KIPOR POWER PRODUCTS CO., LTD.
IG1000 SHOP MANUAL
CARB and CETL Models
The Coast Distribution System
December, 2008
Preface
This manual covers the construction, function and servicing procedure of the KIPOR IG1000.
This manual is applicable to all models certified by the California Air Resources Board (CARB) and
CETL built in December 2008 and onward. The construction of both generators is identical but CARB
model fuel systems use certified materials. Procure the correct parts applicable to your model.
Careful observance of the instructions contained in this manual will result in safe and quality
maintenance and repair 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.
ii
CONTENTS
1. SPECIFICATIONS/WIRING DIAGRAM .................................................................................... 1
1.1 SPECIFICATIONS .............................................................................................................. 1
1.2 WIRING DIAGRAM ............................................................................................................. 3
2. SERVICE INFORMATION ........................................................................................................ 4
2.1 THE IMPORTANCE OF PROPER SERVICING .................................................................. 4
2.2 IMPORTANT SAFETY PRECAUTIONS .............................................................................. 4
2.3 SERVICE RULES ............................................................................................................... 5
2.4 ELECTRICAL PRECAUTIONS ........................................................................................... 5
2.5 SERIAL NUMBER AND BARCODE .................................................................................... 6
2.6 MAINTENANCE STANDARDS ........................................................................................... 7
2.7 TORQUE VALUES .............................................................................................................. 8
3. TROUBLESHOOTING.............................................................................................................. 9
3.1 GENERAL SYMPTOMS AND CAUSES.............................................................................. 9
3.2 HARD STARTING ............................................................................................................. 10
3.3 OIL LEVEL SWITCH ......................................................................................................... 13
3.4 ENGINE STOPS RUNNING.............................................................................................. 13
3.5 ENGINE SPEED UNSTABLE............................................................................................ 14
3.6 ENGINE SPEED TOO HIGH OR LOW ............................................................................. 14
3.7 SMART THROTTLE .......................................................................................................... 15
3.8 LOW OR NO AC OUTPUT ................................................................................................ 15
3.9 NO DC OUTPUT ............................................................................................................... 16
4. MAINTENANCE .................................................................................................................... 17
4.1 MAINTENANCE SCHEDULE ........................................................................................... 17
4.2 ENGINE OIL ..................................................................................................................... 18
4.3 CHECKING THE LOW OIL ALARM .................................................................................. 18
4.4 AIR CLEANER .................................................................................................................. 19
4.5 SPARK PLUG ................................................................................................................... 20
4.6 VALVE CLEARANCE ........................................................................................................ 21
4.7 FUEL TANK AND FILTER ................................................................................................. 24
4.8 FUEL PUMP AND HOSES ................................................................................................ 25
4.9 SPARK ARRESTOR.......................................................................................................... 26
5. MUFFLER ............................................................................................................................. 27
6. AIR FILTER/CARBURETOR ................................................................................................. 28
6.1 AIR FILTER REMOVAL AND INSTALLATION ................................................................... 28
6.2 CARBURETOR REMOVAL AND INSTALLATION ............................................................. 28
6.3 STEPPING MOTOR REMOVAL AND INSTALLATION ..................................................... 29
6.4 CARBURETOR EXPLODED DRAWING .......................................................................... 30
6.5 INSPECTION .................................................................................................................... 31
iii
7. CONTROL PANEL ................................................................................................................ 32
7.1 REMOVAL AND INSTALLATION ....................................................................................... 33
7.2 INSPECTION .................................................................................................................... 33
8. HOUSING/FUEL TANK ......................................................................................................... 35
8.1 HOUSING DISASSEMBLY ............................................................................................... 35
8.2 FUEL TANK ASSEMBLY ................................................................................................... 36
9. RECOIL STARTER/AIR CONDUCT COVER/IGNTION COIL/AIR CONDUCT PLATE ......... 37
9.1 DISASSEMBLY AND REASSEMBLY ................................................................................ 37
