KIPOR Ig2000

KIPOR POWER PRODUCTS CO., LTD.
IG2000/IG2000P/IG2000S SHOP MANUAL

EPA/CARB/CETL Certified Models
Kipor Power Systems, Inc.
Revision 4, July, 2011
Downloaded from www.Manualslib.com manuals search engine

Preface
This manual covers the construction, repair, and servicing procedures for the KIPOR
IG2000 and IG2000P Models. Some models were sold with an “S” suffix, designating
an installed light kit.
The manual is applicable to EPA, CARB, and CETL models.
Careful observance of these instructions will result in better, safer service work.
All information, illustrations, directions and specifications included in this publication

are based on the latest product information available at the time of approval for
printing. Wuxi Kipor Power Co., Ltd., reserves the right to make changes without
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incurring any obligation.
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No part of this publication may be reproduced without written permission.
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CONTENTS
PREFACE ...................................................................................................................................... 1
CONTENTS ................................................................................................................................... 2
1. SPECIFICATIONS/WIRING DIAGRAM...................................................................................... 4
1.1 SPECIFICATIONS .............................................................................................................. 4
1.2 PERFORMANCE CHARACTERISTICS ............................................................................. 5
1.3 PERFORMANCE CURVES ................................................................................................ 6
1.4 DIMENSIONAL DRAWING ................................................................................................. 7
1.5 WIRING DIAGRAMS .......................................................................................................... 8
2. SERVICE INFORMATION .........................................................................................................11
2.1 THE IMPORTANCE OF PROPER SERVICING.................................................................11
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2.2 IMPORTANT SAFETY PRECAUTIONS ............................................................................11
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2.3 SERVICE RULES ............................................................................................................. 12
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2.4 ELECTRICAL PRECAUTIONS ......................................................................................... 13
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2.5 SERIAL NUMBER AND BARCODE .................................................................................. 13
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2.6 MAINTENANCE STANDARDS ......................................................................................... 14
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2.7 TORQUE VALUES ............................................................................................................ 14
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3. TROUBLESHOOTING ........................................................................................................... 15
3.1 GENERAL SYMPTOMS AND CAUSES ........................................................................... 15
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3.2 HARD STARTING ............................................................................................................. 16

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3.3 OIL ALARM ....................................................................................................................... 19

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3.4 ENGINE STOPS RUNNING ............................................................................................. 19

3.5 ENGINE SPEED UNSTABLE ........................................................................................... 20
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3.6 THROTTLE CONTROL SYSTEM ..................................................................................... 20

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3.7 SMART THROTTLE.......................................................................................................... 21

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3.8 LOW OR NO AC OUTPUT ............................................................................................... 21

3.9 NO DC OUTPUT............................................................................................................... 22
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3.10 NO PARALLEL OUTPUT ................................................................................................ 23

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4. MAINTENANCE ..................................................................................................................... 25
4.1 MAINTENANCE SCHEDULE ........................................................................................... 25
4.2 CHECKING THE LOW OIL ALARM .................................................................................. 27
4.3 AIR CLEANER .................................................................................................................. 28
4.4 SPARK PLUG ................................................................................................................... 30
4.5 VALVE CLEARANCE ........................................................................................................ 31
4.6 FUEL TANK AND FILTER ................................................................................................. 34
4.7 FUEL PUMP AND HOSES ................................................................................................ 36
5. EXHAUST SYSTEM ............................................................................................................... 37
5.1 MUFFLER ........................................................................................................................... 37
5.2 EXHAUST TUBE/SECONDARY AIR INJECTION VALVE .................................................. 38
5.3 SPARK ARRESTOR ........................................................................................................... 38

