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Champion 8500W Electric Start Dual Fuel Generator

Model #: 201037

Serial Number Range: ALL

Manufacturer: Champion Power Equipment, Inc., Santa Fe Springs, CA USA

For ordering replacement parts, visit: shop.championpowerequipment.com or call 1-877-338-0999.

Document Revision: REV 20210713

Generator Overview

This document provides detailed parts information for the Champion 8500W Electric Start Dual Fuel Generator. The main generator unit is depicted in Figure A, showing its overall structure including wheels, fuel tank, engine, and control panel.

Generator Parts Diagram (Figure A)

Figure A illustrates the main assembly of the generator, with numbered components indicating their locations. Key parts include the fuel tank (3), frame assembly (5), engine (22), alternator assembly (24), and the outlet panel (38).

Generator Parts List

#Part NumberDescriptionQty.
190007-0625-0301Hexagon Flange Bolt, M6 x 25, Black Zinc4
290408-Y020110-0005Flat Washer, Ø6, Black Zinc4
3ELYL3Q-YXZJ-F000Fuel Tank Assembly - See Figure F1
490698-Y1Z0110-0002Protective Rubber Sleeve2
5ELYL3Q-JJZJ-H000Frame Assembly - See Figure H1
690305-0600-3301Hexagon Flange Nut, M6, Black Zinc2
790685-D090-0EA0Clamp, Ø9 x Ø0.8 x 84
816805-YJ90110-0000Tube, Vent, Air Cleaner, Ø4.5 x Ø8.5 x 1001
990685-D080-0EA0Clamp, Ø8 x Ø0.6 x 71
1016801-YDK0110-00A1Carbon Canister, 750cc1
1182153-YGM0110-00A0Heat Film1
1290685-YJ30110-Q200Clamp, Ø9.5ר81
1318101-Z0D0310-00A0Muffler Outlet Gasket1
1490008-0410-53Hexagon Bolt, M4×10, Black Zinc4
1518250-YGM0110Spark Arrestor1
1690007-0612-A301Hexagon Flange Bolt, M6 x 12, Black Zinc4
1780019-YJP0210-H7A0Guide Hood, Muffler1
1890001-0816-0305Hexagon Flange Bolt, M8 x 16, Black Zinc2
1918030-Y730110-000CMuffler Support White Zinc1
2090001-0816-0109Hexagon Flange Bolt, M8 x 16, White Zinc2
2190303-0800-0301Hexagon Nut, M8, Black Zinc2
22R460DNV00FB-CMP310Engine - See Figure B1
2318100-YGM0210-H7A0Muffler1
24ELYL3Q-DJZJ-E000Alternator Assembly - See Figure E1
2590254-0416-51A0Screw Assembly, M4×16, White Zinc4
2616750-YJ30110-0000Fuel Valve Assembly1
2790124-Y9T0510-00A0Self Tapping Screw, PT5×166
2816757-YJ30110-0000Seat, Fuel Valve1
2935190-YJ70210-0000Micro Switch 2, Engine Stop1
3035190-YJ70110-0000Micro Switch 1, Engine Stop1
3190001-0625-0305Hexagon Flange Bolt, M6 x 25, Black Zinc1
3290415-0600-Z301Lock Washer, Toothed, Black Zinc1
3330009-Y910110-0000Grounding Wire1
3490303-0600-3305Hexagon Nut, M6, Black Zinc1
3590408-0600-E305Flat Washer, Black Zinc3
3690403-0600-0305Spring Washer, Black Zinc2
3790312-0600-0301Wing Nut, M6, Black Zinc1
3835610-YJ80110-H200Control Panel Assembly - See Figure G1
3917003-YJ70110-0100Air Cleaner Support, White Zinc1
4090001-0612-0305Hexagon Flange Bolt, M6 x 12, Black Zinc1
4131114HYGM0110-0001DC Wire Harness, Engine1
4231112HYGM0210-0000DC Wire Harness, Barttery1
4331110-Y9X0110-00A0Battery1
4431115-Y6D0110-0001Band, 246×20×3.5, Battery1
4577100-Z6D0110-0000Gas Pressure Reducing Valve1
4690748-1016-00A0Clamp, Ø10×163
4790729-YJ90110-0000LPG Hose, 9.5×16.8×2501
4890134-YB00110-00A0Bolt, Cross Hexagon Pan Head, M5 x 12, Black Zinc3
4916287-YJ30110-0000Dust Cap1
5035643-YJ70110-Q2A0Knob, Switch Dial, Engine1
5182007-YJ70110-L400Decorative Cover, PMS 109C1
5290007-0616-A305Hexagon Flange Bolt, M6 x 16, Black Zinc4
5377300-YJ70110-0000LPG Hose With Regulator1
54ELYL3Q-XSQ-0000Muffler Assembly1

