KIPOR POWER PRODUCTS CO., LTD. IG2000/IG2000P/IG2000S
Contents
1. POWER PRODUCTS LTD IG2000 IG2000P IG2000S SHOP MANUAL EPA CARB CETL Certified Models Kipor Power Systems Inc Revision 4 July 2011 Preface This manual covers the construction repair and servicing procedures for the KIPOR 162000 and IG2000P Models Some models were sold with an S suffix designating an installed light kit The manual is applicable to EPA CARB and CETL models Careful observance of these instructions will result in better safer 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 Wuxi Kipor Power Co Ltd reserves the right to make changes without incurring any obligation No part of this publication may be reproduced without written permission CONTENTS PREEAGE 2 eere teet aii Puede dde aie ena 1 CONTENTS e E 2 1 SPECIFICATIONS WIRING 4 12 RI ele le lee LE 4 1 2 PERFORMANCE CHARACTERISTICS essen eene 5 1 3 PERFORMANCE CURVES am etii etae a ie pig 6 1 4 DIMENSIONAL DRAWING mener ener 7 1 5 WIRING DIAGRAMS es ice nece ten e Rr pde Un ote e eed Ua ed Ee n debris 8 2 SERVICE INFORMATION 11 2 1 THE IMPORTANCE OF PROPER GERVICING sse 11 2 2 IMPORTANT SAFETY PRECAUTIONS 11 2 3 SERVICE RULES iint et i e pe i b N2. Lua 43 Stepping motor Measure the resistance of stepping motor connection to the inverter Between 1and 3 45 550 Standard resistance Between 2 and 4 45 550 Replace the stepping motor if the resistance excesses the above range ED 0000 Tey as SN N SN N N CH 2 lt r A gt AUN e D E 44 7 Control panel 7 1 Disassembly Installation Front cover Control panel 45 2000 1 2000 1 Igniter AC receptacle Smart throttle switch DC receptacle lo of Ground terminal 7 2 Inspection a Control panel AC receptacle Check the electrode contact disk inside receptacle if it is burnt or the discolored replace it DC receptacle Connect both terminals of the receptacle with a jumper wire to short There must be continuity between the lead wire terminals with the circuit protector ON Replace the DC receptacle if there is no continuity Smart switch There should be continuity with the switch ON and no continuity with the switch OFF 46 Igniter Ignition module Pull off the 10P receptacle from the module Measure the resistance by connecting one test lead with the metal outer case of the engine and the other lead with the 10P connector S
3. 2 ring cl ring I Ye 13 3 Inspection Free length of valve spring Standard mm Service limit mm 26 4 24 9 Valve seat width Standard mm Service limit mm 0 7 1 8 81 Valve rod outer diameter Standard mm Service limit mm Inlet valve 3 965 3 980 3 90 Exhaust valve 3 955 3 970 3 90 gt Ss 7 Valve guide pipe inner diameter Standard mm Service limit mm Inlet Exhaust valve 4 000 4 030 4 060 82 Clearance between valve rod and valve guide pipe Standard mm Service limit mm Inlet valve 0 020 0 065 0 10 Exhaust valve 0 030 0 075 0 12 Cylinder inner diameter Standard mm Service limit mm 58 000 58 020 58 105 Piston skirt outer diameter Standard mm Service limit mm 57 960 57 980 57 850 Clearance between piston and cylinder Standard mm Service limit mm 0 020 0 042 0 120 83 Side clearance of piston ring Standard mm Service limit mm 0 02 0 06 0 15 Piston ring end clearance Locate the piston ring into cylinder with piston top and measure the piston end clearance Standard mm Service limit mm 0 15 0 25 1 0 84 Piston ring height Standard mm Service limit mm T
4. 1 Ignition coil Attach the two leads of meter to the primary coil plug of ignition coil and measure the primary resistance of the ignition coil Primary resistance 0 8 1 30 Attach one lead of the meter to each terminal of primary coil plugs of ignition coil and the other lead to the spark plug cap then measure the secondary resistance of the ignition coil Secondary resistance 15 21kQ e E H 2 Rectifier Measure the on or off positive pressure fall of rectifier with control potentiometer F gt the measurement should agree with the standard as shown in the chart 63 1 Negative 4 64 3 Positive 10 Generator Trigger 10 1 Alternator Disassembly Reassembly Rotor Flywheel nut M12X1 25 70 80 N m Fan Fan pressure plate Pull wheel Pulse coil trigger Seal ring 10 2 Inspection 1 Ignition winding Measure the resistance between the green terminal and yellow green terminal Resistance 0 40 0 550 2 Outer charging winding Measure the resistance between the two blue terminals Resistance 0 12 0 150 3 Sub winding Measure the resistance between the two sub winding terminals White White 0 15 0 30 Resistance 65 4 winding Measure the resistance among th
5. Blocked Check the air filter element for blockage Clear the air filter element No blocked Check the valve clearance Abnormal Readjust the valve clearance Normal Remove the spark plug and check the Abnormal ear electrode adjust clearance electrode clearance for carbon deposit or replace the spark plug Norma Blocked nozzle fo and the carburetor Clean or replace Tighten the nut and or replace the gasket or heat insulation block No blockage Check sealing of inlet line gasket and Abnormal carburetor heat insulation block Normal lix 1 Check the valve clearance M th lind Abnormal 12 Check the carbon deposit in easure the cylinder compression e ab stion chamber 3 Check the piston piston ring Norma and cylinder for damage Perform the throttle control system test 3 6 Throttle control system test 1 Engine speed too high or too low Abnormal _ Perform the generato Check the AC output roubleshooting following the instruction of No or low AC output Norma Abnormal Check the throttle control motor Replace the throttle control motor Norma Replace the inverter unit 20 3 7 Smart throttle doesn t work with zero load engine speed doesn t increase with smart throttle on and load connected Perform the generato Abnormal Check the AC output roubleshooting following the instruction of No or low AC output Norm
