Preface

This manual covers the construction, function and servicing procedure of the KIPOR
IG3000X/E generators. This manual is principally concerned with the generator
specifications, function, troubleshooting and repair. There is a separate manual to cover
engine overhaul which includes the starting systems.

Careful observance of the instructions contained in this manual will result in safe and
quality service work.

All information, illustrations, directions and specifications included in this publication are
based on the latest product information available at the time of approval for printing.

WUXI KIPOR POWER CO., LTD, reserves the right to make changes without incurring
any obligation whatever. No part of this publication may be reproduced without written
permission.
______________________________________________________________________

Table of Contents
______________________________________________________________________

1. Specifications ………………………………………………………………………………. 3
1.1 Specifications …………………………………………………………………………… 3
1.2 Characteristics ………………………………………………………………………….. 4
1.3 Performance curves ……………………………………………………………………. 5
1.4 Dimensional drawings ………………………………………………………………….. 6
1.5 Wiring diagram ……………………………………………………………………………7
2. Service information …………………………………………………………………………..9
2.1 The importance of proper servicing…………………………………………………… 9
2.2 Important safety precautions ………………………………………………………….. 9
2.3 Service rules …………………………………………………………………………….10
2.4 Electrical Precautions …………………………………………………………………..10
2.5 Serial number location. …………………………………………………………………11
2.6 Maintenance standards ……………………………………………………………….. 12
2.7 Torque values …………………………………………………………………… ……..13
2.8 Troubleshooting ……………………………………………………………………….. 14
3. Maintenance ……………………………………………………………………………….. 21
3.1 Maintenance schedule…….. …………………………………………………………. 21
3.2 Engine oil. ………………………………………………………………………………. 22
3.3 Inspection of oil alert switch.
…………………………………………………………...23
3.4 Air filter maintenance …………………………………………………………………..24
3.5 Sparkplug service ………………………………………………………………………25
3.6 Adjusting of valve clearance …………………………………………………………..26
3.7 Fuel filter and fuel switch maintenance ………………………………………………27
4. Air filter and Muffler. ………………………………………………………………………..
28
4.1 Air filter. …………………………………………………………………………………..28
4.2 Muffler…………………………………………………………………………………….29
5. Carburetor……………………………………………………………………………………30
5.1 removal and installation..……………………………………………………………..30
5.2 Stepping Motor disassembly and reassembly………………………………………..31
5.3 Carburetor disassembly and reassembly……………………………………………..32
5.4 Inspection………………………………………………………………………………...33
6. Control panel, charging adjustor and inverter unit …………………………………….34
6.1 Assembly and disassembly…………………………………………………………….34
6.2 Inspection………………………………………………………………………………...34
7. Housing group , fuel tank………………………………..………………………………….37
8. Generator, ignition coil and trigger ………………………………………………………..38
8.1 Generator…………………………………………………………………………………38
8.2 ignition coil and

1
 trigger…………………………………………………………………..39

9. Recoil starter/ Air guiding cover…………………………………………………………41

9.1 Disassembly and reassembly……………………………………………………….41
9.2 Assembly of recoil starter...........................………………………………………..42
10. Start motor……………………………………………………………………………….44
10.1 Removal and reinstallation…………………………………………………………44
10.2 Disassembly and reassembly……………………………………………………...44
10.3 Inspection…………………………………………………………………………….45
11. Cylinder cover/ valve…………………………………………………………………….48
11.1 Disassembly and reassembly……………………………………………………..48
11.2 Inspection……………………………………………………………………………50
12. Crankcase cover, crankshaft, camshaft and piston…………………………………..52
12.1 Remove and assembly……………………………………………………………..52
12.2 Check…………………………………………………………………………………55

2
______________________________________________________________________

1. SPECIFICATIONS
_________________________________________________________________________________________________________　

1.1 SPECIFICATIONS

Dimensions and weights

Model IG3000X/E
Length 491mm
Width 410mm
Overall height 425mm
Net weight 36kg/40kg

Engine
Model KG205GXi/KG205GEXi
Type 4-stroke,overhead valve, single cylinder
Displacement（cm3） 196
Bore x stroke (mm) 68×54
Horsepower （KW）/rpm 4.0 /3600 rpm
Compression ratio 8.5:1
Cooling system Forced air
Ignition system T.C.I
Ignition timing 25 B.T.D.C
Spark plug F7RTC
Carburetor Float type, horizontal butterfly valve

Air cleaner Semi-dry

Governor Electronic control
Lubrication system Forced splash
Oil capacity 0.6L
Starting system Recoil starter /Recoil starter and Electrical

3
 starter
Stopping system Primary circuit ground
Fuel Automotive unleaded gasoline
8.7L
Fuel tank capacity
Fuel consumption (g/kw.h) 480
(at rated load)

Alternator
Model KD 30/KD35
Generator type Multi pole rotation type
Generator structure Self-ventilation drip-proof type
Excitation Self-excitation (Magnet type)
Voltage regulation system PWM(Plush width modulation)
Phase Three phase
Rotating direction Clockwise (Viewed from the generator)
Frequency regulation AC-DC-AC conversion (Inverter type)

1.2 CHARACTERISTICS

Model IG3000X/E
Maximum output (AC) 3.0KVA
Rated output (AC) 2.8KVA
Rated output (DC) 144W
Rated frequency 50Hz 60Hz 60Hz
Rated voltage (AC) 230V 120V 240V
Rated voltage (DC) 12V
Rated current (AC) 12.2A 23.3A 11.7A
Rated current (DC) 12V
Power factor 1.0cosφ
Voltage variation rate- 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 13.5A(230V) 26A(120V) 13A(240)
DC circuit protector 14A
Operating hours at rated load 4.7 Hours

4
Noise level 68~78dB(A)/7m

1.3 PERFORMANCE CURVES

The curves show performance of the generator under average conditions.