6. INTAKE SYSTEM ................................................................................................................. 39
6.1 AIR FILTER REMOVAL AND INSTALLATION ................................................................... 39
6.2 CARBURETOR REMOVAL AND INSTALLATION............................................................. 40
6.3 INSPECTION .................................................................................................................... 43
7. CONTROL PANEL ................................................................................................................ 45
7.1 REMOVAL AND INSTALLATION ...................................................................................... 46
7.2 INSPECTION OF COMPONENTS ................................................................................... 53
8. LIGHT KIT/HOUSING/FUEL TANK/FAN HOUSING ............................................................. 53
8.1 LIGHT KIT DISASSEMBLY AND INSTALLATION ............................................................. 53
8.2 HOUSING DISASSEMBLY ............................................................................................... 54
8.3 FUEL TANK ASSEMBLY ................................................................................................... 56
8.4 FAN HOUSING/ENGINE MOUNTING PLATE .................................................................. 57
8.5 EVAPORATIVE CONTROL SYSTEM ............................................................................... 58
8.6 GUIDE PLATE .................................................................................................................. 59
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9. RECOIL STARTER/AIR CONDUCT COVER/IGNTION COIL .................................................. 60
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9.1 DISASSEMBLY AND REASSEMBLY................................................................................ 60
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9.2 RECOIL STARTER INSTALLATION ................................................................................. 61
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9.3 INSPECTION .................................................................................................................... 63
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10. ALTERNATOR/TRIGGER ..................................................................................................... 65
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10.1 ALTERNATOR................................................................................................................. 65
10.2 INSPECTION .................................................................................................................. 65
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10.3 TRIGGER ADJUSTMENT ............................................................................................... 66

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11. CYLINDER COVER/ROCKER ARM....................................................................................... 67

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11.1 DISASSEMBLY/REASSEMBLY ...................................................................................... 67

11.2 INSPECTION .................................................................................................................. 68
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12. CRANKCASE COVER/CAMSHAFT DRIVE CHAIN ............................................................. 70

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12.1 DISASSEMBLY ............................................................................................................... 70

12.2 CRANKCASE COVER REASSEMBLY ........................................................................... 71
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12.3 ROLLER CHAIN REASSEMBLY .................................................................................... 71

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12.4 CHAIN SUPPORT PLATE/PRESSURE PLATE .............................................................. 73

12.5 CRANKCASE COVER ASSEMBLY ................................................................................ 75
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12.6 INSPECTION .................................................................................................................. 76

13. CRANKSHAFT/PISTON AND CONNECTING ROD ............................................................. 79
13.1 DISASSEMBLY ............................................................................................................... 79
13.2 PISTON/CONNECTING ROD......................................................................................... 80
13.3 INSPECTION .................................................................................................................. 81

1. SPECIFICATIONS
1.1 SPECIFICATIONS
Dimensions and weights

Model IG2000/IG2000P IG2000s
Overall Length in (mm) 20.5 (520) 26.2 (665)
Overall Width in (mm) 11.8 (300) 11.8 (300)
Overall Height in (mm) 16.7 (425) 16.7 (425)
Net Weight lbs (kg) 48.4 (22) 52.8 (24)
Engine
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Model KG158
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Type 4-stroke,OVC, single cylinder, Gasoline engine
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Displacement
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105 cc
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Horsepower/RPM 2.2/4500
Compression ratio st 8.5:1
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Cooling system Forced air-cooled
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Ignition system T.C.I

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Ignition timing 27°B.T.D.C

Spark plug UR5
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Carburetor Float type, Horizontal, butterfly valve

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Air cleaner Semi-dry

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Governor Electronically controlled

Lubrication system Splash
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Oil capacity qt (L) .35 (0.4)

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Starting system Recoil starter

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Fuel used Automotive unleaded gasoline 87 octane
Generator
Model KD20 Alternator
Generator type Multi pole rotation type
Generator structure Self-ventilation drip-proof type
Excitation Self-excitation (Magnet type)
Voltage regulation system Pulse width modulation)
Phase Single phase
Rotation direction Clockwise (Viewed from the generator)
Frequency regulation AC-DC-AC conversion (Inverter type)

1.2 PERFORMANCE CHARACTERISTICS
Model All
Maximum output AC 2.0KVA
Rated output AC 1.6KVA
Rated output DC 100W
Rated frequency 60HZ
Rated voltage AC 120V
Rated voltage DC 12V
Rated current AC 13.3A
Rated current DC 8.3A
Power factor 1.0
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Voltage variation rate Momentary 10% max
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Average 1.5% max
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Average time 3 sec max
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Voltage stability ±1%
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Frequency variation rate Momentary
st 1% max
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Average 1% max
Average time 1 sec max
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Frequency stability ±0.1%