Engine Components

Engine Parts Diagram (Figure B)

Figure B details the internal and external components of the engine. It shows parts like the cylinder head (5), piston (10), crankshaft (19), flywheel (45), carburetor (53), and air cleaner (54).

Engine Parts List

#Part NumberDescriptionQty.
190001-0612-0101Hexagon Flange Bolt, M6 x 12, White Zinc4
212410-Z0D0110-01A0Cylinder Head Cover, White Zinc1
312004-Z0J0510-0000Cylinder Head Cover Gasket1
412003-ZON0110-0100Cylinder Head Bolt, M10x 85, White Zinc4
5R460DNV-QGT-C000Cylinder Head - See Figure C1
630010-Z010110-00A0Spark Plug, F6RTC1
790502-1220-00A0Pin, Ø12 x 202
814081-Z080110-0000Valve Tappet2
913200-Z0J0110-00A0Piston Ring Assembly1
1013111-Z6B0110-00A0Piston1
1113010-Z6B0110-00A0Connecting Rod1
1290804-Y5Z0210-0001Stop Block1
1317004-Z0D0310-0000Tube, Breather, Ø12 x Ø16 x 1081
1414070-Z0D0110-0000Valve Lifter2
1513122-Z100110-0000Piston Pin Clip2
1613121-Z570110-0000Piston Pin1
1711310-Z6B0110-0BA0Crankcase Assembly1
1890548-0202-00A0Bearing 12
1913300-Z0D0110-00A0Crankshaft Assembly1
2013401-Z0D0110-00A0Balancing Shaft1
2190502-0812-00A0Pin, Ø8x 122
2211001-Z0D0110-0000Crankcase Gasket1
2316400-Z100110-0000Governor Gear Assembly1
2490547-6208-00A1Bearing 21
2515010-Z0D0110-L400Oil Dipstick1
2611411-Z0D0110-0BA0Crankcase Cover1
2790001-0840-03Hexagon Flange Bolt, M8 x 40, Black Zinc9
2890682-Z0J0110-0001Oil Seal, Ø50 x Ø40 x 92
2914200-Z0D0110-0009Camshaft Assembly1
3028101-Z080110-0001Plug, Rubber1
3111007-Z080110-0300Drain Plug Bolt, M12x18, Black Zinc2
3209100-Z170310-0100Starter Motor1
3330500-Z170120-0000Starting relay, Starter Motor1
3490001-0612-03Hexagon Flange Bolt, M6 x 12, Black Zinc9
3590685-Z940310-0001Clamp2
3628110-Z710710-L400Shroud1
3728261-Z980110-0001Retainer Ring, Recoil Starter1
3828200-Z590110-H200Recoil Assembly1
3990001-0620-03Hexagon Flange Bolt, M6 x 20, Black Zinc3
4090001-0835-0102Hexagon Flange Bolt, M8 x 35, White Zinc2
4119306-Z0D0110-0100Crankcase Air Deflector, White Zinc1
4290001-0610-03Hexagon Flange Bolt, M6 x 10, Black Zinc2
4390412-Z080110-00A0Washer, Ø21x Ø12x 22
4419304-Z100210-0101Cylinder Body Shroud1
4513510-Z0D0410-0000Flywheel1
4619352-Z100120-00A2Cooling Fan, Engine1
4730400-Z0D0110-0000Ignition Coil1
4890001-0628-01A0Hexagon Flange Bolt, M6 x 28, White Zinc2
4928002-Z0D0110-0000Starter Pulley, White Zinc1
5013501-Z080110-00A0Nut, M16 x 1.5, White Zinc1
5190748-1016-00A0Clamp,Ø10~Ø161
5290729-Z6D0112-0000Vent Hose, 9.5×16.8×4601
53R460DNV-HYQ-D001Carburetor - See Figure D1
5417100-Z0D0210-0000Air Cleaner1
5517151-Z0D0210-0000Element 1, Air Cleaner1
5617151-Z0D0310-0000Element 2, Air Cleaner1
5716061-Z0D0110-0000Governor Arm1
5890412-Z080210-00A0Washer, Ø19.5x Ø8.4x 0.82
5916070-Z100120-0001Governor Support, White Zinc1
6016072-Z010310-0000Governor Support Bolt, M6 x 21, Black Zinc1
6190305-0600-33Hexagon Flange Nut, M6, Black Zinc3
6216063-Z0D0110-0100Spring, Governor1
6390682-Z100210-0001Oil Seal, Ø14 x Ø8x 41
6490501-Z010110-0001Pin, White Zinc1
6516012-Z080110-0000Spring, Throttle Valve Returning1
6616062-Z100110-0001Governeor Rod, White Zinc1
6716520-Z0D0110-0100Air Guide, Engine Fan, White Zinc1
6890305-Z010210-0300Hexagon Flange Nut, M10, White Zinc1
6937060-Z080410-0000Engine Oil Sensor, W/O Nut1
7090001-0616-01A0Hexagon Flange Bolt, M6 x 16, White Zinc2
7190684-Z010310-0001Clip, Ø10.6 x Ø6x 1303
7290685-Z0D0110-0100Clamp, Ø16 x 1.61
7390001-0516-01Hexagon Flange Bolt, M5 x 16, White Zinc2
7490685-Z130210-0100Clamp, Ø17 x 1.41