Performance may vary to some degree depending on ambient temperature and
humidity.
The output voltage will be higher than usual when the generator is still cold, immediately
after the engine starts.

AC external characteristic curve

A C o u tp u t v o lta g e

230

220

Current（A） 0 3 6 9 12 15
A C o u tp u t v o lta g e

240

230

Current（A） 0 3 6 9 12 15
A C o u tp u t v o lta g e

120

110

Current（A） 0 5 10 15 20 25

5
DC external characteristic curve
D C output voltage

26
24
22
20
18
16
14
12
Current（A）
0 2 4 6 8 10 12

1.4 DIMENSIONAL DRAWINGS

Unit : mm

6
1.5 WIRING DIAGRAM

a. IG3000X/E

7
b. IG3000E/X

8
______________________________________________________________________

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.

! Warning
Improper servicing can cause an unsafe condition that can lead to serious injury or
death.
Follow the procedures and precautions in this shop manual carefully.

Some of the most important precautions are stated below.

2.2 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.

9
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.

10
  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.

 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 location

The engine serial number is stamped at the underside of engine side cover. Refer to
this number when ordering or making technical inquiries.

11
2.6 Maintenance standards

Engine
Part Item Standard (mm) Service limit
Cylinder Sleeve I.D. 68.02~68.04 68.17
Piston Skirt O.D 67.97~67.99 67.62
Piston-to-cylinder clearance 0.040~0.060 0.12
Pin bore I.D. 18.002~18.008 18.042
Piston pin O.D 17.990~18.000 17.95
Pin-to-piston clearance . 0.002~0.018 0.080
Piston ring Ring width Top 1.420~1.440 1.32
Second 1.420~1.440 1.32
Ring side clearance Top/second 0.02~0.06 0.15
Ring end clearance Top/second 0.150~0.350 1.0
Small end I.D 18.006~18.017 18.07
Big end I.D 30.015~30.025 30.07
Connecting rod
Big end oil clearance 0.046~0.060 0.12
Big end side clearance 0.45~0.70 1.0
Crankshaft Crank pin O.D. 29.960~29.975 29.90
Valve clearance Intake 0.10±0.02 5.35
Exhaust 0.15±0.02 5.35
Stem OD Intake 5.46~5.48 5.56
Exhaust 5.45~5.47 0.1
Valve
Vessel I.D Intake/Exhaust 5.500~5.518 0.12
Stem and vessel clearance intake 0.020~0.058 2.0
Exhaust 0.030~0.068
Seat width Intake/Exhaust 0.8~1.2
Valve spring Free Length Intake/Exhaust 30.5 29
Cam wheel Cam height Intake/Exhaust 27.63~27.91 27.34
I.D (shaft bore) 27.68~27.94 27.34
Camshaft O.D 13.966~13.984 13.92
Valve lifter I.D (shaft bore) 7.96~7.98 7.87
Crankcase cover Camshaft Bearing 　I.D. .14.000~14.027 14.05

Valve lifter　　　　　I.D. 8.000－8.015 8.06

Cylinder block
Camshaft Bearing I.D. 14.000－14.027 14.05
Main jet 0.70mm —
Carburetor Float height 14mm —
Pilot screw opening 2circles —
Spark plug Clearance 0.6—0.8 —
Ignition coil Resistance Primary side 0.8—1.3Ω —
Second side 15—21kΩ —
Pulse coil Air gap . 0.5~0.75 —
(Trigger) Resistance 80~130Ω —
Starting relay Resistance 3.8~4.1Ω —

Generator
Part Item Type Standard（Ω） Service
120V 230V/240V limit
Ignition coil Resistance Green—Yellow/Green 0.26~0.28 0.26~0.28 —
Outer charging Resistance Blue-Blue 0.12~0.15 0.12~0.15 —

12
 winding coil
Inner charging —
Resistance Purple-purple 0.19~0.21 0.19~0.21
winding coil
Sub winding coil Resistance White—White 0.12~0.14 0.12~0.14 —
Main winding coil Resistance Black—Black 0.8~1.1 3.3-3.5 —

2.7 Torque values

Tightening torque

Item Thread dia. X pitch

Kgf.m N.m

Connecting rod bolt

M7 1.4~1.6 14~16

Cylinder head bolt

M8×60 2.8~3.2 28~32

Spark plug
M14×1.25×19 2.5~3.0 25~30

Crankcase cover
M8×30 2.0~2.3 20~23

Flywheel nut M14×1.5 8.0~9.0 80~90

Tightening bolt of rocker
arm base M8×16 2.0~2.3 20~23

Adjusting nut of rocker axis M6×0.75 1.0~1.2 10~12

M5 bolt、nut 0.6~0.8 6~8

M6 bolt、nut 0.8~1.0 8~10

Standard torque

M8 bolt、nut 2.0~2.3 20~23

M10 bolt、nut 5.5~6.0 55~60

Note：
Use standard torque values for fasteners that are not listed in this table.