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Insulation resistance 10 MΩ min

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AC circuit protector 17.9A @120V

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DC circuit protector 10A

Fuel tank capacity gal (L) .9 (3.5 )
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Operating hours (at rated load) 4

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Noise level NL-FL @23’ (7 m) 54-59

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1.3 PERFORMANCE CURVES
The curves show performance of the generator under average conditions.

Performance will vary depending on ambient temperature, humidity, and altitude.
The output voltage will be higher than usual when the generator is still cold immediately after the
engine starts.
● AC External characteristic curves
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1.4 DIMENSIONAL DRAWING Unit: mm
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1.5 WIRING DIAGRAMS
a. IG2000 pre 2011
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b. IG2000P Pre 2011

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c. IG2000 2011 forward
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d. IG2000P 2011 forward
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2. Service information
2.1 The importance of proper servicing
■ Proper servicing is essential to the safety of the operator and the reliability of the engine. Any
error or oversight made by the technician while servicing can easily result in faulty operation,
damage to the engine or injury to the operator.
■ Improper servicing can cause an unsafe condition that can lead to serious injury or death.
Follow the procedures and precautions in this shop manual carefully.
■ Some of the most important precautions are given below. However, we cannot warn you of
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every conceivable hazard that can arise in performing maintenance or repairs. Only you can
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decide whether you should perform a given task.
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■ Failure to follow maintenance instructions and precautions can cause you to be seriously hurt
or killed. Follow the procedures and precautions in this shop manual carefully.
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2.2 Important safety precautions

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Be sure you have a clear understanding of all basic shop safety practices and that you are
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wearing appropriate clothing and safety equipment. When performing maintenance or repairs, be
especially careful of the following:
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■ Read the instructions before you begin, and be sure you have the tools and skills required to
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perform the tasks safely.

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■ Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the
possibility of several hazards:
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Be careful for carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you run the engine.
Be careful for burns from hot parts.
Let the engine cool before you touch it.
Be careful for injury from moving parts.
■ Do not run the engine unless the instruction tells you to do so. Even then, keep your hands,
fingers, and clothing away.
■ To reduce the possibility of a fire or explosion, be sure when working around gasoline, use only
a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away
from all fuel-related parts.
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2.3 Service rules
1. 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.
2. Use the special tools designed for the product.
3. Install new gaskets, O-rings, etc. when reassembling.
4. When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the
specified torque diagonally, unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before
reassembly.
6. After reassembly, check all parts for proper installation and operation.
7. Many screws used in this machine are self-tapping. Be aware that cross-threading or over
tightening these screws will strip the threads and ruin the hole.
8. Use only metric tools when servicing this engine. Metric bolts, nuts and screws are not
interchangeable with non metric fasteners. The use of incorrect tools and fasteners may damage
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the engine.
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9. Follow the instructions represented by these symbols when they are used.
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■ Electric precautions
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1. Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire
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harness. To disconnect the locking connector, be sure to unlock first, and then disconnect.
2. Check the connector terminals for bend, excessive extrusion, missing terminal, or other
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abnormalities before connecting the connector.

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3. To connect, insert the connector as full as it goes. If the connector is a locking type, be sure that
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it is locked securely.
4. Check the connector cover for breakage and check whether the connector female terminal is
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open excessively. Then, connect the connector securely. Check the connector terminal for rust.
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Remove the rust using an emery paper or equivalent material before connecting the connector.
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5. Set the harness clips in the specified places of the frame securely, and clamp the wire
harnesses.
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6. Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving
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parts and the hot parts.