6. The curves show performance of the generator under average conditions Performance will vary depending on ambient temperature humidity and altitude The output voltage will be higher than usual when the generator is still cold immediately after the engine starts AC External characteristic curves gt gt 2 d 120 5 5 110 Current A 0 3 6 9 12 15 gt o Q 3 240 eem amp z 230 o Current A 0 2 4 6 8 1 4 DIMENSIONAL DRAWING Unit mm NN EH xi IT EE SZ 5 qu M 1 5 WIRING DIAGRAMS a IG2000 pre 2011 White sowar w Bsk INVERTER UNIT DUX B Black Yedow Bue Blue eue wirang i gt a 1 1 i a t Rectifier CN d eS LI E Sub winding White Stock Sach INVERTER UNIT oe Grange Red 162000 2011 forward Y je TYY d ba j Ke m m s 2 E E E ba 3 3 E mir E GK G 5 mz G a
7. 9 8 6 3 Parallel output receptacle Check the continuity between the two terminals of parallel output receptacle Parallel output cable 1 Check the AC receptacle output terminal there should be no continuity between two terminals 2 Connect the AC receptacle output terminal with one lead check the parallel plug there should 50 be continuity among the four plugs 3 There should be continuity between the cable earth terminal and AC receptacle earth terminal Parallel connection plug Parallel connection plug M Grounding terminal Grounding terminal Grounding terminal Output terminal AC Receptacle Capacitor Beginning with models built in December 2007 and ending in July 2008 a capacitor was added to reduce electro mechanical interference and eliminate problems with some digital clocks not displaying the time properly This was an interim solution and all later models had an inverter module modification to eliminate the capacitor 1 LOCATION The capacitor was placed in the output lines between the inverter and the AC receptacles It is physically located inside the service door to the right of the oil dipstick It is mounted on a bracket that bolts to the base plate The base plate was modified to accept the new bracket There is a 2p connection behind the receptacles 2 TROUBLESHOOTING AND TESTING Check the capacitor when troubleshooting issues regarding digital clock displays Should the
8. Abnormal the throttle control system s the engine speed normal test Normal Abnormal Check the DC output Replace the DC receptacle Normal Abnormal Check the DC output Replace the rectifier Normal Measure the resistance between Abnormal the wire harness or replace blue terminals of the rectifier the stator Resistance 0 12 0 150 Normal Rotor losses magnetism and replace the rotor later models had a fuse in the receptacle Check the fuse before replacing the receptacle 3 10 No Parallel Output prior to 2011 model year Make sure that the parallel output cables are inserted into the parallel cable connectors on the control panel C d warning Use only parallel output cables Use only the KIPOR parallel output box Don t use any control panel receptacles when running in parallel Don t disconnect the parallel cables while either generator is operating Check whether the two generators could Abnormal single generato ork well separately roubleshooting Normal 15 ER of the over load indicating Off 1 Check the parallel output cable on 2 Check the parallel output terminal o Check the paralleled UO communication Abnormal Replace the parallel UO ire communication wire Normal Check the paralleled I O communication Abnormal _ Replace the parallel receptacle communication receptacle Norma Replace the inver
9. Micro switch baffle Fuel d Fuel hose Left housing case Diaphragm tube Fuel hose Fuel tank fuel switch Fuel hose 55 8 3 Fuel tank CARB Caution Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel Keep heat sparks and flame away Wipe up spills immediately Loosen the drain screw to drain the carburetor thoroughly before removal Fuel Gauge 1 ai y cr Fuel tank cover Pallet Gasket Thread sleeve gt gt Seal gasket E Bushing Fuel tank S EE Capacity 3 4L Installation clear the e SSES fuel tank before installation E m Filter strainer SL Clam p Cross protection frame for Cross protection frame for P Fuel hose right housing case left housing case 56 8 4 Fan shield Engine mounting plate Fan shield Shock pad See 45cc carbon canister Hollow shaft Mounting plate 57 8 5 Evaporative control system Inlet system Connected to x diaphragm EH tube A NN LL 58 8 6 Guide Plate Exhaust tube Exhaust tube gasket Exhaust guide plate Lower air duct guide plate 59 9 Recoil starter Air conduct cover Ignition coil 9 1 Disassembly
10. clearance 0 6 0 7mm Standard spark plug UR5 30 5 Install the plug finger tight to seat the washer then tighten with a plug wrench Torque valve is 13 15 N m 4 5 Valve clearance Caution Valve clearance inspection and adjustment must be performed with the engine cold Inspection Adjustment 1 Remove the following parts Front cover control panel Rear cover Right left side covers Fuel tank Inverter unit engine bed Recoil starter fan cover Inlet Exhaust side baffle 2 Remove the four bolts and disassemble the cylinder cover Don t remove the valve cover with excessive force or it will deform Replace the valve cover if it is deformed 31 Cylinder cover 3 Turn the rotor to set the piston at top dead center of the compression stroke Timing line of camshaft driving chain should align with the cylinder head seal Insure the intake and exhaust valves are closed Timing mark Exhaust valve Inlet valve Revolve direction Caution the intake valve is open turn the rotor again to align the timing line with the cylinder head seal and both the inlet and exhaust valves should be closed 4 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance IN 0 06mm EX 0 08mm Valve clearance 32 5 If adjustment is necessary proc
