IG6000 / IG6000H - Kipor Generators, Reliance Controls
Contents
1. M SAT g vA S Sie Electric motor stator Trigger ES ag Marion coil Ignition coil bracket 8 3 2 Inspection e Ignition coil Orange Yellow green 0 22 0 240 Resistance value Gray Orange 0 15 0 170 e External charging coil Measure the resistance between the two blue wires Resistance value 0 03 0 040 e Built in charging coil Measure the resistance between the two purple wires Resistance value 0 12 0 160 e Sub winding coil Measure the resistance between two white wires or green depending on the date of manufacture Resistance value 0 08 0 120 33 eMain winding Measure the resistance between two wires in black NOTES Resistance value 0 45 0 600 342. Measure the resistance of fuel shutoff valve resistance value 6 80 Replace the throttle electromagnetic valve if the resistance exceeds the standard value 23 6 Control Panel and Inverter 6 1 Disassembly and reassembly Timing relay Control panel Ignition control module A Zo m Q 9 amp y s af Ge plate 2 Inverter unit Charging regulator Module fixing plate1 6 2 AC Receptacle Check for evidence of burning or contact damage Replace if either condition exists 6 3 DC Receptacle Connect both terminals of the receptacle with a jumper wire and check if the receptacle is conductive with two meter leads inserted into the panel if not conductive press the Reset button on the receptacle panel and measure it again If there is still no continuity replace the DC receptacle 6 4 Smart Throttle Switch The switch is conductive when ON and not conductive when OFF 6 5 Ignition Module Remove the 10P connector from the module and connect one meter lead to the cover and the other lead to the 10P connector and measure resistance 24 Jf Color of wire Circuit unit Stipulated resistance Blue Primary coil of the ignition coil 0 8 1 30 Orange Oil level switch No continuity under normal oil level Yellow Coil of trigger head 80 1300 Yellow Green ground Continuity Green Power coil winding of module 0 37 0 410 Red Engine stop switch
3. ON position hold on for 7 seconds and then place in the OFF position A reading of 12V should be present for 7 12 seconds then the output should drop to 0 volts Yellow Green White Ei ES me Gi Red Blue Cel 5p SE OS NG N S Black Black A E n eee NS Kg 6 10 Ignition Control Relay Start the engine turn off the smart throttle and measure the voltage between green and yellow green wires on the connection of the control module Replace the ignition control module if the voltage exceeds stipulated voltage Ignition voltage 27 32V AC S Yellow Green Black i 7 d Orange Grey I Green Yellow Green O EP fg me n 6 11 Inverter Module Unplug the two stator input connections to the module Start the engine and take a voltage reading at both 4P connections Readings between pins 1 2 2 3 1 3 should be 255VAC x 15V Alternator Input Terminals 4P connectors 27 7 FRAME HOUSING AND FUEL TANK 7 1 Disassembly and reassembly Housing weldment Housing doorweldment Sheath of fue Fuel tank tank inlet Capacity 22L PX Ressembly Clean the squalidity or water in the bottom before assembly N Air drain bar 4 Seal strip for Exhaust grid window Fixed strap for storage batter Storage battery s 8 Storage battery L d gasket Cl Land wheel A i YT Gasket 49 Lock pin Damping cushion Reassembl
4. 8 8 Low AC output Is the overload indicator light ON Loff Is the engine speed normal Smart switch operation On 2500 100rpm Off 3600 100rpm normal y Check the AC receptacle normal Check the AC output connector normal Disconnect the two 4P input connectors on the inverter unit Disconnect spark plug cap or igniter connector and measure the AC voltage of from the stator The output voltage across pins 1 2 2 3 and 1 3 should be 255 volts Check both connectors normal 255 volts Replace inverter unit 2 8 9 No AC output Is the engine speed normal normal y Check AC receptacles normal Check the rectifier normal Measure the resistance between two blue wire on the rectifier Resistance 0 03 0 040 normal Rotor losses excitation replace the rotor abnormal abnormal abnormal on abnormal abnormal abnormal abnormal abnormal abnormal abnormal abnormal 13 output Replace the stepping motor Replace the smart throttle switch Repair or replace the wire harness Disconnect the load and restart the engine Perform the throttle control system troubleshooting Replace the receptacle Replace the connector 1 Check the wiring of the stator leads in the harnes