7. Route and connect the wire harnesses properly. Be sure that the harnesses are not slack,
twisted or pulled taut.
8. Route the wire harnesses properly so that they do not contact with the shape edges and
corners, and the end of the bolts and screws on the body.
9. If a wire harness contacts the end of the bolts/screws or sharp edges and corners, protect the
contact part of the harness with a tube or by winding with an electrician’s insulating tape. If the
wire harness has a grommet, set the grommet securely.
10. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has
the damaged insulation, repair by winding with the electrician’s insulating tape.
11. Read the tester manufacture’s operation instructions carefully before operation with tester.
Follow the instructions of the Service Manual. Be sure that the battery built in a tester is fully
charged and check the meter before inspection using the tester.
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2.4 Serial number location
The engine serial number is stamped on the block above the oil dipstick. Refer to this number
when ordering parts or making technical inquiries.
Serial number
序列号位置
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2.5 Engine maintenance standards
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Part Item
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Maximum speed without load 4300±100rpm —
Engine
Compress force 0.45Mpa/800rpm —
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Cylinder Sleeve I.D. 58.000-58.020 58.105

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Skirt O.D 57.960-57.980 57.85

Piston
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Pin bore I.D. 13.002-13.008 13.05

Piston pin O.D 12.994－13.000 12.95
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Height h 0.97-0.99 0.87

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Ring side clearance 0.02-0.06 0.15

1st ring
Ring end clearance 0.15-0.25 1.0
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Width t 1.95-2.15 1.75

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Height h 1.17-1.19 1.07

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Piston ring 2nd ring

Width t 2.4-2.6 2.2
Height h 1.85-1.98 1.75
Oil ring
Width t 2.3-2.7 2.2
Connecting Small end I.D 13.006—13.017 13.08
rod Big end I.D 24.020—24.033 24.09
Crankshaft Crank pin O.D. 23.967-23.980 23.90
Valve IN 0.10±0.02 ---
clearance EX 0.15±0.02 ---
Valves
IN 3.965—3.980 3.90
Stem O.D.
EX 3.955—3.970 3.90
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Guide I.D. IN/EX 4.000—4.030 4.06
Seat width IN/EX 0.7 1.8
Valve spring Free length IN/EX 26.4 24.9
Cam wheel Cam height 29.026-29.086 28.5
O.D 8.966-8.975 8.92
Camshaft
Camshaft bearing I.D. 9.000-9.015 9.035
I.D(Rocker arm) 6.000-6.012 6.037
Rocker arm O.D.(Rocker arm shaft) 5.972-5.980 5.965
I.D.(Rocker arm shaft bearing) 6.000-6.012 6.037
Main jet 0.60 —
Carburetor Float height 12 —
Pilot screw opening 2 turns out —
Spark plug Gap 0.6—0.7 —
Primary side 0.8—1.3Ω —
Ignition coil Resistance
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Second side 15 —21kΩ —
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Pulse coil Air gap 0.5-0.75 —
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(Trigger) Resistance 80～130Ω —
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2.6 Alternator
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Standard(Ω)
Part Item Type
120V 240V
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Ignition winding Resistance Green-Yellow/Green 0.40-0.55

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Outer charging
Resistance Blue--Blue 0.12-0.15
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winding
White-White (IG)
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Sub winding Resistance 0.15-0.30

White-White (CG)
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Black—Black-Black
(IG)
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1.35-1 0.18-0. 0.65-0.

Main winding Resistance Black-Yellow/Black-Gr 5.0-5.5
.75 21 90
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een/Black-Red
(CG)
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2.7 Torque values
Tightening torque
Item Specification
N·m kgf·m
Connection rod bolt M5X0.8X25 8-10 0.8-1.0
Spark plug M10X1.0X13 13-15 1.3-1.5
Crankcase cover M6X25 8-10 0.8-1.0
Flywheel nut M12X1.25 48-52 4.8-5.2
M5 Bolt, nut 5-7 0.5-0.7
Standard torque M6 Blot, nut 8-10 0.8-1.0
M8 Bolt, nut 18-22 1.8-2.2
Note: Use standard torque values for fasteners that are not listed in this table
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3. TROUBLESHOOTING
3.1 General symptoms and possible causes
Fuel filter clogged Clean

