Controller displays E5, generator shuts down shortly after starting, AC output is unstable

Safety first: Turn controller to OFF, open the generator AC breaker, and disconnect the battery negative cable. Allow the engine to cool before touching any components.

• Inspect throttle and governor linkage: Locate the throttle lever on the carburetor or throttle body and follow the linkage to the governor arm. Ensure there is no debris, corrosion, or bent parts causing the linkage to stick.
• Lubricate pivot points: Apply a small amount of light machine oil to metal pivot points (avoid plastic parts and rubber). Do not overspray onto the air filter or electrical components.
• Check governor spring: Verify the governor spring is attached at both ends and not stretched or broken. Replace if damaged using the correct Champion part.
• Controller settings: Some Champion controllers allow speed calibration. Only adjust if you have the service manual and a frequency meter; incorrect settings can cause severe overvoltage.
• Reset and test: Reconnect the battery, clear the E5 code, and run the generator with no load while monitoring frequency and voltage if you have a meter. If overspeed persists, shut down immediately.

Overspeed conditions can cause catastrophic engine or alternator failure. If you are unsure, do not run the unit and contact a qualified technician.