9.2 AIR CONDUCT PLATE ..................................................................................................... 38
9.3 RECOIL STARTER ........................................................................................................... 39
9.4 IGNITION COIL ................................................................................................................. 42
10. ALTERNATOR/TRIGGER ..................................................................................................... 43
10.1 ALTERNATOR ................................................................................................................. 43
10.2 INSPECTION .................................................................................................................. 43
10.3 TRIGGER ADJUSTMENT ............................................................................................... 44
11. CYLINDER COVER/ROCKER ARM ....................................................................................... 45
11.1 DISASSEMBLY/REASSEMBLY ...................................................................................... 45
11.2 INSPECTION .................................................................................................................. 46
12. CRANKCASE COVER/CAMSHAFT DRIVE CHAIN ............................................................. 47
12.1 DISASSEMBLY ............................................................................................................... 47
12.2 CRANKCASE OIL TRAY ASSEMBLY AND DISASSEMBLY ........................................... 47
12.3 CRANKSHAFT INSTALLATION ...................................................................................... 48
12.4 CRANKCASE COVER ASSEMBLY ................................................................................ 49
12.5 INSPECTION .................................................................................................................. 49
13. CRANKSHAFT/PISTON AND CONNECTING ROD ............................................................. 52
13.1 DISASSEMBLY ............................................................................................................... 52
13.2 PISTON ........................................................................................................................... 53
13.3 INSPECTION .................................................................................................................. 54
iv
1. SPECIFICATIONS and WIRING DIAGRAM
1.1 SPECIFICATIONS
Dimensions and weights
Model
IG1000
Overall Length in (mm)
18.1 (460)
Overall Width in (mm)
9.8 (248)
Overall Height in (mm)
15.6 (395)
Net Weight in (Kg)
30.8 (14)
Engine
Model
KG144
Type
4-stroke,OHV, single cylinder, Gasoline engine
Displacement cu in. (cc)
3.3 (53.5)
Maximum horsepower/rpm
1.3/5500
Compression ratio
8.5:1
Cooling system
Forced air-cooled
Ignition system
T.C.I
Ignition timing
29°B.T.D.C
Spark plug
UR5
Carburetor
Float type, Horizontal, butterfly valve type
Air cleaner
Semi-dry type
Governor
Electronic control
Lubrication system
Forced splash
Oil capacity qt (L)
.19 (0.22)
Starting system
Recoil starter
Stopping system
Primary circuit ground
Fuel
Automotive unleaded gasoline 87 octane
Model
KD10
Generator type
Multi pole rotation
Generator structure
Self-ventilation drip-proof alternator
Excitation
Self-excitation (Magnet type)
Voltage regulation system
Plush width modulation
Phase
Three phase
Rotating direction
Clockwise (Viewed from the generator)
Frequency regulation
AC-DC-AC conversion
Alternator
1
Performance
Model
IG1000
Maximum output AC
1.0KVA
Rated output AC
0.9KVA
Rated output DC
100W
Rated frequency
60HZ
Rated voltage AC
120V
Rated voltage DC
12V
Rated current AC
7.5A
Rated current DC
8.3A
Power factor
Voltage variation rate
1.0
Momentary
10%max.
Average
1.5%max.
Average time
3 sec. max.
Voltage stability
±1%
Frequency variation rate Momentary
1%max.
Average
1%max.
Average time
1 sec. max.
Frequency stability
±0.1%
Insulation resistance
10MΩ min.
AC circuit protector
8.8 A
DC circuit protector
10 A
Fuel tank capacity-gal (L)
.69 (2.6)
Operating hours
4
Noise level NL-FL @ 23’ (7 m)
60-65 dB
2
1.2 WIRING DIAGRAM
3
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 generator. Any error
or oversight made by the technician while servicing can easily result in faulty operation and/or damage to
the equipment or injury to the operator.
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 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:
- Carbon monoxide poisoning from engine exhaust.
- Burns from hot parts.
- Injury from moving parts.
•
Do not run the engine unless the instructions tell you to do so. Keep your hands
and clothing away from rotating parts.
•
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.
4
2.3 Service rules
•
Use genuine KIPOR or KIPOR-recommended parts and lubricants or their equivalents. Parts that
do not meet Kipor’s design specifications may damage the engine.
•
Use the special tools designed for the product.
•
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.
2.4
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.
•
Set 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.
•
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.
5
•
If a wire 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.
•
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.
•
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
The generator serial number identifies your particular unit and is important when ordering parts and
accessories. The bar code is used by your dealer and Coast Distribution for warranty administration. It
identifies the date of manufacture. In this example, 060313 indicates the generator was manufactured on
June 6, 2006.
The generator serial number is stamped on the engine block to the right of the oil dipstick.
The bar code label is placed on the bottom of the generator. It is additionally found on the inside cover of
the operator’s manual and on the carton.
6
2.6 Maintenance standards
Part
Item
Engine
Maximum speed without load
Cylinder
Sleeve I.D.
Skirt O.D
Piston
Pin bore I.D.
Piston pin
O.D
Height
Ring side clearance
1st ring
Ring end clearance
Width
Height
Ring side clearance
Piston ring
2nd ring
Ring end clearance
Width
Height
Ring side clearance
Oil ring
Ring end clearance
Width
Small end I.D
Connecting
rod
Big end I.D
Crankshaft
Valves
Crank pin O.D.
Valve
clearance
Stem O.D.