13
2.8 Troubleshooting

A. General symptoms and possible causes

Symptom Cause(s) Remedy

Carburetor float chamber contains stale Drain old fuel, clean and /or
gasoline, or no fuel reaches carburetor replace
Fuel tank tube clogged Inspect
Fuel filter clogged Clean
Carburetor failure Clean and/or replace*
Engine does Spark plug cap disconnected Install securely
not start or Ignition coil failure Inspect and replace
hard starting Spark plug failure Inspect and replace
Oil level switch (Low oil alarm) failure Inspect and replace
Igniting device failure Inspect and replace
Pulse coil (Trigger) failure Inspect and replace
Choke air inlet not controlled properly The position can be full
open or half open
Engine Carburetor failure Adjust and/or disassemble
speed does and clean
not stabilize, Throttle control motor (stepping motor) Inspect
too high or failure
too low Generator failure Troubleshoot
Inverter unit failure Troubleshoot
Valve clearance misadjusted Adjust

* Carburetor replacement parts are not available. No adjustments or overhaul is

permitted under current EPA/CARB guidelines.

14
B. Hard starting

If the engine does not start or is hard starting after reassembly, check to see whether the
throttle valve is at the full open position.

No fuel
Check the fuel level in the tank Add fuel and restart the engine

Sufficient fuel
Fuel not
Loosen the drain screw and reached Check for blockage of the fuel
Check whether fuel reached tube, fuel filter or fuel pump
the carburetor
Fuel reached Check for blockage in the
the carburetor carburetor port and nozzle
Dry
Remove the spark plug and Clean the electrode and
Check for wet or fouled electrode restart, taking care that the
Wet choke is not closed too much.
If flooding is severe, check the
carburetor float valve.
No spark or
Perform spark test weak spark Perform the ignition system
troubleshooting

Good spark

Install a compression gauge High cylinder Check for carbon deposits in

in the spark plug hole and compression the combustion chamber.
check the cylinder compression
by pulling the recoil starter Check the valve clearance
rope several times Low cylinder Check for worn piston, piston
compression 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/600rpm

 Ignition system fault inspecting and repair- Spark Test

■The engine oil should be added to regulated capacity before diagnosis.

15
 ■Please use F7RTC spark plug which is mated with this product.
■Spark inspecting
a. Remove the spark plug.
b. Install the spark plug onto spark plug cap.
c. Turn the ignition switch of engine to the position” ON”. Then ground the spark
electrode to the cylinder head cover and pull the start motor rope to check
if sparks jump across the electrode.

! Warning

Do not pull the recoil starter rope while touching the high tension wire with a wet hand.
High voltage is generated which is dangerous. Be sure to ground the spark plug and
hold the plug cap with an insulated pair of pliers to perform the spark test.

Make sure no spilled fuel is anywhere on the engine and no fuel is on the spark plug

Keep sparks and any other combustible source away from the spark plug hole.
C. Engine does not start with sufficient oil in the crankcase.
Measure the spark plug gap
and perform the spark plug
Gap: 0.6~0.8 mm
No spark

Perform the spark test again Good spark

Replace the spark plug
using a new spark plug

No spark

Perform test using a new Good spark

Replace the portfire
portfire

No spark

Disconnect low oil alarm and Good spark

Replace the oil level switch
perform spark plug test

No spark

Inspecting the resistance value Abnormal

of alternator ignition coil
Normal
Inspecting the resistance value Abnormal
and the clearance of trigger
Replace the stator of alternator
Replace the trigger or adjust the
clearance of trigger

Normal
Inspecting resistance value of
ignition coil and high tension Abnormal
cable and insulation of high Replace the ignition coil
tension cap

Inspecting and repair or

replace

16
D. Engine oil level is low, but engine does not stop.

Drain all the oil, disconnect the wire

of low oil alarm and measure Disconnect Replace the low oil
linkage of output of low oil alarm alarm
and the ground

Connect

Connect the wire of low oil alarm

and disconnect portfire connector Disconnect Wiring harness fault,
plugs,then measure linkage of replace or repair it
orange wire and the ground

Connect

Portfire fault, replace portfire

E. Engine starts but then stalls（throttle is installed in proper position）

Check if engine oil is enough and see if Oil alarm

Add oil and restart
the engine oil alarm gives a alarm

Enough engine oil

No fuel
Check if the fuel in fuel tank is enough Add Fuel and restart

Enough fuel

Check if the fuel switch and filter are Choked

Clean the fuel switch and filter
choked

Unchoked
Choked Clean or change the oil feeding pipe
Check if the oil feeding pipe is choked
Unchoked

Check if main nozzles in the holes of Choked

Disassembly and clean
carburetor are choked

Unchoked
Check the paper cushion of air inlet Abnormal Tighten the nut or change paper cushion heat
pipe and heat insulation and sealing insulation block
of carburetor
Normal
1. Check if the clearance of valve is proper.
Abnormal
Measure compression of cylinder 2. Check if it accumulates too much carbon in
combustion chamber.
Normal 3. Check abrasion of piston and piston ring and
Abnormal cylinder.
Check clearance of trigger