5. Continuity when OFF and no continuity when ON 6 6 Ignition Switch pl e y EIU Blue Orange Yellow Yellow green Green Red Check for continuity of each group of contacts with the switch in the off on and start positions OFF e e o o pee jc de MERE ME START e 6 7 Bridge Rectifier a Measure the positive voltage drop of each leading feet of rectifier bridge with the diode checking P gt function of the meter and the result should be compatible with the following standard Tester 1 2 3 4 Tester 1 Infinity Infinity Infinity 2 Continuity Infinity Infinity 3 Continuity Continuity Continuity 4 Continuity Infinity Infinity 25 1 Negative terminal 2 AC terminal 3 AC terminal 4 Negative terminal 6 8 Charging Regulator Loosen the positive battery cable when starting the engine and connect a DC current meter between the positive cable and positive terminal The indicated current cannot exceed 1 5A If there is no current present replace the regulator DC charging 13 14V voltage DC charging 15A current i AC Input blue Shell grounding Output positive pole red 6 9 Timing relay Put the ignition switch on the OFF position connect a voltmeter to the white and yellow green wires Place the ignition switch in the
6. control system troubleshooting 2 8 4 Engine oil level is low but engine does not stop not conductive not conductive 2 8 5 Engine speed does not increase or is unstable abnormal clogged abnormal abnormal clogged abnormal abnormal 11 Replace the oil level alarm switch Repair wiring harness Adjust repair choke mechanism Clean or replace air cleaner Adjust the valve clearance Clean the spark plug and adjust the spark plug gap or replace new spark plug Disassemble and clean or replace carburetor Tighten the nuts securely replace the gasket or heat insulation block 1 Check the valve clearance 2 Check combustion chamber for excess carbon 3 Check the piston piston ring and cylinder for wear and damage 2 8 6 Engine stops after starting Check the engine oil level and check if oil level alarm activates when rotation stops sufficient oil Check the fuel in fuel tank sufficient fuel Check for operation of fuel switch and blockage in fuel filter not clogged Check for blockage of fuel hoses not clogged Check for carburetor fuel delivery normal fuel flow Check the intake gasket and the sealing of carburetor heat insulation block normal Measure the cylinder compression normal Check the trigger air g
7. 5 Frequency WE Average variation rate Max 5 Average time Max 05 second Frequency stability 10 1 Insulation resistance Min 10MQ AC circuit protector Amps 120 240 VAC 51 7 25 8 DC circuit protector 15A Fuel tank capacity gal L 5 9 22 Operating hours at rated load 6 Noise level dB 23 7 m no load full load 63 70 1 3 PERFORMANCE CURVES The curves show performance of the generator under average conditions Performance may vary depending upon ambient temperature altitude and humidity eAC External characteristic curves e DC External characteristic curves aBeyon jndjno 20 1 4 Wiring Diagram Trace 0 roofread Signature Date d Maining Winding t id It Halt Circult Inverter Cell Yellow 4 Orange I Blue Dc receptacle 120V 120V 240V 2 3 Yellow Green Yellow Green ke otal page Lp d A Benni be en ee 1660005S240NA 13001 Geer EN Lom QT Electric system basic diagram Draft sign Amount Weight Proportia Gees LLEL T T WUXI KIPOR POWER CO LTD ST II al 2 SERVICE AND MAINTENANCE 2 1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the generator Any error or oversight made by the techni