Intake
Exhaust
Intake
7
Standard(mm)
Service limit
5500±100 rpm
—
1.712-1.714 in
43.500-43.520 mm
1.711-1.712 in
43.460-43.480 mm
0.3937-0.3940 in
10.002-10.008 mm
0.3934-0.3937 in
9.994-10.000 mm
0.030-0.031 in
0.77-0.79 mm
0.0008-0.0024 in
0.02-0.06 mm
0.0039-0.0098 in
0.10-0.25 mm
0.063-0.071 in
1.60-1.80 mm
0.038-0.039 in
0.97-0.99 mm
0.0008-0.0024 in
0.02-0.06 mm
0.0039-0.0098 in
0.10-0.25 mm
0.071-0.078 in
1.80-2.00 mm
0.053-0.058 in
1.35-1.48 mm
0.0008-0.0067 in
0.02-0.17 mm
0.0079-0.1180 in
0.20-0.30 mm
0.3942-0.3946 in
2.00-2.40 mm
0.3942-0.3946 in
10.012-10.024 mm
0.5911-0.5915 in
15.015-15.025 mm
0.5896-0.5899 in
14.975-14.985 mm
0.0031-0.0039 in
0.08-0.10 mm
0.0039-0.0059 in
0.10-0.15
0.156-0.157 in
1.716 in
43.595 mm
1.707 in
43.350 mm
0.3955 in
10.050 mm
0.3920 in
9.950 mm
0.028 in
070 mm
0.0059 in
0.15 mm
0.0314
0.80 mm
0.055 in
1.40 mm
0.0354 in
0.90 mm
0.0059 in
0.15 mm
0.0314
0.80 mm
0.063 in
1.60 mm
0.049 in
1.25mm
0.0090 in
0.23 mm
0.0354 in
0.90 mm
0.3965 in
1.80 mm
0.3965 in
10.070 mm
0.5937 in
15.080 mm
0.5866 in
14.900 mm
--------0.1535 in
Exhaust
Valve spring
Guide I.D.
IN/EX
Free length
IN/EX
Cam wheel
Cam height
O.D
Camshaft
Camshaft bearing I.D.
I.D(Rocker arm)
Rocker arm
O.D.(Rocker arm shaft)
I.D.(Rocker arm shaft bearing)
Spark plug
Ignition coil
Gap
Primary side
Second side
Resistance
Air gap
Pulse coil
(Trigger)
Resistance
3.965—3.980 mm
0.1557-0.1562 in
3.955—3.970 mm
0.1575-0.1579 in
4.000—4.012 mm
0.925 in
23.5 mm
1.101-1.103 in
27.97-28.03 mm
0.1963-0.1967 in
4.988-4.996 mm
0.1976-0.1988 in
5.02-5.05 mm
0.1575-0.1579 in
4.000-4.012 mm
0.1574-0.1579 in
3.988-3.996 mm
0.1574-0.1579 in
4.000-4.012 mm
0.024-0.028 in
0.6—0.7 mm
0.8—1.3 Ω
15 —21 kΩ
0.020-0.0295 in
0.5-0.75 mm
80~130Ω
3.900 mm
0.1540 in
3.900 mm
0.2598 in
4.060 mm
0.866 in
22 mm
1.062 in
26.97 mm
0.1949 in
4.950 mm
0.2008
5.10 mm
0.2598 in
4.050 mm
0.1590 in
3.950 mm
0.1594 in
4.050 mm
—
—
—
—
—
—
—
Part
Item
Type
Standard (Ω)
Ignition winding
Outer charging
winding
Sub winding
Main winding
Resistance
Green-Yellow/Green
0.50-0.70
Resistance
Blue--Blue
0.16-0.20
Resistance
Resistance
White—White
Black—Black
0.25-0.35
2.0-3.0
2.7 Torque values
Item
Specification
Connection rod bolt
Spark plug
Flywheel nut
M5X0.8X25
M10X1.0X13
M10X1.25
M5 Bolt, nut
Tightening torque
Ft lb.
N·m
5.9-7.4
8-10
11-13
48-52
4.4-6.0
6-8
M6 Blot, nut
5.9-7.4
Standard torque
Note: Use standard torque values for fasteners that are not listed in this table.
8
8-10
3. Troubleshooting
This troubleshooting section contains troubleshooting trees organized by common groups of symptoms.
Some testing information is contained in these sections. The following chapters of this manual focus on
individual components and sub assemblies which will give you the assembly and reassembly
procedures along with detailed specifications and testing procedures.
3.1 General symptoms and possible causes
Engine does
not start or
hard starting
Engine speed
does not
stabilize, too
high or too low
Fuel filter clogged
Clean
Fuel tank tube clogged
Clean
Fuel switch clogged
Clean
Carburetor faulty
Readjust and clean
Ignition coil faulty
Inspect and replace
Spark plug faulty
Inspect and replace
Trigger faulty or trigger clearance
Inspect and replace
faulty
Spark plug cap looses
Fix it securely
Low oil alarm faulty
Inspect and replace
Ignitor faulty
Inspect and replace
Ignition winding faulty
Inspect and replace
Throttle opening fault
Set in fully close or half close position
Carburetor faulty
Adjust and/or disassemble and clean
Throttle control motor (stepping
Inspect and replace
motor) faulty
Inverter unit faulty
Inspect and replace
Valve clearance misadjusted
Readjust
9
3.2 Hard starting
No fuel
Check the fuel level in the tank.
Add fuel and restart the engine.