Perform fault inspecting and repairing Rearrange clearance of trigger

control system of throttle valve

17
F. Engine speed does not increase or stabilize.
Clogged
Check the air cleaner Clean the air cleaner

Not clogged
Abnormal
Check the valve clearance Readjust valve gap

Normal
Remove the spark plug and
check the electrodes for carbon
and spark plug gap.
Normal
Check for blockage of the main
jet and holes of carbunetor
Abnormal Clean electrodes and adjust the
spark plug gap or replace a new
spark plug
Clogged
Disassemble and clean

Not clogged
Check for paper cushion of air Abnormal Tighten the nuts securely or install a
intake and heat insulation of new carburetor heat insulator or
carburetor gasket.

Normal
Abnormal Check if the gap of valve is correct.
Check the cylinder compression Check if it exists too much carbon in
combustion chamber.
Normal Check the piston, piston ring and
Perform the throttle control cylinder for wear and damage.
system troubleshooting

G. Smart throttle Problems

1.Engine speed is too high, hunting or too low.

Abnormal Perform the generator

Check the AC output troubleshooting following the
instruction of “No or low AC output”
Normal
Check control motor for Abnormal Replace the control motor for throttle
throttle valve valve
Normal
Replace the inverter unit

2. Smart Throttle system does not work under no load. (engine speed does increase

18
 after connecting load with Smart Throttle system ON.)

Abnormal Perform “No or low AC output”

Check the AC output
troubleshooting
Normal
Check the throttle control Abnormal
Replace the throttle control motor
motor
Normal
Abnormal
Check the smart switch Replace the smart switch
Normal
Check each Smart switch Abnormal
Repair or replace the wire harness
connection
Normal
Replace the inverter unit

H. No or Low AC output

ON
Is the overload indicator light ON? Disconnect the load, and restart the
engine.
OFF

Is the engine speed normal?

Engine speed: Abnormal Perform the throttle control system
Smart switch ON：3000±100rpm troubleshooting
Smart switch OFF：3600±100rpm
Normal
Engine stopped and check AC Abnormal
Replace the AC receptacle
receptacle
Normal
Disconnect the 6P connector from
the inverter unit.Pull the recoil
starter and measure the AC
voltage between the white and
Check and repair the harness of stator
black terminals Voltage:
Abnormal or replace the stator.
120V model：
Magnetic force of the rotor magnet is
black－black：＞30V low. Replace the rotor.
white－white：＞1V
230V/240V model：
black－black：＞60V
white－white：＞1

Normal

Replace the inverter unit.

The stator output may be checked with the engine running. Disconnect the 6P connector
from the inverter unit.  starting Check voltage between pins 1 & 4, pins 2 & 4, and pins 1
& 2. There should be 280 to 330 Volts AC.  If one or more of the three tests fail, the
problem is either a damaged wire harness or a defective alternator.
I. No DC output

19
 Is the engine speed normal?
Abnormal Perform the throttle control system
Engine speed: 5500±100 min-1(rpm)
troubleshooting.
(Smart switch OFF)

Normal
Abnormal
Check the DC output Replace the DC receptacle.

Normal

Check the rectifier Abnormal Rectifier is faulty. Replace the

rectifier.
Normal
Measure the resistance between the
blue DC coil terminals of the rectifier Abnormal Check the wire harness (input line)
4P connector. replace the stator.
Resistance value：0.12~0.15Ω
Normal

Rotor lose magnetism ,replace rotor

J. Engine will not start Electrically

Measure the voltage of Abnormal

Change a new accumulator
accumulator
Normal
Abnormal
Check the ignition switch Replace the ignition switch

Normal
Abnormal
Check the starting relay Replace the starting relay

Normal
Abnormal
Check the starting motor Replace the starting motor

Normal
Check , repair or change
main harness wire

K. Starting Battery Will Not Hold a Charge

Abnormal
Check ignition switch Replace ignition coil

Normal
Abnormal
Check charging adjustor Replace charging adjustor

Normal
Measure resistance value of Abnormal Check, repair wiring harness of
charging winding alternator and change stator
Resistance value：0.19~0.21Ω
Normal
Check, repair or change wiring
harness

20
______________________________________________________________________

3 MAINTENANCE
______________________________________________________________________
3.1 Maintenance schedule

Regular service period① Eac First Every 3 Every 6 Every

h month or months months year or
Item perform at every use 10 Hrs. or or 100 300
indicated month or operating 50Hrs. Hrs. Hrs.
hour interval, whichever
comes first
Engine Oil Check ●

Replace ● ●

Air cleaner Check ●

Clean ●②

Spark plug Clean-Adjust ●

Spark catcher Clean ●

Valve Check- ●③
clearance Adjust
Fuel tank and Clean ●③
filter
Fuel line Check Every 2 year (Replace if necessary③)

Note:

①Interval operating time in normal troubleshooting.

②When it is used in dusty place, filter should be cleaned every 10 hours or everyday.
③Maintenance should be carried out by the qualified technicians. 3.2 Engine oil

3.2. Engine Oil

21
A. Checking Oil Level

Engine should be shut off and generator be on level ground when checking the oil level.