8. 7 3600 Compression ratio 8 511 Cooling system Forced air Ignition system Transistorized controlled ignition Ignition timing 28 B T D C Spark plug F7RTC Carburetor Horizontal float type Air cleaner Dry replaceable element Governor Inverter module control Lubrication system Forced splash Oil capacity qt L 1 2 1 1 Starting system Electric starter Stopping system Electric ground Fuel Generator Model Automotive unleaded gasoline 87 octane KD50 Generator type Multi pole rotation type Generator structure Self ventilation drip proof type Excitation Self excitation Magnet type Voltage regulation system Pulse Width Modulation Phase Three phase Rotating direction Clockwise Viewed from the generator Frequency regulation AC DC AC conversion Inverter type 1 2 Generator Specifications Model IG6000 Maximum output AC 6 0 KVA Rated output AC 5 5 KVA Rated frequency HZ 60 Rated voltage AC 120 240 Maximum current amp 25 50 Rated current amp 23 9 45 8 Rated voltage DC 12V Rated current DC 12A Power factor 1 0 ae Momentary Voltage variation Max 10 Average rate Max 1 5 Average time Max 3 seconds Voltage stability 11 Momentary Max
9. G6000 Engine shop manual 2 8 1 General symptoms and possible causes Fuel filter clogged Clean Fuel hose clogged Clean Fuel switch won t operate Replace Carburetor defective Clean and or replace Ignition coil defective Inspect and replace Engine does not Spark plug defective Inspect and replace start or hard Defective timing relay Inspect and replace starting Trigger defective or improper air gap Inspect and replace Spark plug cap disconnected Install securely Oil level alarm defective Inspect and replace Ignition coil defective Inspect and replace Valve clearance misadjusted Adjust valves Carburetor faulty Clean and or replace Engine speed g P defective Throttle control motor stepping motor Inspect and replace does not stabilize Inverter unit defective Inspect and replace 2 8 2 Hard starting or no start Check the fuel level in the tank Sufficient fuel Check fuel switch is in ON position lon Loosen the drain screw and check whether fuel reaches bowl and whether the fuel level is normal normal Remove and check spark plug and check if electrode is wet or dry wet Valve clearance misadjusted no fuel off abnormal dry Adjust valves Add fuel and restart the engine Turn on it and restart the engine Check fuel sys
10. ICI roO re The Coast Distribution System WUXI KIPOR POWER CO LTD IG6000 IG6000h Generator Service Manual The Coast Distribution System June 1 2007 Preface This manual covers the construction function and servicing procedure of the Coast Distribution System KIPOR IG6000 model generator This manual is principally concerned with the generator specifications function troubleshooting and repair There is a separate manual to cover engine overhaul which includes the starting systems These models may be of significantly different design than the original KGE7000Ti and other models currently sold outside North America Contact Kipor for current service information Careful observance of the instructions contained in this manual will result in safe and quality service work All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing KIPOR POWER CO LTD reserves the right to make changes without incurring any obligation whatever No part of this publication may be reproduced without written permission TABLE OF CONTENTS a ode ed tet tao i a md CL E LI an 1 1 1 General SOS CINCAMOMS CONT EC EE EN ET ict Moe 1 1 2 Generator LE 2 1 3 Performance CUY Sii he Eea aaeeei aeara TETE oeiee atida iE kP ETEK iiaei Eat 3 EW Olne RRE LEE A EREM E EE 5 2 1 The Importance of Proper Sene 29 4 od p aes odo Nae certes Len