Sufficient fuel
Loosen the drain screw and
check whether fuel reached the
float chamber and the oil level.
Abnormal
Check the fuel lines for blockage.
Normal
Dry
Remove the spark plug and
check for wet or fouled electrode.
Check for blockage in the carburetor
intake port and nozzle.
Clean the electrode and restart,
Ensure the choke is not closed. If
flooding is severe, check the
carburetor float valve.
Wet
No spark or
Install the spark plug and ground weak spark
the electrode. Check the spark.
Perform
the
troubleshooting
ignition
system
Normal
Install a compression gauge in
the spark plug hole and check the
cylinder compression by pulling
the recoil starter rope several
times
Low cylinder
compression
1. Check the valve clearance
2. Check for carbon deposits in the
combustion chamber.
3. Check for worn guides and seals.
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
80 psi/0.55Mpa
10
C. Ignition system
■ Fill in oil to the demanded level.
■ Use the genuine spark plug A7RTC.
■ Spark plug inspection
1. Disassemble spark plug
2. Install spark plug onto spark plug cap.
3. Set the oil switch to the “ON” 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. Normally you
should see the spark jump the electrode gap when the plug is firing.
■ Don’t pull the recoil starter while touching the high tension wire with wet hands. High voltage
generates, which is very dangerous.
■ Fire may be caused if fuel spilled around the spark plug, so make sure that you test after draining off
fuel completely.
■ Fuel inside cylinder will be burnt if the spark plug is near the hole, so please turn off the engine first.
Pull the recoil starter several times to release the unborn gas in the cylinder.
11
3.2 Hard Starting Continued
Measure the spark plug gap and
perform the spark plug test. Gap:
024-028 in (0.6—0.7mm)
No spark
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
spark test with a new ignition module.
Replace the ignition module
No spark
Check the engine switch
Good spark
Replace the engine switch
No spark
Disconnect the low oil alarm and
perform spark test
Good spark
Replace the low oil alarm
No spark
Check the resistance of motor
ignition winding
Abnormal
Replace the motor stator
Normal
Check the trigger
Abnormal
Normal
Check the ignition coil resistance
and high pressure cable, high
pressure insulation cap.
Replace the trigger or readjust
trigger clearance
Abnormal
Replace the ignition coil
Normal
Inspection or replace wire harness.
12
3.3 Engine oil level is low, but engine does not stop. (Defective oil switch)
Drain out oil completely, disconnect alarm No continuity
connection wire, and check the continuity
Replace the oil level alarm
between alarm outlet terminal and ground.
Continuity
Reset the alarm connection wire, disconnect No continuity
Repair or replace the wire
ignition module and check the continuity
harnesses
between the plug orange wire and ground.
Continuity
Ignition module fault: replace module.
3.4 Engine stops running (Throttle is at the correct position)
Check the oil level and oil alarm
Oil alarm
Fill in oil and restart the engine
Sufficient oil
Check whether there is enough fuel in the
fuel tank.
No fuel
Add fuel and restart the engine
Sufficient fuel
Check the fuel switch and fuel filter for
blockage
No blocked
Check the fuel supply line for blockage
Blocked
Clear the fuel switch and fuel
filter
Blocked
Clear or replace the fuel supply
line
No blocked
Check the carburetor nozzles for blockage
Blocked
Clean or replace carburetor
Not blocked
Check seal between inlet gasket and
carburetor heat insulation block
Abnormal
Normal
Measure the cylinder compression
Abnormal
Normal
Check the trigger clearance
Abnormal
Normal
Perform the throttle control system test
13
Tighten
gasket.
nuts
and/or
replace
1. Check the valve clearance
2. Check the carbon deposit in
combustion chamber
3. Check the piston, piston ring
and cylinder for damage
Readjust the trigger clearance
3.5 Engine speed can’t increase or unstable (choke is at the correct position)
Blocked
Check the air filter element for blockage
Clear the air filter element
No blocked
Abnormal
Check the valve clearance
Readjust the valve clearance
Normal
Remove the spark plug and check the
electrode clearance for carbon deposit
Abnormal
Clear electrode, adjust clearance
or replace the spark plug
Normal
Check the
blockage
carburetor
and
nozzle
for
Blocked
Disassemble and clear
No blockage
Check sealing of inlet line papery gasket and
carburetor heat insulation block
Abnormal
Normal
Measure the cylinder compression
Abnormal
Normal
Screw the nut, and replace the
papery gasket or heat insulation
block
1. Check the valve clearance
2. Check for carbon deposits
in combustion chamber
3. Check the piston, piston ring
and cylinder for damage
Perform the throttle control system test
3.6 Engine speed too high or too low
Check the AC output
Abnormal
Perform the generator
troubleshooting following the
section onf “No or low AC output”
Normal
Check the throttle control motor
Abnormal
Normal
Replace the inverter unit
14
Replace the throttle control motor
3.7 Smart system doesn’t work with zero load or engine speed doesn’t increase with Smart
system on and load connected.
