Champion generator problem

[gutsnthegrass]

Runs like a champ, but no electrical output.  Any ideas?

[follow maggie]

Make sure the GFIs or breakers aren’t tripped

[Mudman]

I am betting if ya plug in a load it dies???  If so I know whats up.  Had a similar issue with mine, a 3-4k genny?  Hint is oil...

[luckyman]

I have a champion generator that has lost out put 3 times now. It was from running it out of fuel while under heavy load. It burned the winding's at the commentator or armature. not sure the correct name. To fix I had to pull the end off the generator to access the winding's. find the break and solder a small piece of copper wire to reconnect. after fixing twice i was done. the third time running it out while under load and burning it out I retired it and bought a bigger generator that wouldn't be as over worked. I had the repair pdf from champion. their help line helped me to diagnose the problem then emailed me the repair procedure.

[Oh Mah]

not to thread jack but what makes a champion generator surge up and down?

runs great while under a load but when idleing it surges.

[luckyman]

you can try cleaning the carburetor. That can be cause by a lean condition.
It can have a weak or damaged gov spring also.

[Oh Mah]

ok thanks. 

[Buckmark]

Runs like a champ, but no electrical output.  Any ideas?

I am assuming the volt meter shows no output correct?
If that is the case it may of just lost its field which is easy to reflash
I am assuming you own an electric drill with reverse? If so great, take the drill and plug it into the gen, now put it on reverse (it works on forward also) now hold the switch on the drill to on and with your other hand grab the chuck and give it a quick but good spin in either direction letting go quickly, it may take a few times but if the drill begins to run then you are good to go and the volt meter will be showing output.

If this works then in the future make sure to disconnect any load from the unit be fore shutting down and that will help.
You may have to do this periodically in the future as the gen head is wearing out and needs repairs ( i wont get into that)

I have a 3500w gen i use at my property that started giving me the same problem 2yrs ago (happens to be a Champion, not that that makes a difference) which i just do the refield trick and it has worked for me just fine (even with unpluging the load sometimes i have to reflash it)
I have had this Gen 14yrs and it has like 500+ hrs on it and owes me nothing, when it finally fails i will replace it.

Note: you can use a hand grinder also but i find the drill easier and safer