11. anres ENEE EEN 24 6 1 Disassembly and Heassembhy AAA 24 6 2 AC Ree Eee hansen tet 24 6 3 DO eco 24 6 4 Smart Throttle Gwitch mm rehenn nnne nennen sr nre s se rrt nennen renes se rn nnns 24 6 5 Ignition Modules E 24 6 6 eiae bs lic Rc E 25 6 7 lee EE E EE 25 6 8 Charge 516 0 iro EM ere ne arr mae te een Tn 26 A a arai a AEE aa a a E aA aaar aE E a Einara RENN 26 6 10 Ignition Control Module aid eesti ia 27 6 11 Inverter Module etre eR ER iei RE HAERES nieder paint dt EUG 27 7 Frame Housing and Fuel Tank 28 7 1 Disassembly and Heassemblv A 28 7 2 1G600h Handle Asserrbly rk Ai do de eaae 29 8 Ignition Coil Reie Tee EE 30 8 1 Component AS MUNG ANON aus rer eee 30 8 2 lgnition Col and H tte e eo Ae eed ert A disse 31 8 2 1 Disassembly and Heassembiy AA 31 ue ITT EN EE ee EE Eege 33 8 3 1 Disassembly and Heassembly A 33 8 32 INSPECUON ane Em 33 1 SPECIFICATIONS AND DIAGRAMS 1 1 General Specifications Dimensions and weights Model IG6000 IG6000H Overall length in mm 31 6 802 48 6 1235 Overall width in mm 19 5 498 25 6 650 Overall height in mm 24 6 624 30 3 770 Dry weight Ibs Kg Engine Model 209 95 223 103 KGS390GETi Type 4 stroke OHV single cylinder Displacement cu in cc 23 7 389 Bore x stroke in mm 3 46 x 2 51 88x64 Maximum horsepower KVA 7
12. ap normal Perform throttle control system troubleshooting 2 8 7 Throttle control system a Engine speed is too high Check AC output normal Check the stepping motor normal Replace the inverter unit Check the AC output oil level alarm no fuel clogged clogged not fueling abnormal abnormal abnormal abnormal abnormal abnormal 12 Add oil and restart the engine Add fuel and restart the engine Clean the fuel switch and filter Clean or replace the hoses Disassemble and clean Tighten the nuts securely replace the gasket or heat insulation block 1 Check the valve clearance 2 Check if too much carbon in burning room 3 Check the piston piston ring and cylinder for wear and damage Readjust the clearance Perform the generator troubleshooting flowing the instruction of No or Low AC output Replace the stepping motor b The engine speed does not increase when smart throttle is on and load is increased Perform the generator troubleshooting flowing the instruction of No or Low AC normal y Check the stepping motor normal Check the smart throttle switch normal y Check Smart switch wire normal Replace the inverter unit 2
13. ations may damage the engine and void the warranty Use special tools designed for the product when specified Always install new gaskets O rings etc when reassembling components Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Many screws used in this machine are self tapping Be aware that cross threading or over tightening these screws will strip the threads and ruin the hole Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the engine Electrical Precautions Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector terminals for bend excessive extrusion missing terminals or other abnormalities before connecting the connector To connect insert the connector as far as it goes If the connector is a locking type be sure that it is locked securely Check the connector cover for breakage and check whether the connector female terminal is not opened excessively Then connect the connector securely Check the connector terminal for rust Remove the rust using an emery paper or equivalent material before connecting the connector S
14. cap and remove the spark plug with plug sleeve 2 Remove carbon on the electrodes of spark plug with a wiey brush and check sealing washer for resistance value is not within the damage 3 Check the resistance value of spark plug and replace if the stated value Resistance value of 3 9KQ spark plug 4 Measure the plug gap with a wire type feeler gauge If the gap is not compatible with the standard adjust by bending the side electrode Spark plug gap 028 034 in 0 7 0 8 mm Standard spark plug F7RTC 0 7 0 8 E Y UF 5 Install the plug and tighten securely after adjustment 18 3 6 Valve clearance adjustment Caution e Valve clearance inspection and adjustment must be performed on a cold engine 1 Remove spark plug valve cover bolt valve cover and valve cover gasket Spark plug Valve cover gasket e ee Valve cover d M 2 Insert a feeler gauge in the spark plug installation hole Rotate the engine so the piston is at top dead center and both intake and exhaust valves are closed 3 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance intake 0039 0001 in 0 10 0 02 mm Valve clearance exhaust 0059 0001 0 15 0 02 mm 19 4 If adjustment is necessary proceed as follows a lock the rocker lever adjustment screw and loosen the nut b move t