Check the AC output
Abnormal
Perform the generator
troubleshooting following the
section on “No AC or low voltage”
Normal
Check the throttle control motor
Abnormal
Replace the throttle control motor
Normal
Check the Smart Throttle switch
Abnormal
Replace the smart Throttle switch
Normal
Check Smart switch connection wire
Abnormal
Repair or replace the wire harness
Normal
Replace the inverter unit
3.8 No or low AC output
Is the overload indicator light ON?
ON
Disconnect the load, and restart the
engine
OFF
Is the engine speed normal?
Smart switch
ON: 4200±100rpm
OFF:5500±100rpm
Abnormal
Perform the throttle control system
test
Normal
Stop the engine and check the AC
receptacle
Abnormal
Replace the AC receptacle
Normal
Disconnect the main winding and sub
winding (CG) 6p connector on inverter
unit. Start the generator and measure
the voltage between pins 1&4, 2&4, 1&2.
Each reading should be at least 290
volts.
Abnormal
Normal
Replace the inverter unit
15
1. Check and repair stator wiring
harness or replace stator
2. Check rotor magnetism. If
decreasing, replace the rotor
3.9 No DC output
Check the engine speed
Normal
Abnormal
Perform the throttle control system
troubleshooting
Abnormal
Check the DC receptacle
Replace the DC receptacle
Normal
Check the 5 amp fuse
Normal
Check the rectifier
Abnormal
Abnormal
Replace the fuse
Replace the rectifier
Normal
Measure the resistance
between the two blue wires
on the rectifier.
Resistance: 0.16-0.20Ω
Abnormal
Normal
The rotor loses excitation,
replace the rotor
16
Check and repair the wiring
harness or replace the
stator
4. Maintenance
4.1 Maintenance schedule
Regular service period
Item perform at every indicated
month or operating hour interval,
Each use
whichever comes first
Engine Oil
Air filter
Check
Every 3
Every 6
Every
month or
months or
months or
year or
20 Hrs.
50Hrs.
100 Hrs.
300 Hrs.
●
Replace
Check
First
●
●
●
Clean
●*
Spark plug
Clean-Adjust
●
Spark catcher
Clean-Adjust
●
Valve clearance
Check-Adjust
●**
Fuel tank and filter
Clean
●**
Fuel line
Check
Every 2 year (Replace if necessary)
Note:
* Service more frequently when operating in dusty areas.
** Service by KIPOR authorized service center.
4.2 Engine oil
■ Checking for the oil level
Stop the engine and check the oil level, be sure to put the engine on a flat and level surface when
checking.
1. Loosen the maintenance cover screw and remove the cover.
2. Remove the oil filler cap and check the oil level.
17
3. If the oil level is low, add to the edge of the oil filler port.
■ Replace the engine oil
1. Remove the oil dipstick and oil drain bolt, drain out dirty oil.
2. Reinstall the oil drain bolt tightly.
3. Fill with fresh oil of the proper viscosity (see operator’s manual).
4. Check the oil level.
5. Tighten the oil dipstick.
■ Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Avoid burns from
hot oil.
4.3 Checking the 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.
18
2. Stop engine, disconnect oil alarm connector, check the connector conduction, no conduct is normal.
3. Drain out the oil inside engine and check the conduction, conduct is normal.
4.4 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 and allow to dry.
5) Dip the element in clean engine oil and squeeze out all the excess oil.
6) Install the air cleaner element in the air cleaner case.
Clean the air cleaner rubber and the air cleaner case if necessary. Be sure that the air cleaner cover
seals are set securely.
7) Install the air cleaner cover. Be sure that the air cleaner cover seals are set securely.
8 Install the maintenance cover securely.
19
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 with no element or a damaged element. Engine damage will result.
4.5 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 accord with the asked valve.
Spark plug resistance
20
3~9KΩ
4) Measure the plug gap with a wire-type feeler gauge. Adjust by bending the side electrode if the
measure is not accord with the asked valve.
Spark plug clearance
.024-.028 in. (0.6~0.7mm)
Standard spark plug
A7RTC
0.6-0.7
5). Install the plug finger tight to seat the washer, and then tighten with a plug wrench.
Torque valve is 8.-~9.6 ft lbs, 11~13 N.m
4.6 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
21
2) Remove the four tighten bolts and disassemble the cylinder cover. Don’t remove the cylinder cover
with excessive force as it may deform. Replace the cylinder cover if it is deformed.
3) Remove the spark plug; screw the dial indicator in the spark plug hole. Rotate the rotor in a clockwise
movement and set the piston at top dead center.
Caution
■ Make sure both the intake and exhaust valves are closed.
22
4) Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance.
Valve clearance
Intake
.0031-.0039 in (0.08-0.10mm)
Exhaust
.0039-.0059 in (0.10-0.15) mm
5) If adjustment is necessary, proceed 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.
23
6) Clean the liquid gasket of the cylinder block and cylinder head cover. Apply liquid gasket (Three Bond
1207B or equivalent) to the cylinder block installation surface as shown.