11. wire and check the continuity between alarm outlet terminal and ground Replace the oil level alarm Continuity plug and check the continuity between the plug orange wire and ground Continuity Igniter fault replace the igniter 3 4 Engine stops running Throttle is at the correct position Oil alarm Check the oil level and oil alarm Fill oil and restart the engine Sufficient oil Reset the alarm connection wire disconnect No fuel igniter plug and check the continuity Fill in fuel and restart the engine between the plug orange wire and ground Blocked Clear the fuel switch and fuel ilter Sufficient fuel Check the fuel switch and fuel filter fo blockage No blocked Block Check the fuel supply pipe for blockage pres Ge or replace the fuel supply No blocked Check the fuel switch and fuel filter fo Blocked 7 blockage Disassemble and clear blocked Check sealing of inlet gasket and carburetor Abnormal ighten nut or replace the heat insulation block gasket Normal 1 Check the valve clearance Check the carbon deposit in Measure the cylinder compression ABNORMA combustion chamber 3 Check the piston piston ring Normal and cylinder for damage Abnormal Check the trigger clearance Readjust the trigger clearance Normal Perform the throttle control system test d 19 3 5 Engine speed can t increase or unstable choke is the correct position
12. A e m bE Sa e Stop Switch Imiti Finding rr Trigger Finding 13 6 1 a Spark Flug 211 ps Coi Single Phase Receptacle d IG2000P 2011 forward amp 21 Ks zo Secondary Winding White a Inverter Principal Winding Black Single Phrase Receptacle d 2 E et ka pie o m et o 10 Green verlaod Alarm Furi Blue RH m i DC Receptacle 4 AS Biue Low oil alarm 2 y T 5 Aix Rectifier D SIB 3 E 3 Yellow Green Black I 2 Service information 2 1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the engine Any error or oversight made by the technician while servicing can easily result in faulty operation damage to the engine or injury to the operator d 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 given below However we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs
13. Assembly of chain support plate pressure plate Chain support plate 1 Put the upper groove of chain support plate into block press the other end to seize the support plate fully 2 Insert the location pin into cylinder block location hole and align them set the support plate and clip block into cylinder block Adjust the clip block location to align the clip bolt with cylinder block bolt 3 Install inner hexagonal bolt and tighten hard Location SIO pin Chain pressure plate 1 Install the spring pin shaft spring and chain pressure plate as the picture shows 2 Insert the spring into block location hole set the chain pressure plate into cylinder block and spring into location hole Pay attention that the spring pin should be inserted as far as location 3 Adjust the block location to align the block bolt hole with cylinder block bolt hole 4 Install the inner hexagonal bolt and tighten it 5 Hold the spring free end to seize the block as picture shows knock the spring pin with copper hammer 73 the spring to seize the block 74 12 5 Assembly of crankcase cover 1 Clean any remaining sealant on the cylinder block and crankcase cover with cloth 2 Apply gasket sealant on the cylinder block sealing face as shown 3 Reassemble the crankcase cover in the opposite direction of disassembly Caution Install the crankcase cover on the cylinder block wit
14. ER i a ee i Pa aa 12 2 4 ELECTRICAL 13 2 5 SERIAL NUMBER AND 13 2 6 MAINTENANCE 5 5 14 2 7 TORQUE VALUES i Rea En t e YR 14 3 TROUBLESHOOTING rere ee er oer e crie ee Ep deena REUS 15 3 1 GENERAL SYMPTOMS AND 5 15 3 2 HARD STARTING eran NR teret ere etuer tree neue ea ETE nu 16 33 OIL ALARM etit ll Ne e n certe DE X PER HER Der xu und d 19 3 4 ENGINE STOPS RUNNING eem 19 35 ENGINE SPEED UNSTABLE AA J iren 20 3 6 THROTTLE CONTROL 20 SU SMART TAROT TLE E HE 21 3 3 LOW ORNO AG ONT PUT i i ntt Ee sese i e pui 21 3 9 NO DE OUT PSI etes tito a nece ee Si Aa ele De ede dup eee 22 3 10 NO PARAERSEEPMOUTBPUT iii tt nene a EO i e xe n Rn d ed ie 23 4 25 4 T1 MAINTENANCE SCHEDULE dei evo eh ioe 25 4 2 CHECKING THE LOW OIL AL ARM 27 ASAIR CLEANER tete eerte Renee eec e ee 28 AVA SPARK PLUG e SR decedere o ee da 30 45 VALVE CLEARANCE ir tton ppt at bebes ben 31 4 6 FUEL TANK AND FILTER 2 recreo mt teo ae ete ce nne tene eege 34 4 7 FUEE PUMP AND
15. HOSES e cv 36 5 EXHAUST SYSTEM ntt nm e e d e 37 ut eerte RIEN muti mies 37 5 2 EXHAUST TUBE SECONDARY AIR INJECTION VALVE 38 e E EE EN el 38 INTAKE SYSTEM ii tite eedem ei 39 6 1 AIR FILTER REMOVAL AND 1 emm eene 39 6 2 CARBURETOR REMOVAL AND INSTALLATION eee meme 40 M 43 T BEE 45 7 1 REMOVAL AND INSTALLATION 46 7 2 INSPECTION OF A 53 8 LIGHT KIT HOUSING FUEL TANK FAN HOUSING emere 53 8 1 LIGHT KIT DISASSEMBLY AND 53 8 2 HOUSING DISASSEMBLY sse emen ene nnne nenne rennen eren 54 8 3 FUEE TANK ASSEMBLY ere en e t afe 56 8 4 FAN HOUSING ENGINE MOUNTING PLATE emm emen 57 8 5 EVAPORATIVE CONTROL SYSTEM AA 58 86 GUIDE PLATE Sohne foot e Nu o ere deed 59 9 RECOIL STARTER AIR CONDUCT COVER IGNTION 60 9 1 DISASSEMBLY AND 2 60 9 2 RECOIL STARTER INSTALLATION AE 61 9 3 INSPECT ION rione c ie Puce ote t c codice Pe Dae ba dae P Ei aded 63 10 ALTERNATOR TRIGGER p eene eene ri enne nnne 65 104 ALTERNATOR ee eos etd ed etas de festo