15. cian while servicing can easily result in faulty operation and or damage to the equipment or injury to the operator Warning Improper servicing can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully Some of the most important precautions are stated below 2 2 Safety Precautions Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following e Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely e Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Carbon monoxide poisoning from engine exhaust Burns from hot parts Injury from moving parts e Do not run the engine unless the instructions tell you to do so Keep your hands and clothing away from rotating parts e To reduce the possibility of fire or explosion exercise extreme caution when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 2 3 Service Rules 2 4 Use genuine KIPOR or KIPOR recommended parts and lubricants or their equivalents Parts that do not meet Kipor s design specific
16. et the harness clips in the specified places of the frame securely and secure the wire harnesses Clamp the cables securely Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and hot parts Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled overly taut e Route the wire harnesses properly so that they do not contact sharp edges and corners and the end of the bolts and screws on the body e lfawire harness must contact the end of the bolts or screws or sharp edges and corners protect the contact part of the harness with a loom or by winding with electrical insulating tape If the wire harness has a grommet set the grommet securely e Take care not to pinch the wire harnesses during installation of a part If a wire harness has damaged insulation repair by winding with electrical insulating tape e When using an electrical tester like a volt ohm meter or clamp on meter read the manufacturer s operating instructions carefully before operating the tester Be sure that the tester battery is fully charged and the meter is functioning properly 2 5 Serial Number and Bar Code Location The engine serial number is stamped beside the engine oil drain plug This number is used to identify the specific engine version DIGITAL INVERTER GENERAT The bar code is found in three locations on the generator on the packing carton and o
17. g 21 5 Carburetor WARNING This carburetor is not to be rebuilt nor adjusted and no repair parts will be furnished The only maintenance permitted other than cleaning is to replace the main jet for high altitude compensation 5 1 Disassembly and reassembly NOTE loosen the drain bolt at the bottom of the bowl and drain fuel from the carburetor before removal Carburetor gasket A Reassembly Check if there is any dam u age in the gasket before ope of air choke I SHI PE ke NS Air choke iu duis bottom case Air intake pipe gasket weldment Sealed gasket Reassembly GR Filter fixed price Check if there is any dam ES f Filter elementt age in the gasket before Air filter cover assembl Insulator block of carburetor fl H Reassembly al HP D D y et Check if there is any Reassembly damage in the insulator Check if there is any EA before assembly damage in the gasket me before assembly 22 e Disassembly and installation of stepping motor 3 Stepping motor B je 1 p Stepping motor base Fork Fork spring disassembly Hold tight to prevent spring from coming loose Fork spring L A 5 2 Stepping motor fuel shutoff solenoid 1 Measure the resistance of outlet terminals of stepping motor 1 and 3 50 550 2and4 50 550 resistance value Replace the stepping motor if the resistance exceeds the standard 2