(1) Remove the oil dipstick, check oil level.

lower limit
upper limit screw the oil dipstick
tightly ,then unscrew it

(2) Add the proper viscosity engine oil to the upper limit if oil level is low. Be careful
to over fill.

B. Changing engine oil

(1) Remove the oil dipstick and unscrew oil drain plug to drain used oil.

(2) Replace the drain plug and secure tightly.

(3) Add the proper viscosity oil to the upper oil limit level.
.
(4) Reinstall the dipstick and screw it tightly

22
 3.3 Inspection of the Oil Alert Switch

(1) Disconnect the orange connection of the oil alert wire when engine is running, and
ground one end to the engine block as shown below to ensure that the engine will
stop when the oil alert lamp is lit.

NOTE: On early models, the oil alert connection is in the back of the generator on
the opposite side of the service door.

Lead of ignitor
Lead of oil alarm Ground through the case
of engine

(2) Stop the engine and disconnect the orange wire of the oil alert after insuring that the
engine oil is at the proper level. Test the conductivity between the end shown in the
figure and the case of engine, No conductivity indicates a normal condition.

Lead of ignitor
Lead of oil alarm

(3) Drain all the engine oil in the engine repeat the test. The switch is working properly
if there is normal conductivity.

23
 3.4 Air Filter Maintenance

(1) Open the service door.

(2) Open the cover of air filter and take out the filter element.
(3) Blow the inner side of filter element using compressed air or lightly knock it to
remove dirt. If any dirt remains, change the element. Be sure to use a genuine Kipor
element to maintain a proper seal and avoid engine damage.
(4) Reinstall the filter element and close the service door.

Blow the innerr side of Filter element

air filter element using subassembly
the compressed air Air filter cover

! Attention ！

Don’t operate the generator without the filter element in place or serious engine
damage
may result.

24
3.5 Spark Plug Servicing

(1) Remove the spark plug cap, and use a spark plug wrench to remove the spark plug.
(2) Check the condition of the porcelain insulator. Replace the spark plug if it is chipped
or cracked.
(3) Remove carbon or other deposits with a stiff wire brush. Check if the sealing washer
is damaged.
(4) Check the resistance of the spark plug and replace it if it is not within the specified
resistance value.

Resistance of spark plug 3~9KΩ

(5) Use a feeler gauge to check the electrode gap. Adjust the electrode to the following
specification by carefully bending the side electrode to the specified value.

Clearance of
. 0.6~0.8mm
spark plug
Standard spark
F7RTC
plug

0.6-0.8

(6) Reinstall the spark plug and screw it tightly after regulating, the specified torque is
25~30 N.m

25
3.6 Adjusting of valve clearance
! Attention ！

Valve adjustment should only be performed on a cool engine.

(1) Remove valve cover.

Gasket of cylinder head cover

cylinder head cover

(2) Pull the starter rope gently and set the piston in top dead center (the scale of
starting wheel should align with the sign “△” on the air guiding cove
(3).Insert a feeler gauge into the gap between rocker and valve to measure the valve
clearance.

Intake： 0.10±0.02mm
Valve Clearance
Exhaust：0.15±0.02mm

(4) If adjustment is necessary, proceed as follows:

a. Hold rocker axis using the wrench and loosen the lock nut.
b. Loosen the lock nut of rocker axis to gain the specified intake and exhaust valve
clearance.
c. Hold rocker axis using a wrench and tighten the lock nut.
d. Check the clearance of valve after adjustment.

26
3.7 Fuel filter and fuel switch maintenance

Fuel tank

Filter seal cushion

Fuel element

Fuel switch

! Attention ！

■ Keep smoking materials and any open flames away during fuel system
maintenance.

■ Make sure that there is no leaking fuel after service.

(1) Drain all fuel from the tank and carburetor and remove the fuel tank.
(2) Loosen the nuts between fuel switch and fuel tank and remove the filter element.
(3) Turn the fuel switch to the open position. Clean it with a suitable solvent then blow
dry with compressed air.
(4) Remove any foreign material from the fuel filter and insure the filter net is
undamaged. Replace if necessary
(5) Properly install seal cushion and filter element and tighten the nuts between fuel
switch and the fuel tank.

27
______________________________________________________________________

4. Air Filter and Muffler

4.1 Air filter

● Disassembly and assembly

Bottom case of air filter

Filter element
Air filter cover
Carburetor
Install:
make sure that gaskets have no
damages and bendings and pay
attention to inner and outer sides.

28
4.2 Muffler

● Disassembly and assembly

5．Carburetor
! Attention ！

■ Loosen the gasoline drain bolts before disassembly to drain fuel in the carburetor.

■ Smoking and any source of combustion are strictly forbidden in the process of
disassembly.

5.1 Removal and installation

29
 Carburetor gasket A
Reassembly：
Check if there is any
damage in the gasket
Rope of air choke
before assembly

Air choke weldment

Air intake pipe gasket
Reassembly： Gasket of Air filter bottom case
Check if there is any carburetor
damage in the gasket
before assembly
Filter element
Insulator block of Carburetor
carburetor assembly Air filter cover
Reassembly： Carburetor gasket B
Check if there is any Reassembly：
damage in the insulator Check if there is any
block before assembly. damage in the gasket
before assembly

5.2 Stepping motor disassembly and reassembly

30
 stepping motor

stepping motor base

fork spring
fork disassembly：
hold it tightly for fear that the spring
will lose when it is disassemblied.

fork spring
fuel control fork
lever

5.3 Carburetor disassembly and reassembly

NOTE: With the exception of changing the 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

31
drawing is for information only.