16. OU 75 21 90 2 7 Torque values Tightening torque en Specification Connection rod bolt M5X0 8X25 0 8 1 0 Spark plug M10X1 0X13 13 15 1 8 1 5 M6X25 0 8 1 0 Flywheel nut M12X1 25 48 52 4 8 5 2 M5 Bolt nut 0 5 0 7 Standard torque M6 Blot nut 0 8 1 0 Bolt nut 18 22 1 8 2 2 Note Use standard torque values for fasteners that are not listed in this table 14 3 TROUBLESHOOTING 3 1 General symptoms and possible causes not start or Trigger faulty or trigger clearance Inspect and replace hard starting faulty Spark plug cap loose Install securely Low oil alarm faulty Inspect and replace Igniter faulty Inspect and replace Ignition winding faulty Inspect and replace Throttle opening fault Set in fully closed or half closed position Carburetor faulty Clean or replace Throttle control motor stepping Inspect and replace Engine speed does not motor faulty stabilize too tal tand nverter unit fau nspect and replace high or too low y P P Valve clearance misadjusted Readjust 15 3 2 Hard starting Check the fuel level in the tank NO tue Add fuel and restart the engine ocn fuel Loosen the drain screw and No Add fuel and restart the engine check whether fuel reached the carburetor Good spark Remove the spark plug and check for wet or fouled electrode Check for blockage in the carbureto port and nozzle C
17. Only you can decide whether you should perform a given task Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this shop manual carefully 2 2 Important 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 Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Be careful for carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Be careful for burns from hot parts Let the engine cool before you touch it Be careful for injury from moving parts Do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away To reduce the possibility of a fire or explosion be sure when working around gasoline use only a nonflammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from all fuel related parts 11 2 3 Service rules 1 Use genuine KIPOR or KIPOR recommended parts and lubricants or their equi
18. Reassembly Seal sleeve Ignition coil Air conduct cover Recoil starter Rectifier bracket Rectifier Starter rope Assembly check the starter rope for damage before Handle cover installation Handle 4 Starter shell Starter spring _ Disassembly put on the gloves when disassembly Starter reel Assembly install the starter to the reel first and then install the reel to the starter Friction spring gt Pallet spring Pallet 60 9 2 Installation of recoil starter 1 Set the spring into the starter reel and hang the spring outer hook inside the reel groove Spring Starter reel 2 Smear lubrication grease on the starter outer shell claw install the starter reel Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw Starter reel i Starter shell 3 Make a knot at one end of the rope pass the other end through the reel hole Wind the reel anticlockwise 4 turns to fix the reel 61 4 Pull out rope thrum from starter outer shell hole completely pass H through the handle and make a knot then turn the handle cover Loosen the reel to untension the spring taking care not to allow the reel to pop out Pawl Pawl plate Fixed bolt Pawl spring Friction spring 6 Pull the starter for several times and check the ratchet wheel returning 62 9 3 Inspection
19. al Abnormal Check the throttle control motor Replace the throttle control motor Normal Check the Smart switch Replace the smart switch Normal A Check Smart switch connection wire brormal Repair or replace the wire harness Normal Replace the inverter unit 3 8 No or low AC output Em ON Disconnect the load and restart the Is the overload indicator light ON engine Perform the throttle control system est Norma Stop the engine and check the AC Abnormal receptacle Replace the AC receptacle Normal Is the engine speed normal Abnormal Smart switch ON 3200 100rpm OFF 4300 100rpm Disconnect the 6P connector on inverte unit pull the recoil starter with force and measure the AC voltage between black terminal and white terminal 1 Check and repair stator wire Abnormal harness or replace stator 2 Rotor inner magnetism White White gt 1V decreases replace the rotor Normal Replace the inverter unit 21 Inverter unit Main winding Sub winding Measure voltage Phase wire color Black Black Black Model Sub winding color White White Item 120V 240V Voltage between 30V 60V phase wires Sub windin S 1V voltage Phase sequence arrangement Green phase Red phase ec 990 eer ta Black Ine Yellow A phase 120 240V Main winding Black White Sub winding 22 3 9 No DC output ls th d 2
20. bon from the spark catcher steel net check for damage and replace if necessary 4 Install the removed parts in the reverse order of removal 38 6 INTAKE SYSTEM Caution Loosen the drain olt and drain out fuel before disassembly Keep heat flame and sparks away 6 1 Disassembly Installation of air filter Ventilation tube Diaphragm tube Fixed screw 2 Carburetor gasket amp f E NN E Installation check the 3 N gasket for deflection and Air filter shell damage Pay attention to the inner and outer direction Fine filter element Rough filter element Air filter cover 39 6 2 Disassembly Installation of Carburetor Diaphragm tube Carburetor gasket A Installation check the gasket for damage before installation Air filter shell Carburetor stud Insulation block Installation check the block for damage Oil inlet tube before installation 40 Inlet pipe gasket Installation check the gasket Ee For distortion or damage Disassembly Installation of Stepping motor Stepping motor Fork spring Disassembly Fork Hold the spring firmly to avoid dropping it Fork spring Idle adjusting cap 41 Stepping motor cover Fork Stepping motor seat Throttle lever LS gt Disassembly Installation of Carburetor Fork spring Idle adjusting cap mixture adjusting screw sealed Foam tube Installa