18. hading first x Insert parts 30 8 2 Ignition coil and trigger 8 2 1 Disassembly and reassembly 8 2 2 Inspection a Ignition coil e using an ohmmeter measure the primary resistance of the coil Primary resistance value 0 8 1 30 e measure the secondary resistance of the coil Secondary resistance value 15 21KQ e Trigger Measure the trigger resistance Trigger head resistance 80 1300 e Trigger Air Gap Adjustment Adjust the clearance between the trigger head and rotor Trigger head 020 029 in 0 50 0 75 mm clearance Insert the feeler gauge between the bulge on the trigger head and the rotor to measure clearance Loosen the two bolts on the bracket to obtain the proper When tightening apply equal torque to both mounting bolts to prevent cocking the trigger to one side Recheck the clearance after the adjustment has been made 32 8 3 Alternator 8 3 1 Disassembly and reassembly Seal ring for bus line Motor rotor Assembly Remove amp clean off the grease dirty amp when install the rotor Wire pressing board Flywheel nut M8x1 5 Tf d TON N Y ai Zo d PS OPEN Y 88 5 95 9 ft Ib KEU BA sit EE I Ren stig r LI I Er Eeg NE JEU PH Jl E lee dii E KIT RM
19. he rocker lever adjustment screw until the correct clearance is acheived c tighten the nut on the rocker arm adjustment screw d recheck the clearance 3 7 Fuel switch and fuel filter cleaning Fuel tank LU Sealing gasket Filter core or element _ Fuel switch ey l E 1 Drain the fuel from the tank then remove the fuel tank 2 Loosen the connection nut between fuel switch and tank and remove the filter core 3 Open the fuel switch to start cleaning and dry it with compressed air 4 Remove any clogged foreign material from the fuel filter core and check the fuel filter for damage 5 Install the sealing gasket filter core and fasten the connection nut between fuel switch and oil tank 20 4 AIR CLEANER AND MUFFLER 4 1 Air cleaner e Disassemble and reassemble Sealed gasket Filter fixed price S Filter element Carburetor gasket E Air filter cover Jf Ir ze Install ME Make sure that gaskets have no K damage or deformation Check d sealing surfaces on all four sides S 4 2 Muffler e Assembly Muffler syphon Assembly Clean the carbon inside muffler syphon using the brush before installing Fireproofing cap Assembly Clean the carbon using the brush before instal ling BA F Ze Y fa ye Gei Pd r Exhaust pipe gasket r Muffler gasket e Assembly Knock it to remove carbon in side by using rubber hammer Cover of muffler before installin
20. level again 5 Tighten the dipstick e drain the used oil while the engine is warm Warm oil drains quickly and completely e please dispose of the used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation 16 3 3 Low Oil alarm inspection Disconnect the orange oil alarm wire when the engine stops and ground the terminal specified in the diagram and confirm that the alarm light is on and the engine stops or won t restart gt Outlet terminal of ignition module Outlet terminal of oil alarm Ground through engine cover 3 4 Air Cleaner 1 Open the door of cabinet 2 Remove the air cleaner cover and remove the filter element 3 Check the element for excessive dirt or damage Replace as necessary Caution eExcess oil will restrict air flow through the foam filter core and may smoke at the engine start Cover of ail cleaner Clean Twist to dry Dip into oil Squeeze out the excess oil GE Vu r e 0 0 a a 17 4 Install the air cleaner element in the air cleaner case Caution Do not operation the engine without an air filter element or with a damaged air filter Rapid engine wear will result 3 5 Spark plug inspection and adjustment 1 Remove the spark plug
21. n the inside cover of the operator s manual 2 6 Alternator Maintenance Standards Standard Q Service ype limit 120V 240V Orange 9 0 22 0 24 Ignition winding Resistance Yellow Green Gray orange 0 15 0 17 External charging winding Built in charging winding Resistance Blue blue 0 03 0 04 Resistance Purple Purple 0 12 0 16 White white Sub winding Resistance Ve 0 08 0 12 green green Black black Main winding Resistance 0 45 0 60 0 09 0 10 red red 2 7 Fastening Torques Tightening torque Item Specification Ft Ib N m Connecting rod bolt M8 14 8 16 3 20 22 Cylinder cover bolt M10x1 25x80 31 0 34 0 42 46 Spark plug M14x1 25x19 18 4 22 2 25 30 Crankcase side cover bolt Rotor nut M18x1 5 88 5 95 9 120 130 M8x30 14 8 17 0 20 23 Rocker arm shaft bolt M8x16 14 8 17 0 20 23 Adjusting nut of rocker M6x0 75 7 8 8 8 10 12 arm shaft M5 bolt nut 4 4 5 9 6 8 M6 bolt nut 5 9 7 4 Standard torque M8 bolt nut 14 8 17 0 M10 bolt nut 40 6 44 3 Note Use standard torque values for fasteners that are not listed in this table 2 8 Troubleshooting This section gives very general information regarding symptoms and possible causes Refer to subsequent sections regarding testing and removal and replacement of specific components and systems Engine overhaul is addressed in the I