Cylinder Head Components

Cylinder Head Part Diagram (Figure C)

Figure C provides an exploded view of the cylinder head assembly, highlighting components such as the valve rockers (1), cylinder head cover gasket (3), valve springs (4), exhaust valve (7), and inlet valve (14).

Cylinder Head Part List

#Part NumberDescriptionQty.
114310-Z0D0110-0000Valve Rocker2
212419-Z950310-00A0Cylinder Head Pin Limit Plate1
312109-Z0D0110-00A0Valve Lock Clamp4
412103-Z990110-0000Valve Spring2
590203-Z010110-0301Stud, M8 x 34, Black Zinc2
612140-Z6B0110-0BA0Cylinder Head Subassembly1
712121-Z6B0110-00A0Exhaust Valve1
814318-Z990111-00A0Rocker Arm Shaft Assembly2
990001-0612-03Hexagon Flange Bolt, M6 x 12, Black Zinc1
1012104-Z010110-0000Rotator, Valve2
1112112-Z0D0110-0000Valve Spring Retainer2
1212101-Z020110-0000Seal Guide1
1390204-Z100410-00A0Stud, M8 x 34, Black Zinc2
1412111-Z0D0210-00A0Inlet Valve1
1512131-Z6B0110-00A0Cylinder Head Gasket1

Carburetor Components

Carburetor Part Diagram (Figure D)

Figure D illustrates the carburetor assembly, showing its various parts including gaskets (1, 2, 5), fuel tube (7), and main jets (10).