Air stroke rod

Fork Fork spring

Gasket of air stroke

Assembly of accelerator Restorating
spring of air
choke
Accelerator piece

Adjusting screw of Gasket

the mixture ratio Idle adjusting screw
Reassembly:
Inspect the abrasion of the Stopper of
front head,then install it. channel

Needle base
Main nozzle Float pin
Reassembly： Oil control needle
Clean channels with compressed Reassembly：
air before installation. Inspect the abrasion of the head
check if it is a proper direction and the action of spring,then install
Seal ring of
fuel cup it.
Main jet
Reassembly：
Clean channels with
Float chamber
compressed air before
installation.
Fuel drain bolt of fuel cup
Float
Reassembly： Reassembly：
Check for smooth Make sure there is no fuel
movement after leakage after installing.
installation.

Bolt of float chamber

Reassembly：
Make sure there isn't any
fuel leakage after assembly.

5.4 Inspection
Height of float
Place the carburetor as shown in the following figure, measuring the height between
float and the chamber. (The height of float)

32
 Specified height 14mm
Float should be replaced if the height can’t meet the requirement.

Float

● Stepping motor

Measuring the resistance of stepping motor leading wires

Specified 1 and 3：45~55Ω

resistance 2 and 4：45~55Ω

Replace the stepping motor if the resistance value exceeds the specified range.

1 2

4 3

6. Control panel, charging adjustor and inverter unit

6.1 Disassembly and assembly

33
6.2 Inspection

A. Smart Throttle switch

There should be continuity between both poles of the switch when placed in the on
position. If not, replace the switch.

B. Ignition Module (3 in one switch)

Pull out 10P connector plug from the ignition module. Connect an ohm meter to ground
and measure the resistance in the various 10p connector pins to measure the
resistance. Use the following chart for reference:

Color Circuit unit Specified resistance value

Blue Primary ignition coil 0.8~1.3Ω
It is not lit under the condition
Orange Low oil alarm
that oil position is normal
Yellow Trigger coil 80~130Ω
Kelly Grounding wire Put through
Ignition device power coil
Green 0.26~0.28Ω
winding
Red Engine fire extinguishing The Ignition switch is put

34
 through when it switches on,
switch ( five feet)
otherwise it will disconnect.

Blue Orange Yellow Kelly Green Red

C. Ignition switch (Ei )

Check connection between each group terminal, the results should agree with the states
listed in the following table, otherwise it should be replaced.

1 2 3 4 5 3
4 2
OFF
ON

START 5 1

D. Rectifier

Use the item of instrument to test connection between each group feet of rectifier
(plus voltage falls), the results must agree with standard listed in the following table.

Positive
Electric pen
1 2 3 4
Negative
Electric pen
1 Block Block Block
2 Connect Block Block
3 Connect Connect Connect
4 Connect Block Block

35
 （1）Negative terminal (-) （2）AC terminal (～)

（4）AC terminal (～) （3）Negative terminal (+)

E. Charging adjustor

Start the engine and disconnect the wire of charging adjustor with two electrodes of the
battery, then measure the voltage between output terminal of charging adjustor and
grounding wire.

13~14V
DC charging voltage

output anode(gray)

AC input（purple）
Grounding（Kelly）

AC input（purple）

][

7. Housing group and Fuel tank

Disassembly and Reassembly

36
　

8. Generator, ignition coil, trigger

8.1 Generator

A. Disassembly and Reassembly

37
 Rotator
Stator pin
Reassembly：
Stator Clean the dirty and
oil stain on the tape
surface of rotator
before installation.
Nut of flywheel
Fan M14X1.5
80-90 N.m
Fixing board of chuck

Rope clutch
Trigger
Semicircle key
Reassembly： Ignition coil
Check if all installed
Wire holding board
properly be careful not
to miss any parts.
Bus seal ring

B. Inspection
（1）Ignition winding
Measure the resistance between green wire and olive wire
Resistance value 0.26~0.28Ω
（2）Outer use charging winding
Measure the resistance between two blue wires.
Resistance value 0.12~0.15Ω
（3）Built-in charging winding
Measure the resistance between two purple wires.
Resistance value 0.19~0.21Ω
（4）Sub winding
Measure the resistance between two white wires.
Resistance value 0.12~0.14Ω

（5）Main winding

Measure the resistance between three black wires.

120V 230/240V
Resistance value
0.8~1.1Ω 3.3~3.5Ω

8.2 Ignition coil and trigger

A. Disassembly and reassembly

38
 Trigger

Wire holding board

Ignition coil

B. Inspection

(1) Ignition coil

●. With an ohmmeter check the resistance between the two wires going to the coil

primary resistance 0.8~1.3Ω

●Check resistance between one end of primary ignition coil terminals and spark plug
cap to measure sub resistance of ignition coil.

Sub resistance 15~21KΩ

39
(2) Trigger

Test the resistance between the trigger wires.

Resistance of trigger 80~130Ω

Adjustment:

Adjust the clearance between trigger and salient of the rotor.

