Update on the 'sliced' wires inside the Champion 2000.
Yesterday I finally took apart all three Champion 2000 that I own. What I found is the following: First, all three units had the same two wires that were rubbing against other parts of the genny. I saw friction against the plastic floor of the unit, against the part of the engine under or near the pull cord and against a piece of plastic behind the carb/air filter area.
Second, since each unit is assembled by human beings, there are some slight differences as to the position of the wires. Meaning that in one unit I had a wire rubbing against the plastic piece near the carb, while in the other two I did not. In one unit I had two wires rubbing against the pull cord area.
I solved the problem of the wires by simply moving them further away from the friction points. In one case, two wires are going around a kind of small plastic box; I simply pushed it away from the pull cord area. Both wires wrapped around that small plastic box were rubbing against the pull cord area and the insulation was gone to some degree.
Since I have three units and ran them in different locations, I observed ths following: Running the unit on a lawn will help a great deal at reducing vibration and therefore rubbing of the wires. Running on a concrete floor (garage), also helped but not as much as running on the lawn. The worst was by far on my balcony with a fiberglass floor. Over there vibration were pretty bad and resulted in the greatest damages to the wires. I could feel the vibration throughout the house. The pics I posted are from that unit.
Hope it helps.