22. s Repair or replace the harness 2 Replace the alternator Perform the throttle control system troubleshooting Repair wiring or replace receptacles2 7 9 Replace the rectifier Check and repair the wire harness or replace the stator 2 8 10 Electric Starter N Check the battery voltage normal y Check ignition switch normal Check the ignition relay normal Check the starting motor normal Vv Check and repair or replace main wire harness Check ignition switch normal Check charging regulator normal Measure resistance of charging coil winding Resistance 0 12 0 160 y Check and repair or replace wire harness abnormal abnormal abnormal abnormal 8 11 The battery will not charge or maintain a charge abnormal abnormal abnormal 14 Charge or replace the battery Replace the ignition switch Replace ignition relay Replace the starting motor Replace ignition switch Replace the charging regulator Check and repair electric wire harness or replace stator 3 INSPECTION AND ADJUSTMENT 3 1 MAINTENANCE SCHEDULE Regular service period 1 Each use Each Every3 Every6 Every year Hem pertetim ar E indicated month or months months or or every month or operating hour in
23. ser 5 2 2 Safety Precautiols o iem vel ae Pi at o NR AK eee 5 29 SEM nii o EN MH DD EAS 6 2 4 Electrical Precautioris 3 ioa it onere ei Eee ED E det SERIES bales Ee Be Eh as 7 2 5 Serial Number and Bar Code Location eese nennen nnne nnne nennen 7 2 6 Alternator Service SIandalds EE 8 2 7 Rastening IOrqUes v er E RR do e i im d CORE ER 8 2 8 Tro blesShootlng s uoc n D de eee 9 2 8 1 General Symptoms and NEE 9 2 8 2 Hard Starling or NO Stati socer ete Ete o xke Oe Rae bu eere Pn d eee 9 2 5 e ON Sy vaska 10 2 8 4 LOW Oil TT 11 2 8 5 Engine Speed Problems stevens i agora ee AAA 11 2 8 6 Engine Stops After TINO DE 12 2 8 7 Throttle Control SVSIBITI eiie A EE 12 2 8 8 LOW AG OUIDUL ai ce eit Ded rb e e ee E ope Ou Ea eX Era edv ae e TUAE 13 2 8 9 NOAG QUIPULA iaa EU aon id Up adosado b peo ene cia SE 13 28 10 Electric Selek ER 14 2 811 Battery Charging DEE 14 E Ee Ee en Ee RA Le E nn E 15 ad lu Ee 15 3 2 Engine li M einen a nce ee i ee 15 9 3 Low Oil Level Switch EE 17 SAPD CISA Si airs rsa O 17 95 SPAN PUG sto DV 18 O A O estes 19 3 7 Fuel Switch Fuel Filer Haas AN AS secs as ace A alee eda 20 4 gie RT 21 NE Ide rm 21 Lund 21 SLOT V TC cPEE C 22 5 1 Disassembly and Reassembly iet e HC Rer e AGR 22 5 2 Stepping Motor Fuel Shutter getest EE Leere ee ees 23 6 Control Panel and Inverter Module uge rre dn tiere i Bub e debeo
24. sulation cap y Check or replace wiring harness normal spark normal spark abnormal abnormal abnormal abnormal 10 Perform the ignition system troubleshooting 1 Check valve clearance 2 check cylinder head gasket for leakage 3 Check combustion chamber for excess carbon buildup 4 check valve seats and guides 5 check for worn piston piston rings and cylinder Replace the spark plug Replace Ignitor Replace the ignition module Replace the coil Adjust the air gap and or replace the trigger Check the ignition coil Drain out all engine oil disconnect the low oil alarm wire and check if the outlet terminal is connected to ground conductive Connect the alarm wire loosen ignition module receptacle and check if the orange wire is connected with the ground conductive Replace ignition module Check choke for proper operation OK Check the air cleaner not clogged Check the valve clearance normal Remove the spark plug and check the electrodes for carbon and spark plug gap normal Check for blockage of the main jet not clogged Check the air intake gasket and the sealing of heat insulation block of carburetor normal Perform the cylinder compression check normal Perform the throttle
