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Proper place for discussion? Champion gas powered generator fuel cap doesn't fit right

1.8K views 7 replies 4 participants last post by  SW Dweller  
#1 ·
Please move to the appropriate forum if this is not appropriate!

Recently I acquired a Champion generator from a relative, model number 200911. I was there in September 2020 when this generator was purchased and helped transport it. Fast forward 3.5 years, relative is passed away, I purchased generator from the family. If I recall correctly back to 2020 I can recall that the fuel cap felt weird, difficult to remove and reinstall. Anyways, the generator sat for this entire time, not being used once, engine oil is brand new, started right up on the first pull if you can believe it. But I couldn't remove the fuel cap as the fuel cap was so tight or seized in place that the ratcheting mechanism within the cap head failed and would not allow me to put any torque on the lower portion of the fuel cap. Therefore, I had to destroy the cap and separate it. As you can see, the lower portion of the fuel cap doesn't thread in all of the way. It is very, very tight, and there seems to be a mismatch between the threads cut in the fuel tank and the fuel cap, the best I can tell based upon how NOT smooth the cap threads in and out. I can purchase a new cap online but am concerned that I will run in to the same issue once it arrives. Do you have any recommendations for what I can check for, measure, etcetera? I contacted Champion customer service days ago and have yet to receive any response thus far. Thanks!

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#2 ·
I don’t think that customer service is going to be able to help you, because they won’t know what the pitch/etc. of the threads will be in order for you to check whether you’ve got the correct cap. From what I can see on the Champion website, there are at least three different caps (at least, different part numbers) that all look similar, so I think that the odds are good that somebody in China included the wrong part (although you’d think that they’d realize when threading it in if it was wrong). The other possibility is that it was cross-threaded when first installed and that caused the problem. The good news is that the female part installed in the tank doesn’t seem to be damaged, so for the minimal cost involved (excluding shipping) I think that your best bet to order the correct part number and cross your fingers that the female part isn’t the wrong component for this generator.

 
#7 ·
Yes sir, that is the first thing I did, and the cap looks identical to what was on the generator originally. I stopped at ordering because of the issue I am encountering with the difficulty in threading in the cap. The threads on the cap do not appear damaged either, and I do know that it was most certainly not some average idiot who would have mistakenly cross-threaded the cap in causing this conundrum.

By the way still waiting to hear back from Champion, day 4...hah!

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