21. capacitor fail there will be no impairment of any other generator function or output As the capacitor is connected directly to the output power supply it has the potential to store a high voltage charge and should be discharged prior to testing Unplug the 2p connector and short circuit the capacitor by placing the end of an insulated screwdriver across the two terminals WARNING Do not touch the exposed terminals nor attempt to take any measurements before discharging the capacitor Use the capacitance checking mode of a multimeter Replace the capacitor if any reading is outside the standard value of 10uF 596 52 8 Light Kit Housing Fuel tank Fan housing Inverter unit 8 1 Disassembly and installation of accessory lamp Caution Stop the engine and let the lamp cool completely before disassembly Handle Mounting pad Lamp shell Fixed seat Reflector Glass Lamp bulb Mounting pad Sealing ring Lamp cover Right bracket Nut Screw Lamp shell swivel 53 8 2 Disassembly and installation of housing case Top cover Right housing case Fuel tank cover Filling port gasket Left housing case Right cross protection frame Spilt washer Inverter unit Protection sleeve e x Inverter mounting pad Left cross protection frame 54 Left housing case Left housing case Fuel pump Fuel switch lever Fuel switch
22. connector cover for breakage and check whether the connector female terminal is open 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 5 Set the harness clips in the specified places of the frame securely and clamp the wire harnesses 6 Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and the hot parts 7 Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled taut 8 Route the wire harnesses properly so that they do not contact with the shape edges and corners and the end of the bolts and screws on the body 9 If a wire harness contacts the end of the bolts screws or sharp edges and corners protect the contact part of the harness with a tube or by winding with an electrician s insulating tape If the wire harness has a grommet set the grommet securely 10 Take care not to pinch the wire harnesses during installation of a part If a wire harness has the damaged insulation repair by winding with the electrician s insulating tape 11 Read the tester manufacture s operation instructions carefully before operation with tester Follow the instructions of the Service Manual Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester 12 2 4 Serial numb
23. dry Dip the element in clean engine oil and squeeze out the excess oil Excess oil will restrict air flow through the foam element and may smoke at engine start 5 Install the air cleaner element in the air cleaner case 6 Clean the air cleaner sealr and the air cleaner case if necessary Be sure that the air cleaner cover seals are set securely 7 Install the maintenance cover securely 28 Maintenance screw Filter element Air filter cover Fixed bolt Filter element Wash Dry Dip in engine oil Squeeze firmly Caution A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the Maintenance Schedule Never run the engine in case there is no element or the filter is damaged as it will do great harm to the engine 29 4 4 Spark plug Inspection Cleaning 1 Remove the spark plug cap and remove the spark plug 2 Remove carbon or other deposits with a plug cleaner or stiff ire brush Check the sealing washer for damage 3 Measure the plug resistance replace the spark plug if the measure is not accordance with the specification Spark plug resistance 3 9K 0 4 Measure the plug gap with a feeler gauge Adjust by bending the side electrode if the reading is not within the specification Spark plug
24. e 3 Check the diaphragm tube for deterioration crack and gasoline leakage If there is any abnormality in the diaphragm tube replace the tube 4 Check to see whether water or foreign material has been accumulated in the fuel pump If there is water or foreign material accumulated in the pump replace the fuel pump 5 Check the fuel switch and fuel duct blow away any foreign matter with compressed air with fuel switch turned on 6 After assembly check for gasoline leakage from each component Fuel pump Fuel tube Diaphragm tube d lt lt 2 gt to Carburetor fh A pressure port Fuel tank Ia 17 P S Fuel switch Fuel tube H 36 5 EXHAUST SYSTEM Caution Muffler removal installation must be performed with the engine cold 5 1 Muffler Disassembly Reassembly Muffler Installation remove the carbon deposits by lightly tapping with 4 rubber hammer Spark Arrestor Installation remove the carbon deposit by a brush Seal strip of rear cover Rear cover Muffler mark T 37 5 2 Exhaust tube secondary air injection valve Disassembly Reassembly Exhaust tube Secondary air injection valve d A Second air injection valve 5 3 Spark Arrestor Caution Do maintenance after engine has cooled completely 1 Remove the rear cover 2 Disassemble the spark arrestor from the muffler 3 Remove the car
25. e main winding terminals Black Black Black 1 35 1 75 Resistance b Trigger Attach the two testers in the trigger and measure its resistance Trigger resistance 80 1300 10 3 Adjustment Adjust the clearance between trigger and the projection part of rotor Trigger clearance 0 50 0 75 m Insert a feeler gauge between the trigger and the projection part of the rotor loosen the trigger fixed plate bolt to adjust the clearance slightly Never move the plastic part of trigger 66 11 Cylinder cover Rocker arm 11 1 Disassembly Reassembly Cylinder cover Valve clearance adjusting nut Adjusting screw Rocker shaft Rocker arm of intake valve Rocker arm of exhaust valve Breather cover BN Sealant 1mm diameter S Cylinder cover 67 11 2 Inspection Rocker arm outer diameter Standard mm Service limit mm 5 972 5 980 5 965 Rocker arm inner diameter of inlet exhaust valve Standard mm Service limit mm 6 000 6 012 6 037 68 Inner diameter of rocker arm bearing Standard mm Service limit mm 6 000 6 012 6 037 69 12 Crankcase Cover Cam timing drive chain 12 1 Disassembly Spark plug Chain press plate Sprin Retainer ais Camshaft timing driving chai