25. tem for blockage Check carburetor for fuel delivery Clean and dry the carburetor and observe choke action is severe check if any fuel leakage and if the floating valve is normal Attach the spark plug on plug cap ground the electrode on the cylinder head start the engine and check the spark conditions normal Install a compression gauge in the spark plug hole and restart the engine and check the cylinder compression normal compression 80 psi 55 Mpa Install the spark plug Restart the engine according to the starting procedure 2 8 3 Ignition system troubleshooting mSpark plug inspection 1 Remove spark plug no spark or weak spark low cylinder compression 2 Attach the removed spark plug to the plug cap 3 Ground the negative electrode of the spark plug against the cylinder head or engine block and engage the electric starter and check to see if a spark jumps across the electrode Measure the spark plug gap and perform the spark test Standard gap 028 034 in 0 7 0 8 mm no spark Perform the spark test again using a new spark plug no spark Perform the spark test again using a new spark plug no spark Check ignition module normal Check resistance of ignition coil normal Check trigger air gap and trigger resistance normal Check the ignition coil resistance and high voltage cable and in
26. terval whichever comes first every 10 or every every 100 300 hours i hours 50 hours hours Project Engine Oil Check Replace Air cleaner Check Replace Spark plug Clean Adjust Spark Arrestor Clean Valve clearance Check Adjust Fuel tank and filter Clean Fuel line Check Every 2 years and replace if necessary Note Service more often in dirty dusty conditions Should be performed by trained service center personnel 3 2 Engine oil e Checking the oil level Stop the engine and check the oil level be sure to put the engine on a flat floor when checking 1 Remove the oil dipstick and check the level Wc e Lower limit 2 If the oil level is low add to the edge of the oil filler port upper limit e Engine oil change 1 Remove dipstick and oil drain bolt and drain out the used oil 2 Tighten the oil drain bolt securely 15 3 Pour the specified amount of fresh engine oil through the oil filler port Engine oil capacity 1 2 qt 1 1L X Recommended engine oil Use a high detergent premium quality 4 stroke engine oil certified to meet or exceed U S automobile manufacturer s requirements for API Service Classification SG SF Select the appropriate viscosity for the average temperature in your area SAE Viscosity Grades Multi viscosity 4 After refilling check the oil
27. y Check if the damping cushion is aging or rupture before assembly Chassis Fuel tank cover Reassembly Check if air vent is blocked before assembly Glass of float window Oil dipstick Assembly Check if the float rotating smoothly before assembly Filter net of fuel tank Reassembly Check if the mesh is blockedor damage before assembly Elastic cushion of fuel tank Oil switch subassembly Reassembly Check if filter element is blocked or damaged and clean filter element and oil switch before assembly Fuel feeding pipe Reassembly Check if there is repture and aging before assembly Replace every two years Sleeve of lt elasticcushion _ Framework weldment On DX Y E d r Es SES N Inverter unit al ll e A Module fixing plate 1 Charging fegulator 28 Front cover Rubber sleeve 7 2 IG6000h handle assembly 9aym pue 2994 PUEISYO jeg pueis a anaes ea respuey DR uodans jreupuey buds eppueH anaajs BOIS maJos DulueluDi 29 8 ALTERNATOR IGNITION COIL TRIGGER STARTER MOTOR FAN COVER 8 1 Component Identification Pa E go gt E S AN Ka Electric start Air board Disassembly Remove motor first 4 UN E bo Seal ring for cylinder Tightening bolt for cylinder cover ads rj Cylinder top sheath Disassembly LA Remove cylinder s
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