810	1
10	16750-Y020211-0001	Fuel Valve With Filter	1
11	90685-Z030610-0G00	Clamp, Ø8 x 7 x 0.6	1
12	30431-Y020110-0001	Rubber Sleeve, Ø9 x Ø11 x 60, Fuel Tube	1

Outlet Panel Part Diagram

Figure G depicts the outlet panel assembly. It features the control panel housing (1), control module (2), switches (3, 5), circuit breakers (6, 7), push button covers (8), and various receptacles (10, 14, 15) with their respective covers (11, 12, 13). An intelligauge (4) is also present.

Outlet Panel Part List

#	Part Number	Description	Qty.
1	35680-YJJ0110-Q200	Housing, Control Panel	1
2	30008-YGK0110-0000	Control Module	1
3	35160-Y450110-0000	Switch, Engine	1
4	35632-YGK0110-0000	Intelligauge, VFT-2	1
5	35623-Y820210-0000	Voltage Select Switch	1
6	31234-YGK0210-0000	15 Amp Circuit Breaker, Push Button	2
7	31234-YB00110-0000	20 Amp Circuit Breaker, Push Button	1
8	35654-YGK0110-0000	Cover, Push Button	3
9	35650-YJJ0110-H200	Control Panel	1
10	35614-Y090110-0000	L14-30R Receptacle, 30A, 125V/250V	1
11	35654-YBE0210-0000	Receptacle Cover, L14-30R	1
12	35654-YGK0310-0000	Receptacle Cover, TT-30R	1
13	35654-YBE0110-0000	Receptacle Cover, 5-20R	1
14	35614-Y2D0110-0000	TT-30R Receptacle, 30A, 125V	1
15	35614-Y730110-0000	5-20R Receptacle, 20A, 125V	1

Frame Assembly Part Diagram

Figure H shows the frame assembly of the generator. It includes the main frame structure (1) and vibration mounts (4, 6) with associated pads (3) and fasteners (2, 5).

Frame Assembly Part List

#	Part Number	Description	Qty.
1	51100-YJJ0110-H2A0	Frame, Ø25, 590 X 465 X 505	1
2	90001-0612-0305	Hexagon Flange Bolt, M6 x 12, Black Zinc	4
3	51014HY450110-00A0	Vibration Pad, Frame	4
4	51005HY020120-0000	Vibration Mount 1, Frame	2
5	90305-0800-3305	Hexagon Flange Nut, M8, Black Zinc	8
6	51011HY020120-0000	Vibration Mount 2, Frame	2

Wiring Diagram

The wiring diagram illustrates the electrical connections for the alternator, control panel, and engine. It shows main windings, vice windings, field windings, AVR, VFT-2, circuit breakers, voltage switch, receptacles (L14-30R, TT-30R, 5-20R), engine switch, ignition coil, and spark plug. A color list is provided for wire identification:

Code	Color
BL	Black
Gr	Gray
W	White
Bu	Blue
Y	Yellow
G	Green
Br	Brown
Y/G	Yellow/Green
B/W	Black/White
R/W	Red/Green
Bu/W	Blue/White

	Champion 3550W Dual Fuel Portable Generator Model #201042 Parts Information Comprehensive parts list and diagrams for the Champion 3550W Dual Fuel Portable Generator (Model #201042). This document details all components for the generator, engine, fuel tank, alternator, outlet panel, and frame, including part numbers, descriptions, and quantities, facilitating maintenance and repair.
	Champion 3500W Dual Fuel Portable Generator Parts Information (Model #201296) Comprehensive parts list and diagrams for the Champion 3500W Dual Fuel Portable Generator, Model #201296. Covers generator, engine, cylinder head, carburetor, alternator, fuel tank, control panel, frame assembly, and wiring.
	Champion 4650W Dual Fuel Inverter Generator Parts Information and Diagrams Comprehensive parts list and diagrams for the Champion 4650W Dual Fuel Inverter Generator, Model #200994. Find part numbers, descriptions, quantities, and assembly views for all components.
	Champion 4500W Dual Fuel Inverter Generator Parts List and Diagrams Comprehensive parts list and diagrams for the Champion 4500W Dual Fuel Inverter Generator (Model #200988), detailing components, part numbers, and quantities for various assemblies including the inverter, engine, fuel tank, and more.
	Champion 12,000W Electric Start Generator Parts Information Detailed parts list and diagrams for the Champion 12,000W Electric Start Generator, serial number range Y2211120118+. Includes generator, engine, cylinder head, carburetor, alternator, fuel tank, control panel, and frame assembly components.
	Champion 6250W Dual Fuel Generator Parts Information Detailed parts list and diagrams for the Champion 6250W Dual Fuel Generator, Model #100592. Includes generator, engine, carburetor, alternator, fuel tank, outlet panel, and frame assembly components.
	Champion 1200W Portable Generator Parts Information - Model 201069 Comprehensive parts list and diagrams for the Champion 1200W portable generator (Model #201069). Includes detailed breakdowns of generator, engine, cylinder head, alternator, fuel tank, control panel, and frame components, along with a wiring diagram.
	Champion 201169 6500W Tri-Fuel Generator Parts Information Detailed parts list and diagrams for the Champion 201169 6500W Tri-Fuel Electric Start Generator. Includes generator, engine, carburetor, alternator, fuel tank, control panel, and frame assembly components.

Champion 4000W Portable Generator