26. eed as follows a Loosen the adjusting screw lock nut and adjust the valve clearance by turning the adjusting Screw in or out b Secure the adjusting screw with a socket wrench and tighten the lock nut to the specified torque c After tightening the lock nut check the valve clearance again Feeler gauge 6 Clean the liquid gasket of the cylinder block and cylinder head cover Apply the liquid gasket Three Bond 1207B or equivalent to the cylinder block installation surface as shown Liquid gasket 1 5 2 0 in diameter 7 Install the removed parts in the reverse order of removal 33 4 6 Fuel tank Fuel filter EPA CETL Models Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately Cleaning 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover Front cover and control panel Right Left side cover 2 Disconnect the fuel tube from the fuel tank and remove the fuel filter 3 Remove the clogged foreign material from the fuel filter and check the fuel filter for damage Replace the fuel
27. er location The engine serial number is stamped on the block above the oil dipstick Refer to this number when ordering parts or making technical inquiries Serial number 2 5 Engine maintenance standards Pat Standard mm Service limit 4300 100 0 45Mpa 800rpm 58 000 58 020 58 105 EUE 57 60 57 80 13 002 13 008 Piston pin op 12 994 13 000 h 0 97 0 99 ee side clearance 0 02 0 06 1st ring Date end clearance 0 15 0 25 Bees EE t 1 95 2 15 Piston ring 1 17 1 19 0 02 0 06 2 015 025 10 24 26 L3 1 85 1 98 bum 003018 020050 10 23 27 L 22 ere SmalendiD end 1 0 13 006 13 017 24 020 24 033 23 967 23 980 Valve 0400002 clearance 0 15 0 02 a Valves 3 965 3 980 3 955 3 970 13 EE 4 000 4 030 0 7 26 4 29 026 29 086 0 89668975 EUM 9 000 9 015 D Rocker arm 6 000 6 012 Rocker arm 5 972 5 980 I D Rocker arm shaft bearing 6 000 6 012 Main jet 0 60 Carburetor 12 2 turns out 0 6 0 7 Resistance 15 21kO Pulse coil 0 5 0 75 Trigger 807 1300 2 6 Alternator Bou T Standard Q Ignition winding Green Yellow Green 0 40 0 55 Resistance Blue Blue 0 12 0 15 Es White White IG 15 0 Sub Sub winding Resistance White White CG 0 15 0 30 Black Black Black 1 35 1 0 18 0 0 65 0 Main winding Resistance Black Yellow Black Gr 5 0 5 5
28. filter if necessary 4 Remove the fuel tank and clean it with solvent and allow the fuel tank to dry thoroughly 5 After cleaning install the fuel tank and set the fuel filter in the tank Connect the fuel tube 6 Install the removed parts in the reverse order of removal 7 Fill the fuel tank with gasoline and check the fuel hoses for gasoline leakage Ventilation hose Ka lt A AF Fuel tank R S i Fuel filter Clamp Fuel hose 34 4 6 Fuel tank Fuel filter CARB Models Fuel System 5 Fuel Indicator Gas Cap Strainer Si Sleeve D Sleeve P Gasket Fuel Tank Cover Bushing on Vent Hose Washer Certification No Cotter Pin X6800BM Q 08 006 Retention Hook Vent Hose Fuel Hose Fuel Tank Negative Pressure Hose Certification 5 C U 05 012 T Fuel Hose SE Carton canister Fuel Hose Curved Hose 35 4 7 Fuel hose Fuel pump Diaphragm tube Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover Front cover and control panel Right Left side cover 2 Check the fuel tube for deterioration cracks and gasoline leakage If there is any abnormality in the fuel tube replace the tub
29. he 1 ring 0 97 0 99 0 87 The 279 ring 1 17 1 19 1 107 Piston pin outer diameter Standard mm Service limit mm 12 994 13 000 12 950 85 Piston hole inner diameter Standard mm Service limit mm 13 002 13 008 13 050 d Clearance between piston pin and piston pin hole Standard mm Service limit mm 0 002 0 014 0 080 Connection rod small end inner diameter Standard mm Service limit mm 13 006 13 017 13 080 N 86 Connection rod big end inner diameter Standard mm Service limit mm 24 020 24 033 24 090 Crankshaft neck outer diameter Standard mm Service limit mm 23 967 23 980 23 900 87 Connection rod big end side clearance Standard mm Service limit mm 0 1 0 4 0 8 Oil film clearance of connection rod big end 1 Wipe off the oil on the surface of crankshaft neck 2 Set the plastic wire feeler at the crankshaft neck and install the connection rod Tighten the bolt to the prescribed torque pay attention that don t revolve the crankshaft The tighten torque is 8 to 10N m 3 Disassemble the connection rod measure the plastic wire feeler thickness 4 Replace the connection rod if the clearance exceeds the service limit and measure the clearance again Grind the crankshaft neck if the new clea
30. hin three minutes after applying sealant Revolve the crankshaft if necessary 75 4 Tighten the crankcase cover bolt slowly to the prescribed torque 5 Wait 20 minutes after installation before filling with oil and starting the engine Cylinder block Sealant 1 1 5mm diameter 12 6 Inspection Inspection of oil alarm 1 Stand the oil alarm check the oil alarm output wire and copper earth wire there should be no continuity 2 Bottom up the oil alarm check again there should be continuity 3 Bottom up the oil alarm completely in the oil check the float there should be no continuity 76 Cam height Standard mm Service limit mm 29 026 29 086 29 15 Cam inner diameter Standard mm Service limit mm 9 000 9 015 9 035 ob S E EX Ka A V K ED 7 5 gt S lt D A lt gt _ P g l dh d N yj Camshaft outer diameter Standard mm Service limit mm 8 966 8 975 8 920 77 Decompression block Check the return spring for damage and weary make sure the decompression block could perform well Depression block Return spring ed A o gt 78 13 Crankshaft Piston 13 1 Disassembly Reassembly Valve spring Valve spring seat Disassembly press down the spring seat slight