0.020~0.030 in.
clearance of trigger
(0.50~0.75mm)

Insert the gauge between the salient of the trigger and the rotor to measure the
clearance. If it is not within the specified range, readjust the trigger to the recommended
clearance.
9. Recoil starter\ Air guiding cover
9.1 Disassembly and Reassembly

40
 Air guiding cover

Recoil starter
Assembly：
Check if it is a proper
direction before installation.

Handle of recoil starter

Recoil starter

9.2 Assembly of recoil starter

①. Install the spring in the starter reel, and then put the outer hook of the spring in the

41
block of reel.

Spring

Starter reel

②. Spread lubricating grease on the ratchet of outer case, and then install the reel with
spring, rotate the reel anticlockwise to make the inner hook of spring hitch to the block of
the outer case.

Reel of starter

Outer case of starter

③ Make a knot at the ends of the starter rope which is like figure ‘8’ as shown in the
following, thread another end through the hole on the reel and pull out it. And then install
the reel, rotate it for 4 loops anticlockwise, and then hold the reel so it does not turn
back.

42
 ④ Pull the other end thought the hole of the outer case , and then thread through
handle. Make a knot at the end and install the handle cover. Release the reel to let the
spring draw the rope back. Be careful not to let the reel jump out of the case.

⑤ Install pawl of starter and other parts, and then fix them with bolts.

Pawl Guiding board of pawl

(lubricating grease on
Spring cap the back side)

Fixing bolt
(with screw locking glue)

Pawl spring
Friction spring

⑥ Pull the rope several times to check if it is engaging

10. Starter Motor

10.1 Removal and reinstallation

43
10.2 Disassembly and reassembly

sheath of brush

spring

brush

brush bracket
bracket
oil seal
retaining spring
overdrive clutch
rubber cushion
gasket
ball bearing driving gear
Check if the bearing is
backword spring
good before installation
retainer ring

thrust bushing
rear cover
Reassembly：
Check if there is any abrasion
in bushing of armature or gasket of case
absence of grease before
installation.

housing
Reassembly：
armature
Check if there are
any gaskets or bolts reassembly：
stuck on the magnet Check if there is any rust or
before installation. damage on the surface of ring
header before installation,it
can be finshed by sand paper retaining spring gasket
if it is necessory.

A. Disassembly of driving gear

Stand the starter in an upright position, push down on the bushing, and remove the
retainer ring with long nose pliers. Remove the driving gear.

44
 Thrust bushing

10.3 Inspection

(1) Starting relay

Insert two instrument pens into two connection-pegs of starting relay to measure primary
resistance of ignition coil.

Resistance of ignition coil 3.8~4.1Ω

Electrify two lead wires of starting relay with voltage of 12v, relay should have motion
and make noise, keep electricity on and test if lead bolts of two main contact points are
connected. If it is connected, it means normal.

（2）Electrical motor

 Brush length
Measure the length of brush, if abrasion is larger than service limit it should be changed
with another one.

Standard value (mm) Service Limit (mm)

10 5

45
  Depth of isinglass

If isinglass is blocked or lower than the minimum limit, it should be sheared with edge.
Standard value (mm) Service limit in. (mm)

1.0 0.2

 Turnon of sector body

Check turnon of sector body, if there is any disconnection, armature should

be replaced.

 Insulation between ring header and axis

Check turnon between ring header and axis, if there is any disconnection
armature should be replaced.

46
  Insulation between brushes

Demount armature to check turnon of brushes. It is normal if it

disconnected

 Overdrive clutch

①Rotate the overdrive clutch to check if it turns smoothly. Then revolve the over- drive
clutch to the thrust bushing and release it, under the force of spring it can restore, but if
it doesn’t work properly even with lubricating oil, it should be replaced with another one.

overdrive clutch

②Check the tooth surface of small gear, if there is any damage or abrasion it should be
replaced.
11. Cylinder cover\valve
11.1Disassembly and reassembly

a. Disassembly and reassembly

47
 bolt of cylinder cover M8X60 28-32 N.m
Assembly: assembly of cylinder cover
tighten and loosen bolts should proceed Assembly：
according to decussation path,bolts should be Remove carbon in the combustion
evenly tighened step by step till to specified chamber and check the state of
torque. contact before installation.

cylinder head cover

cylinder cover
assembling pin

air vent pipe gasket of cylinder head cover cylinder cover gasket
Assembly： Assembly: Assembly:
Check if there is any Check if there is any damage or Check if there is any damage
leakage or aging in the aging in the gasket of cylinder in the gasket of cylinder cover
pipe before installation. head cover before installation. before installation.

b. Disassembly and reassembly

48
 spring base of exhaust valve
disassembly：
Press the base of spring slightly and
offset to bypass hole,then take down.

Reassembly：
Be careful not to mix up with exhaust valve
spring base of intake valve.
stud spark plug assembly：
AM8X20 Check if there is any
spring base of spring base of cylinder damage and carbon on
intake valve exhaust valve cover conical surface
before installation.
adjusting cushion block of exhaust
valve(only for exhaust valve) valve spring
valve vessel
adjusting nut of rocker axis
10-12 N.m

intake valve
rocker axis assembly：
don't mix up with exhaust valve
valve rocker spring base of cushion of diameter of conical surface:
intake valve intake pipe intake valve： 24
bolt of rocker axis exhaust valve： 23
stud of air
20-23 N.m intake pipe
valve stem
handspike guiding board assembly： oil seal of intake valve vessel
Be sure that there
assembly：
is not any abrasion
in both ends and Check if there is any damage
the stem is stright in oil seal before installation.