7) Install all parts in the reverse order of removal.
4.7 Fuel tank/Fuel filter
Caution
■ 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 filter if necessary.
4) Remove the fuel tank and clean it with cleaning 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 tube for gasoline leakage.
24
4.8 Fuel pump and hoses
Caution
■ 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) Make sure the negative pressure tube is firmly connected to the port on the engine block. See page
37.
3) Check the fuel tube for deterioration, cracks and gasoline leakage. If there is any abnormality in the
fuel tube, replace the tube.
4) Check the diaphragm tube for deterioration, crack and oil leakage. If there is any abnormality in the
diaphragm tube, replace the tube.
5) 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.
6) Check the fuel switch and fuel duct, blow away the foreign matter with high pressure gas with oil
switch turned on.
7) After assembly, check for gasoline leakage from each part.
25
4.9 Spark arrestor
Caution
■ Make sure the muffler has cooled completely before attempting any maintenance on this part.
(1) Remove the rear cover
(2) Disassemble the arrestor from muffler
(3) Remove the carbon from the spark arrestor steel mesh with a stiff wire brush. Check for damage and
replace it if necessary.
(4) Install the removed parts in the reverse order of removal.
26
5. Muffler
Caution
■ Muffler removal/installation must be performed with the engine cold.
● Disassembly/Reassembly
27
6. Air filter/Carburetor
Caution
■ Loosen the drain oil bolt and drain out fuel before disassembly.
■ Keep heat, flame and sparks away.
6.1 Air filter removal and installation
6.2 Carburetor removal and installation
28
6.3 Stepping motor removal and installtion
29
6.4 Carburetor exploded drawing
Note: With the exception of changing the main jet for altitude compensation, no adjustments to
this carburetor are permitted under EPA and CARB guidelines. No repair parts will be furnished.
Fork
拨叉
拨叉弹簧
Fork spring
阻风门杆
Choke valve
阻风门片
Choke plate
怠速调整限位帽
Idle
adjusting cap
(Fixed)
Carburetor block
本体
混合比调节螺丝
Idle mixture
screw (fixed)
出厂前位置已确
定,不可调节
Needle seat
针座
泡沫管
组装:
Foam tube
先用压缩空气清除通
路中的脏物再安装。
注意安装方向。
控油针
组装:
Oil control needle
先对端部的磨损、弹簧的动
作进行检查,再进行安装。
控油针弹簧
Oil control needle spring
主量孔
Seal ring of oil cup
油杯密封圈
组装:
先用压缩空气
Main jet
清除通路中的
脏物再安装。
浮子销
Float pin
浮子
组装:
Float
安装后应当用手指触
动,对其动作确认。
油杯
Bowl
油杯锁紧螺丝密封圈
Sealing ring
油杯放油螺栓
组装:
安装后确认没有燃油
漏出。
Carburetor drain bolt
油杯螺栓
组装:
安装后确认没有燃油
漏出。 Bowl bolt
30
6.5 Inspection
● Float height
Place the carburetor as the picture shows, measure the float height between float and carburetor block.
Height
0.0047 in (12mm)
Replace the carburetor if the float height is not the right size.
● Stepping motor
Measure the resistance of stepping motor lead-out wire.
Standard resistance
Between 1and 3:45~55Ω
Between 2 and 4:45~55Ω
Replace the stepping motor if the resistance excesses the above range.
31
1
2
4
3
7. Control panel
7.1 Removal/Installation
32
7.2 Inspection
a. Control panel
● AC receptacle
Check the electrode contact disk inside receptacle; if it is burnt or discolored, replace for it.
● DC receptacle
After checking the fuse, 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.
● Ignition Module
Pull off the 10P receptacle from the module, measure the resistance by connecting one testing pen with
the metal outer case of engine, and the other testing pen with the 10P connector.
Color
Circuit unit
Standard resistance
Blue
Primary coil of the ignition coil
0.8-1.3Ω
Orange
Oil level alarm
Yellow
Trigger coil
80-130Ω
Yellow/Green
Ground wire
Continuity
Green
Igniter unit power coil winding
0.5-0.7Ω
Red
Engine switch
There should be no continuity with correct
oil level
There should be no continuity with the
switch ON, continuity with the switch OFF
33
● Engine switch
Check the continuity of connector, there should be continuity when the micro switch is depressed.
● Rectifier
Measure the on or off (positive pressure fall) of rectifier with control potentiometer
measurement should accord with the standard as shown in the chart.
Positive
Negative
1
1
2
3
4
OFF
OFF
OFF
OFF
OFF
2
ON
3
ON
ON
4
ON
OFF
ON
OFF
34
, the
8. Housing / Fuel tank
8.1 Housing disassembly and reassembly
● Left housing case
35
8.2 Fuel tank assembly
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.
