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Open Roads Forum  >  Do It Yourself Modifications and Upgrades (DIY)

 > Extended run gas cap for Champion Digital Hybrid 4000?

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justALnow

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Posted: 11/10/19 09:36am Link  |  Quote  |  Print  |  Notify Moderator

I'm trying to build an extended run fuel system for my Champion Digital Hybrid (Model #100302), but can't find the replacement gas cap.

Anyone have any links to one?





agesilaus

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Posted: 11/10/19 09:54am Link  |  Quote  |  Print  |  Notify Moderator

Be careful online, I ordered one for my 3500/4000 and when itm arrived it was the wrong cap, one with female instead of male screw thread for the cap. The seller never replied to queries so I'm stuck with it. It was well made tho, milled aluminum but worthless.

It is just a gravity feed system with a tube into the cap from the gas tank. Which is a outboard fuel tank. The vent on the gen is plugged and the gas tank needs an open vent. If you want to drill and tap the cap on your gen you could probably put it together fot $10 or $20. Not much open space on my cap anyway. I don't see any obvious way to drill the top of the tank unless you braze or maybe jbweld a fitting on top of the hole. No inside access.

* This post was edited 11/10/19 10:06am by agesilaus *


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Posted: 11/10/19 10:38am Link  |  Quote  |  Print  |  Notify Moderator

Nobody makes a correct replacement cap that I'm aware of
How ever SuperGen used to sell a kit for champion generators, came with a vacuum operate pump,, connecting hoses, nipple etc,
A diy install, I put one on a 3500
CAT5 inverter generator, worked fine as long as both were on the same level ground, my champ was on a sliding compartment tray/drawer so I would put the extension tank/can on a snack table or chair next to the genny, sorry don't have a link, using my phone not my laptop


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SidecarFlip

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Posted: 11/10/19 10:49am Link  |  Quote  |  Print  |  Notify Moderator

Drill and tap the existing cap for a nylon threaded fitting, add a hose and another gas can but keep the bottom of the can higher than the genny. Conversely, you could add a pulse fuel pump and run from a marine porta tank.


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agesilaus

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Posted: 11/10/19 10:50am Link  |  Quote  |  Print  |  Notify Moderator

Where does the power come from for a pump?

justALnow

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Posted: 11/10/19 10:53am Link  |  Quote  |  Print  |  Notify Moderator

MrWizard wrote:

Nobody makes a correct replacement cap that I'm aware of
How ever SuperGen used to sell a kit for champion generators, came with a vacuum operate pump,, connecting hoses, nipple etc,
A diy install, I put one on a 3500
CAT5 inverter generator, worked fine as long as both were on the same level ground, my champ was on a sliding compartment tray/drawer so I would put the extension tank/can on a snack table or chair next to the genny, sorry don't have a link, using my phone not my laptop


Thanks! Kind of what I'm finding...

I built a system for my Honda 2200 and it works great ... Parts were readily available on line!

Bobbo

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Posted: 11/10/19 07:03pm Link  |  Quote  |  Print  |  Notify Moderator

agesilaus wrote:

Where does the power come from for a pump?

From the generator, maybe? It has a 120v and a 12v outlet.


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MrWizard

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Posted: 11/11/19 03:33am Link  |  Quote  |  Print  |  Notify Moderator

Pulse pump,.vacuum operated, kit comes with spacer with hose nipple on it, spacer goes between carburetor and intake manifold, manifold vacuum, drives the pump,

jjrbus

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Posted: 11/14/19 06:31am Link  |  Quote  |  Print  |  Notify Moderator

This man is a gold mine of info, possibly you will find some info there to help. Contact him and if he sees a market he may make one up.

https://www.pinellaspowerproducts.com/

jjrbus

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Posted: 11/14/19 06:33am Link  |  Quote  |  Print  |  Notify Moderator

Was curious after posting and took a peak.

https://www.pinellaspowerproducts.com/pr........erators/products-for-champion-3100-3400/

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 > Extended run gas cap for Champion Digital Hybrid 4000?
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