11．2 Inspection
●Free length of valve spring

49
 Standard
Service limit(mm)
value（mm）
30.5 29

●Width of valve base

Standard
Service limit(mm)
value（mm）
0.8~1.2 2.0

●Cylinder cover
Clean the carbon deposition in combustion chamber and the odd parts attached on the cylinder
cover surface, check the spark plug hole, valve seat and valve guide if there is crackness.

Check the cylinder cover if there is distortion with the ruler and clearance gauge.
Service limit Over 0.1mm，you should change

50
●Outside diameter of valve stem

Standard value（mm） Service limit(mm)

Intake valve 5.46~5.48 5.35
Exhaust valve 5.45~5.47 5.35

●Inside diameter of valve guide

Standard value（mm） Service limit (mm)

Intake, exhaust valve 5.500~5.518 5.56

51
●The clearance between the valve stem and valve guide

Standard
Service limit(mm)
value（mm）
Intake valve 0.020~0.058 0.10
Exhaust valve 0.030~0.068 0.12

12．Crankcase cover, crankshaft, camshaft and piston

12．1Remove and assemble
a：Crankcase cover

b：Crankshaft， camshaft， piston

52
●Alignment of the timing pip
Align the camshaft with the timing pip of the timing gear(the small gear on the camshaft),
and install.

53
c：Piston

54
The assemble of the piston ring

NOTE:
●Make the factory mark towards up while installing.
●Note the position of the first ring and the second ring right.
●You should check if the piston ring can rotate smoothly after installation.
●You should make the open end of each piston ring keep away from the direction of the
piston pin, and stagger about 120° each other.
The 1st ring (with chrome plate)
The 2nd ring (with phosphor surface)
Oil ring

12．2 Check
●Check for the low oil alarm
（1）Make the low oil alarm in the standing state, and measure the alarm extension line
and the copper earth wire with the meter, between them should be through.
（2）Make the alarm in the inversion state and measure it, it should be broken.
（3）For checking of the float, put the alarm into oil fully, make sure the result.

Lead wire
Copper earthing
terminal

●The rock of the bearing

Clean the bearing and make it dry, rotate the bearing, and check the play. If there is
abnormal voice and rock, you should change a new one.

55
●The inside diameter
The standard value（mm） Service limit (mm)
68.02~68.04 68.17

●The outside diameter of the piston skirt section

The standard value（mm） Service limit (mm)

67.97~67.99 67.62

10mm

56
●The clearance between the piston and cylinder
The standard value（mm） Service limit(mm)
0.040~0.060 0.120

●The clearance of the side of the piston ring

The standard value（mm） Service limit(mm)

0.020~0.060 0.150

● The clearance of the piston ring end

Located the piston ring with the top of the piston into the cylinder sleeve, and then
measure the clearance of the piston ring end.

The standard value（mm） Service limit(mm)

0.150~0.350 1.0

●The width of the piston ring

The standard value（mm） Service limit(mm)

The first ring 1.420~1.440 1.320

57
 The second ring 1.420~1.440 1.320

●The outer diameter of piston pin

The standard
Service limit(mm)
value（mm）
17.990~18.000 17.950

●The inside diameter of the piston pin hole

The standard value（mm） Service limit(mm)

18.002~18.008 18.042

58
●The clearance of the piston pin and piston pin hole

The standard value（mm） Service limit(mm)

0.002~0.018 0.080

●The inside diameter of the small end of connection rod

The standard value（mm） Service limit(mm)
18.006~18.017 18.070

●The inside diameter of the big end of connection rod

The standard
Service limit(mm)
value（mm）
30.015~30.025 30.070

●The outside diameter of crank journal

The standard
Service limit(mm)
value（mm）
29.960~29.975 29.900

59
●The side clearance of connecting rod big end
The standard value（mm） Service limit(mm)
0.45~0.70 1.0

●The oil film of the connecting rod big end

（1）Clean the oil on the surface of the crank journal
（2）Set the plastic insulated wire on the crank journal, and then install the connecting
rod, and fasten the bolt as the specific torque. Note: Don’t run the crankshaft while
fastening the bolt.
The fasten torque 14~16N.m.。
（3）Remove the connecting rod, measure the thickness of the plastic insulated wire
clearance gauge.
（4）While the clearance is over the service limit, you should change the connecting
rod, and then measure it again. While using the new connecting rod, the clearance is
also over the service limit; you should furbish the crank journal, and use the connecting
rod smaller than the standard value.
The standard
Service limit(mm)
value（mm）
0.046~0.060 0.120

60
●The height of the camshaft
The standard value（mm） Service limit(mm)
Air intake 27.63~27.91 27.34
Air exhaust 27.68~27.94 27.34

61
●The outside diameter of the camshaft
The standard value（mm） Service limit(mm)
13.966~13.984 13.920

●The inside diameter of the camshaft bearing

The standard value（mm） Service limit(mm)
14.000~14.027 14.050

62