]
36
9. Recoil starter/ Air conduct cover/ Ignition coil/ Air conduct plate
9.1 Disassembly/Reassembly
37
9.2 Air conduct plate
Disassembly/ Reassembly
38
9.3 Disassembly and reassembly of recoil starter
(1) Set the spring into the starter reel, and hang the spring outer hook inside the reel groove.
39
(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.
(3) Make a “8” knot at one end of the rope, pass the other end through the reel hole. Wind the reel
anticlockwise 6 turns to fix the reel.
40
(4) Pull rope through from starter outer shell hole completely; pass it through the handle and make a
figure eight knot, then turn off handle cover. Loosen the reel to release tension on the spring taking care
not to allow the reel to pop out.
(5) Install the revolving axis, revolving axis parts and friction spring, fix it with bolts.
(6) Pull the starter for several times, and check the revolving axis.
41
9.4 Ignition Coil
● Attach the two leads of tester to the primary coil plug of ignition coil, and measure the primary
resistance of the ignition coil.
Primary resistance
0.8—1.3Ω
● Attach one lead of the tester 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
42
15—21kΩ
10. Alternator/Trigger
10.1 Alternator
Disassembly/Reassembly
10.2 Inspection
(1) Ignition winding
Measure the resistance between the green terminal and yellow/green terminal.
Resistance
0.50-0.70Ω
(2) Outer charging winding
Measure the resistance between the two blue terminals.
Resistance
0.12-0.15Ω
(3) Sub winding
Measure the resistance between the two sub winding terminals.
Resistance
White-white
0.25~0.35Ω
(4) Main winding
Measure the resistance among the terminals of the main winding.
Resistance
Black-black-black
2.0~3.0Ω
43
(5) Trigger
Attach the two test leads to the trigger and measure the resistance.
Trigger resistance
80-130 Ω
10.3 Trigger adjustment
Adjust the clearance between trigger and the projection part of rotor.
Trigger clearance
0.0197-0.0275 in (0.50-0.75 mm)
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, to avoid it separates from
the fixed plate and damages the trigger.
44
11. Cylinder cover/ Rocker arm
11.1 Disassembly/ Reassembly
45
11.2 Inspection
● Rocker arm outer diameter
Standard in (mm)
Service limit in (mm)
0.1570-0.1573 (3.988-3.996)
0.1555 (3.950)
● Rocker arm inner diameter of inlet/exhaust valve
Standard in (mm)
Service limit in (mm)
0.1575-0.1579 (4.000-4.012)
0.2598 (4.050)
● Inner diameter of rocker arm bearing
Standard in (mm)
Service limit in (mm)
0.1575-0.1579 4.000-4.012
0.2598 in 4.050
46
12. Crankcase cover/ Camshaft drive chain
12.1 Disassembly
12.2 Crankcase oil tray disassembly and reassembly
1. Clean any remaining gasket material from the cylinder block and crankcase oil tray.
47
2. Apply a 0.040~0.059 in (1~1.5 mm) layer of liquid gasket material [1207B or equivalent] evenly on the
sealing face of the crankcase oil tray.
3. Reassemble the crankcase cover in the reverse order of disassembly.
Caution
Make sure to reassemble the crankcase oil tray three minutes after applying the gasket material.
12.3 Crankshaft reinstallation
1. Revolve the crankshaft slowly, placing the timing mark pointing up.
2. Install the valve tappet, move the tappet aside and then reassemble the camshaft. Note that the timing
mark on the camshaft and driving gear should be oriented downward and aligned with the timing mark
on the timing gear.
48
12.4 Crankcase cover assembly
1. Remove any remaining gasket material on the cylinder block and crankcase cover.
2. Apply a 0.040~0.059 in (1~1.5 mm) layer of liquid gasket material [1207B or equivalent] evenly on the
cylinder block sealing face.
3. Reassemble the crankcase cover in the reverse order of disassembly.
Caution
Install the crankcase cover on the cylinder block 3 minutes after applying the gasket material.
4. Screw on the crankcase cover bolts slowly and tighten to the prescribed torque.
12.5 Inspection
● Inspection of the oil alarm
(1) Place the oil alarm in the position shown below. There should be no continuity between the oil alarm
output wire and copper ground wire.
(2) Turn the oil alarm 180° and check again; there should be continuity.
(3) Immerse the oil alarm completely in oil; check the float- there should be no continuity.
Caution: Wait two minutes after immersing the alarm in oil before measuring.
49
● Cam height
Standard in (mm)
1.101-1.103 (27.97-28.03)
Service limit in (mm)
1.062 (26.97)
● Cam inner diameter
Standard in (mm)
0.1976-0.1988 (5.02-5.05)
Service limit in (mm)
0.2008 (5.10)
● Camshaft outer diameter, tappet shaft outer diameter
Standard in (mm)
0.1963-0.1967 (4.988-4.996)
Service limit in (mm)
0.1949 (4.950)
50
●Valve tappet inner diameter
Standard in (mm)
Service limit in (mm)
0.1968-0.1975 (5.000~5.018)
0.1988 (5.050)
51
13. Crankshaft/ Piston
13.1 Disassembly/Reassembly
52
13.2 Piston
Assembly of piston ring
Caution
● Set the manufacture label up.