Carburetor Part List

#Part NumberDescriptionQty.
117002-Z0D0110-0000Gasket, Inlet1
216003-Z0D0110-0001Carburetor Insulator Plate1
316001-Z100110-0000Carburetor Gasket1
416100-Z6D0111-00M0Carburetor Assembly1
517001-Z0D0110-0000Air Cleaner Gasket1
690685-Z080210-0001Clamp, Ø9 x 0.8 x 8, White Zinc1
790686-Z6D0210-00M0Fuel Tube, Ø4 x Ø10 x 4901
830431-Z120310-0000Rubber Sleeve, Ø13 x Ø11.5 x 1801
916112-Z080110-0000Seal Ring, Ø54 x Ø57, Float1
1016161-Z0C0110-00A1Main Jet (H128×0.39), Standard1
16161-Z191210-00A1Main Jet (H128×0.41), Altitude 3000-6000 Feet/
16161-Z100410-00A1Main Jet (H128×0.43), Altitude 6000-8000 Feet/
1190681-Z080110-0000Seal Ring, Ø22.6 x Ø2.41
1216108-Z080210-0000Valve, Solenoid1

Alternator Components

Alternator Part Diagram (Figure E)

Figure E shows the components of the alternator, including the rotor (1), stator (2), terminal block (3), carbon brush subassembly (4), and AVR (8).

Alternator Part List

#Part NumberDescriptionQty.
131330-YJ80110-0000Rotor, AL, Ø190 x 1581
231310-YJ80110-0000Stator, AL, Ø190 x 1581
331303HY090110-0000Terminal Block1
431320-YHD0120-0000Carbon Brush Subassembly1
590001-0516-0105Hexagon Flange Bolt, M5 x 16, White Zinc6
630049-Y950110-0101Bolt, M10 x1.25 x 285, Rotor, White Zinc1
730048-Y950110-0100Bolt, M6 x 199, Stator, White Zinc4
830060-YHD0110-0000AVR1
951124-YJ70110-0100Mounting Bracket, White Zinc1
1090001-0512-0301Hexagon Flange Bolt, M5 x 12, Black Zinc2
1190001-0612-0305Hexagon Flange Bolt, M6 x 12, Black Zinc1
1231317-Y030110-0000Nut, Stator, M5, Black Zinc2
1390403-0500-03Spring Washer, Black Zinc2
1431300-YJ80110-0000Alternator Assembly, AL, Ø190 x 1581
1530023-YC20110-00A0Stopper, Engine Fan Vent1
1630024-Y730110-0001Vent, Engine Fan1
1790001-0510-0105Hexagon Flange Bolt, M5 x 10, White Zinc1
1830021-YJ70111-00A0End Housing1
1931316HYDK0110-0000Bolt, Stator, M5 x 2352
2090408-Y030110-0100Flat Washer, Ø10.4 × Ø30 × 4, White Zinc1
2130022-YJ70110-L400Cover, End Housing1
2230009-YJ70110-0000Grounding Wire1
2390007-0512-A301Hexagon Flange Bolt, M5 x 12, Black Zinc2
2490727-Y020110-00A0Band, 4×2002

Fuel Tank Components

Fuel Tank Part Diagram (Figure F)

Figure F displays the fuel tank assembly, featuring the fuel tank cap (1), fuel filter (2), fuel gauge (10), and the main fuel tank (13).

Fuel Tank Part List

#Part NumberDescriptionQty.
116730-YGM0110-00A0Fuel Tank Cap1
216652-YGM0110-00A0Fuel Filter1
315150-YGK0110-00A0Reversal Valve1
416804-YJ90110-0000Tube, Vent, Evaporative, Ø4.5 x Ø8.5 x 8651
590740-Z010610-00A1Clamp, Ø91
616680-YJ30110-00A0Fitting, Fuel Tank Drain1
790685-D105-0EA0Clamp, 10.5×8×0.81
890686-YJ70210-00M0Tube, Fuel, Ø4 x Ø10 x 3051
930431-Z120310-0000Rubber Sleeve, Ø13 x Ø11.5 x 1801
1037200-YGM0110-00A0Fuel Gauge1
1116601-Y020120-0001Vibration Mount 1, Ø12.5 x 16, Fuel Tank4
1290683-Y020110-0005Bushing, White Zinc4
1316620-YGM0310-L4A0Fuel Tank, 7.7gal, PMS 109C1

Outlet Panel Components

Outlet Panel Part Diagram (Figure G)

Figure G illustrates the outlet panel, which includes the control panel housing (1), intelligauge display (2), various circuit breakers (3, 5, 6), and receptacles (8, 14, 16).