31. k Warning Don t pull the recoil starter while touching the high tension wire with wet hands High voltage is generated and very dangerous Drain the gasoline from the fuel tank and carburetor Pull the recoil starter several times to release the unburned gas in the cylinder with the engine switch OFF 17 and perform the spark plug test Standard clearance 0 6 0 7mm Perform the spark test again using a Good spark new spark plug Replace the spark plug No spark Remove the control panel Perform Good spark the spark test using new igniter Replace the igniter No spark Good spark Check the engine switch Replace the engine switch No spark Good spark Disconnect the low oil alarm and perform spark test Replace the low oil alarm No spark Abnormal Check the resistance of motor ignition winding Replace the motor stator Normal Check the trigger Normal Abnormal Replace the trigger or readjust trigger clearance Abnormal Check the ignition coil resistance and high pressure cable high pressure insulation cap Inspection or replace wire harness Replace the ignition coil 18 3 3 Engine level is low but engine does not stop Defective oil alarm device Drain out oil completely disconnect alarm No continuity connection
32. lean the electrode and restart Wet care that the choke is closed too much If flooding is severe check the carburetor float valve No spark or Remove the spark plug and Weak spark check for wet or fouled electrode Perform the ignition system roubleshooting ore spark Low cylinder Install a compression gauge and compression 1 Check the valve clearance check ylinder compression 2 Check for carbon deposits in the pulling the recoil starter rope combustion chamber several times 3 Check for valve cone and base 4 Check for worn piston piston ring or cylinder Normal compression Install the spark plug securely Restart the engine according to the starting procedure Cylinder compression check 1 Remove the spark plug cap and spark plug 2 Install a compression gauge in the spark plug hole pull the recoil starter rope several times with force and measure the cylinder compression Cylinder compression 0 45Mpa 800rpm 16 Pressure gauge c Ignition system Fill in oil to the demanded level Use specified spark plug Spark plug inspection 1 Disassemble spark plug 2 Install spark plug onto spark plug cap 3 Set the oil switch to the ONT position Ground the negative electrode i e threaded part of the spark plug against the shroud and pull the recoil starter rope to check the spark plug You should see a clear spar
33. ly and disassemble it Oil seal of inlet valve Cylinder block Piston Installation install the piston with V label towards inlet valve Oil seal Bearin s Crankshaft lt Semicircle Installation pay attention ey not to hurt the oil seal during installation Inlet valve Driving gear seat Timing gear Exhaust valve 2 Installation check for damage before installation Don t mix the Connection rod cover inlet valve and exhaust valve Inlet valve 22 Exhaust valve 20 21 Inlet valve Connection rod bolt M5X0 8X25 8 10M m 79 13 2 Piston Connecting Rod Label 1st ring UU 2 Oil ring Piston Piston pin Piston clip e A Installation set the front end the piston groove and clamp the other end Install the ring clip by revolving Pay attention that the opening should not face the gap of piston pin hole 1 Installation the connection rod big end points to the right side of piston A label 80 Assembly of piston rings Caution Setthe manufactory label upwards Pay attention not to mix the location of the 1 ring and 2 ring Check the piston ring for flexibility after installation Stagger each piston ring opening apart piston pin for 120 1 ring
34. n Roller chain Driving shaft Crankcase cover O seal ring Block Location pin of crankcase cover Pn EE AR Spring pin roll Chain plate 70 1 alarm O seal ring e Oil gear shaft Crankcase cover Gasket Oil gear Retainer ring 12 3 Reassembly of roller chain 1 Install the crankshaft piston and connection rod assembly on the cylinder block 2 Revolve the crankshaft align the timing mark of crankshaft timing shaft with the timing mark of crankcase Step 1 3 Install the roller chain on the cam timing drive chain level the timing mark upward Step 2 4 Put the roller chain into the crankcase set the end of roller chain to the crankshaft timing gear Step 3 straighten the chain to align the timing mark of cam timing drive chain with cylinder head sealing face Caution Don t remove the timing mark of crankshaft timing gear during installation If the timing mark of cam timing drive chain is not parallel with cylinder head sealing face adjust the meshing of chain and cam 5 Install the O seal ring into the drive shaft and then assemble the drive shaft Step 4 Pay attention that the opening of drive shaft should upward 6 Install chain pressure plate Step 5 71 Timing mark Timing mark 72 12 4
35. rance still exceeds the service limit and use the connection rod less than the standard valve Standard mm Service limit mm 0 040 0 066 0 120 Plastic gauge 88 Bearing vibration Clean the bearing and check the clearance between the crankshaft journal and connecting rod big end by revolving bearing by hand Replace the bearing if there is abnormal noise or vibration Clearance Eco Clearance A ul SC Be y M Axial direction Circle direction 89
36. rvice Classification SE SF or SG 4 Check the oil level fill to the upper limit level if necessary 5 Tighten the oil dipstick 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 Do not throw it in the trash pour it on the ground or down a drain Drain the used oil while the engine is warm Warm oil drains quickly and completely 26 4 2 Checking low oil alarm 1 Disconnect oil alarm connector when the engine is still running connect the two plugs be sure that oil alarm lights and engine stops Orange alarm Yellow Orange igniter outlet terminal outlet terminal Green the two plugs are connected 2 Stop engine disconnect oil alarm connector check the connector conduction no conduct is normal 27 d Igniter outlet terminal Alarm outlet terminal check the conductivity between the two wires 3 Drain out the oil inside engine and check the conductivity conducivity is normal 4 3 Air cleaner Inspection Cleaning 1 Loosen the cover screw and remove the maintenance cover 2 Disengage the locking tab by pushing it and remove the air cleaner cover 3 Remove the element from the air cleaner case 4 Clean the element in warm soapy water rinse and allow to dry thoroughly or clean with a high flash point solvent and allow to