● Pay careful attention not to mix the location of the 1st ring and 2nd ring.
● Check the piston ring for flexibility after installation.
● Stagger each piston ring opening 120°apart.
53
● There may be two different kinds of piston rings for the same model generator. They can be
distinguished by different manufacture labels. Don’t intermix piston rings of different manufacture on the
piston.
13.3 Inspection
● Free length of valve spring
Standard in (mm)
Service limit in (mm)
0.925 (23.5)
0.866 (22)
54
● Valve stem outer diameter
Standard in (mm)
Service limit in (mm)
Intake valve
0.156-0.157 (3.965-3.980)
0.1535 (3.900)
Exhaust valve
0.1557-0.1562 (3.955-3.970)
0.1535 (3.900)
● Valve guide pipe inner diameter
Standard in (mm)
Intake/Exhaust valve 0.1575-0.1579 (4.000-4.012)
Service limit in (mm)
0.2598 (4.060)
● Clearance between valve stem and valve guide pipe
Standard in (mm)
Service limit in (mm)
Intake valve
0.0008-0.0018 (0.020-0.047)
.0039 (0.10)
Exhaust valve
0.0012-0.0022 0.030-0.057
.0047 (0.12)
55
● Cylinder inner diameter
Standard in (mm)
Service limit in (mm)
1.712-1.714 (43.500-43.520)
1.716 (43.595)
● Piston skirt outer diameter
Standard in (mm)
Service limit in (mm)
1.711-1.712 (43.460-43.480)
1.707 (43.350)
● Clearance between piston and cylinder
Standard in (mm)
Service limit in (mm)
0.0008-0.0024 (0.02-0.06)
.0047 (0.120)
56
● Piston skirt outer diameter
Standard(mm)
Service limit(mm)
57.960-57.980
57.850
● Clearance between piston and cylinder
Standard in (mm)
Service limit in (mm)
0.0078-0.0165 0.020-0.042)
0.0047 (0.120)
● Side clearance of piston ring
Standard in (mm)
Service limit in mm)
0.0008-0.0024 (0.02-0.06)
0.0059 (0.15)
● Piston ring end clearance
Locate the piston ring into cylinder with piston top, and measure the piston end clearance.
Standard in (mm)
Service limit in (mm)
0.0059-0.0098 (0.15-0.25)
0.0394 (1.0)
57
● Piston ring height
Standard in (mm)
Service limit in
(mm)
st
The 1 ring
The 2
nd
ring
0.0030-0.031 (0.77-0.79)
0.028 (0.70)
0.038-0.039 (0.97-0.99)
0.0354 (0.90)
● Piston pin outer diameter
Standard in (mm)
Service limit in (mm)
0.3934-0.3937 (9.994-10.000)
0.3920 9.950
● Piston pin bore inner diameter
Standard in (mm)
Service limit in (mm)
0.3937-0.3940 (10.002-10.008)
0.3955 (10.050)
58
● Clearance between piston pin and piston pin hole
Standard in (mm)
Service limit in (mm)
0.00008-0.00055 (0.002-0.014)
0.00314 (0.080)
● Connecting rod small end inner diameter
Standard in (mm)
Service limit in (mm)
0.3942-0.3946 (10.012-10.024)
0.3965 (10.070)
● Connecting rod big end inner diameter
Standard in (mm)
Service limit in (mm)
0.5911-0.5915 (15.015-15.025)
0.5937 (15.080)
59
● Crankshaft neck outer diameter
Standard in (mm)
Service limit in (mm)
0.5896-0.5899 (14.975-14.985)
0.5866 (14.900)
● Connecting rod big end side clearance
Standard in (mm)
Service limit in (mm)
.0039-.0236 (0.1-0. 6)
0.0315 (0.8)
60
● Oil film clearance of connection rod big end
(1) Wipe all oil from the surface of the crankshaft neck.
(2) Set the plastic wire feeler at the crankshaft neck and install the connecting rod. Tighten the bolt to the
prescribed torque being careful not to rotate the crankshaft. The tightening torque is 5.9-7.4 ft lb. (8-10
N.m).
(3) Disassemble the connecting rod and measure the plastic wire feeler thickness.
(4) Replace the connecting rod if the clearance exceeds the service limit.
Standard in (mm)
Service limit in (mm)
0.0012-0.0019 0.030-0.050
0.0039 0.10
61
●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (cylinder block)
Service limit in
Standard in mm)
0.1976~0.1988 (5.02~5.05)
(mm)
0.2008 (5.10)
●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (gear case cover)
Service limit in
Standard in mm)
0.1976~0.1988 (5.02~5.05)
(mm)
0.2008 (5.10)
62
● Bearing vibration
Clean the bearing and dry it. check the clearance between crankshaft journal and connecting rod big end
by rotating the
bearing by hand. Replace the bearing if there is abnormal noise or vibration.
63