Outlet Panel Part List

#Part NumberDescriptionQty.
135680-YJ80110-Q2A0Control Panel Housing1
290803-Y030110-0000Intelligauge Display1
331234-YGK0110-000030Amp Circuit Breaker, Push Button2
435654-YGK0110-0000Cover, Push Button4
535627-YDK0210-000035Amp Circuit Breaker, 2P Flip1
631234-YBE0210-000020Amp Circuit Breaker, Push Button2
790305-0400-71A0Hexagon Flange Nut, M4, White Zinc10
835614-Y9X0110-00005-20R GFCI Receptacle, 20A, 125V2
935654-YBE0110-0000Receptacle Cover, 5-20R2
1030008-YJ30210-0000Control Module, Carburetor1
1130008-YJ30110-0000OVF Module1
1230007-Y9X0210-0000Charging Module1
1335160-YJ90110-0000Switch, Engine1
1435614-Y090110-0000L14-30R Receptacle, 30A, 125V/250V1
1535654-YBE0210-0000Receptacle Cover, L14-30R1
1635614-Y400110-0000L14-50R Receptacle, 50A, 125V/250V1
1735654-Y2T0110-0000Receptacle Cover, 14-20R1
1835650-YJ80110-H200Control Panel1
1935660-YJ80110-0000Wire Harness, Control Panel1

Frame Components

Frame Part Diagram (Figure H)

Figure H shows the frame assembly of the generator, including the main frame (1), wheels (4), support legs (10), and handles (19).

Frame Part List

#Part NumberDescriptionQty.
151100-YJ80110-H2A0Frame1
244001-V580110-L401Cover, Hub Decorated, PMS 109C2
344020-YGM0110-0300Roll Pin, Ø16 x 95, Black Zinc2
444110-YGM0110-L400Wheel, 9.5 in, PMS 109C2
590501-Y2C0110-03A1R-Clip,Ø3 x 65.5, Black Zinc2
690306-1000A0301Hexagon Flange Nut, M10, Black Zinc4
751012HY030120-0000Vibration Mount 1, Frame4
890305-0800-3305Hexagon Flange Nut, M8, Black Zinc9
990001-0850-0301Hexagon Flange Bolt, M8 x 50, Black Zinc4
1051016-YJ70110-H2A0Support Leg2
1190305-0600-3301Hexagon Flange Nut, M6, Black Zinc2
1224329-YJ70110-H200Bracket, Anti-Rotation2
1351014-YJ70110-0000Vibration Mount, Support Leg, 53x40x162
1490001-0620-0305Hexagon Flange Bolt, M6 x 20, Black Zinc2
1524329-YGM0210-H2A0Heat Shield1
1690504-Y9X0110-0305Pin Shaft, Ø8 x 40, Black Zinc2
1790722-YEC0110-0001Plug, End2
1890583-YGK0110-03A0R-Clip, Ø2 x 35, Black Zinc2
1954110-YJ90110-H2A0Handle, Ø25 x 1.21
2054101-YGM0110-L400Handle Sheath, PMS 109C1
2190103-0416-5301Cross Recess Pan Head Screw, M4×16, Black Zinc2

Wiring Diagram

The wiring diagram on page 20 details the electrical connections for the generator, showing connections between the alternator, control panel, engine components (like the starter motor, fuel solenoid, and ignition coil), and battery. It includes a color list for wire identification.

This document is for informational purposes regarding parts identification.

Models: 201037, 8500W Electric Start Dual Fuel Generator

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