37. s 65 10 2 INSPEGTIQN E PN aee se i o ea ba 65 10 3 TRIGGER ADJUSTMENT uS 10 1 11111 eene nennen nennen nnne rennen 66 11 CYLINDER COVER ROCKER ARM 67 11 1 5 5 67 T2 INSPEGTION t EE e ME 68 12 CRANKCASE COVER CAMSHAFT DRIVE CHAIN AA 70 12 1 DISASSEMBEY EE ME 70 12 2 CRANKCASE COVER 71 12 3 ROLLER CHAIN BEASSEMBLY 71 12 4 CHAIN SUPPORT PLATE PRESSURE emen 73 12 5 CRANKCASE COVER A 75 12 6 INSPEGTION tieu 76 13 CRANKSHAFT PISTON AND CONNECTING ROD eene 79 13 1 DISASSEMBLY EE 79 13 2 PISTON CONNECTING ROU 80 13 3 INSPECTION rc 81 1 SPECIFICATIONS 1 1 SPECIFICATIONS Dimensions and weights 1G2000 1G2000P IG2000s Overall Length in mm 20 5 520 26 2 665 Overall Width in mm 11 8 300 11 8 300 Overall Height in mm 16 7 425 16 7 425 Net Weight Ibs kg 48 4 22 52 8 24 Engine Semi dry Oil capacity at L Starting system Recoil starter Automotive unleaded gasoline 87 octane Generator 1 2 PERFORMANCE CHARACTERISTICS Model Voltage variation rate Momentary 1096 max Average 1 596 max Average time 3 sec max Frequency variation rate Momentary 196 max Average 196 max Average time 1 sec max 1 3 PERFORMANCE CURVES
38. tandard resistance Primary coil of the ignition coil 0 8 1 30 There should be no continuity with correct Orange Oil level alarm Sg Bech Trigger coil 80 1300 Yellow Green Continuity Igniter unit power coil winding 0 26 0 280 1 There should be no continuity with the Engine switch A switch ON continuity with switch OFF Blue Orange Yellow Green Red Yellow Green Engine switch 47 Engine switch Check the continuity of connector there should be continuity when depressing the micro switch Press down 48 Aero receptacle parallel UO communication port Check the continuity between connector and aero receptacle there should be continuity between the two terminals with the same serial number 8P connector Aero receptacle 9 8 6 3 Black pte T Red Yellow Blue 4 2 Conducted between N same series number gt gt lt 7 White Purple Orange Green 1 2 4 7 8P connector Aero receptacle Aero plug Parallel UO communication data wire Check the continuity of aero plugs there should be continuity between two plugs with the same serial numbers 49 Parallel connection communication interface aero receptacle 2 1 7 4 4 1 SER B z Conducted 44 OT between same T 2 9 series number
39. ter unit 4 4 1 Maintenance schedule Regular service period 1 mE First Every 3 Every 6 Every Item perform at every indicated Each use month or months or months or year or MOG Or Ope ang 20Hrs 50Hrs 100Hrs 300 whichever comes first Caisse check j Replace Cen Spark ontore Fuel tank and Cem cn 2 year if a Note 1 For commercial use operation hours are determined by proper maintenance 2 Service more frequently when operating in dusty areas 3 Service by an authorized Kipor service center Checking the oil level Stop the engine and check the oil level be sure to put the engine a flat floor when checking 1 Loosen the screws of the maintenance cover and remove the cover 2 Remove the oil filler cap and check for the oil level 3 If the oil level is low add to the edge of the oil fill port 25 Maintenance cover Cover screw M V fi 4 Upper level NLL AS SE ISIN Upper limit Oil dipstick Cl 13 S D SSS Lower limit Ta cM Oil fill port X Replace the engine oil 1 Disassemble the oil dipstick and oil drain bolt drain used oil 2 Tighten the oil drain bolt 3 Refill with clean oil Oil capacity is 0 4L Recommended oil SAE10W 30 or Se
40. tion clear foreign U material with compressed i air before installation Main metering jet Installation clear foreign material with compressed air gt before installation Pay attention to the installation direction F Float Sealing ring of carburetor bowl Bowl bolt Installation check for fuel leakage after installation 42 Choke valve Fork f Choke valve plate Carburetor block th Needle seat Fuel control needle Installation check the end and spring before installation p Ls Gi Fuel control needle Sealing ring of bowl Float pin Lf Bowl g Bowl drain bolt Installation check for fuel leakage ater installation NOTE With the exception of changing main jet no adjustments modifications or other maintenance is permitted on EPA and CARB certified engines This includes any Kipor generator ever sold in North America This drawing is for information only Kipor will not supply any carburetor parts other than stepping motors and main jets 6 3 Inspection Float height Place the carburetor on a level surface as shown measure the float height between the float and carburetor block Height 12mm Replace the carburetor if the float height is not correct Float 1 12 oT
41. valents Parts that do not meet Kipor s design specifications may damage the engine 2 Use the special tools designed for the product 3 Install new gaskets O rings etc when reassembling 4 When torquing bolts or nuts begin with larger diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 5 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 6 After reassembly check all parts for proper installation and operation 7 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 8 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 may damage the engine 9 Follow the instructions represented by these symbols when they are used Electric precautions 1 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 2 Check the connector terminals for bend excessive extrusion missing terminal or other abnormalities before connecting the connector 3 To connect insert the connector as full as it goes If the connector is a locking type be sure that it is locked securely 4 Check the
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