Fuel tank tube clogged Clean
Fuel switch clogged Clean
Carburetor faulty Clean or replace
Ignition coil faulty Inspect and replace
Spark plug faulty Inspect and replace
Engine does
not start or Trigger faulty or trigger clearance Inspect and replace
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hard starting faulty
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Spark plug cap loose. Install securely
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Low oil alarm faulty Inspect and replace
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Igniter faulty Inspect and replace
Ignition winding faulty st Inspect and replace
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Throttle opening fault Set in fully closed or half closed position
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Carburetor faulty Clean or replace

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Engine speed
Throttle control motor (stepping Inspect and replace
does not
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motor) faulty
stabilize, too
Inverter unit faulty Inspect and replace
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high or too low

Valve clearance misadjusted Readjust
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3.2 Hard starting
Check the fuel level in the tank. No fuel Add fuel and restart the engine.
Sufficient fuel
Loosen the drain screw and No fuel indicated Add fuel and restart the engine.
check whether fuel reached the
carburetor.
Good spark
Remove the spark plug and Dry Check for blockage in the carburetor
check for wet or fouled electrode. port and nozzle.
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Clean the electrode and restart,
Wet taking care that the choke is not
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closed too much. If flooding is severe,
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check the carburetor float valve.
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No spark or
Remove the spark plug and weak spark st
Perform the ignition system
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check for wet or fouled electrode. troubleshooting
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Good spark
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Low cylinder
Install a compression gauge and compression 1. Check the valve clearance
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check ylinder compression by 2. Check for carbon deposits in the

pulling the recoil starter rope
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combustion chamber.
several times 3. Check for valve cone and base.
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4. Check for worn piston, piston ring

or cylinder.
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Normal
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compression
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Install the spark plug securely.

Restart the engine according to
the starting procedure.
■ Cylinder compression check

1. Remove the spark plug cap and spark plug.
2. Install a compression gauge in the spark plug hole, pull the recoil starter rope several times with
force and measure the cylinder compression.
Cylinder compression 0.45Mpa/800rpm
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缸压计
Pressure gauge
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c. Ignition system
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■ Fill in oil to the demanded level.
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■ Use specified UR5 spark plug
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■ Spark plug inspection
1. Disassemble spark plug
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2. Install spark plug onto spark plug cap.

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3. Set the oil switch to the “ON” position. Ground the negative (—) electrode (i.e. threaded part) of
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the spark plug against the shroud and pull the recoil starter rope to check the spark plug. You
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should see a clear spark.

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■ Don’t pull the recoil starter while touching the high tension wire with wet hands. High voltage is
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generated and very dangerous.

■ Drain the gasoline from the fuel tank and carburetor.
■ Pull the recoil starter several times to release the unburned gas in the cylinder with the engine
switch OFF.
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Measure the spark plug gap and
perform the spark plug test.
Standard clearance: 0.6—0.7mm
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Perform the spark test again using a Good spark
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Replace the spark plug
new spark plug
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No spark
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Remove the control panel. Perform Good spark
the spark test using a new igniter. Replace the igniter
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No spark
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Good spark
Check the engine switch Replace the engine switch
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No spark
Good spark
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Disconnect the low oil alarm and Replace the low oil alarm
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perform spark test
No spark
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Check the resistance of motor Abnormal

Replace the motor stator
ignition winding
Normal
Check the trigger Abnormal Replace the trigger or readjust

trigger clearance
Normal
Check the ignition coil resistance Abnormal

and high pressure cable, high Replace the ignition coil
pressure insulation cap.
Normal
Inspection or replace wire harness.

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3.3 Engine oil level is low, but engine does not stop. (Defective oil alarm device)
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
igniter plug, and check the continuity Repair or replace the wire
between the plug orange wire and ground. harnesses
Continuity
Igniter fault, replace the igniter.
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3.4 Engine stops running (Throttle is at the correct position)
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Oil alarm
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Check the oil level and oil alarm Fill oil and restart the engine
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Sufficient oil
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Reset the alarm connection wire, disconnect
igniter plug, and check the continuity st
No fuel
Fill in fuel and restart the engine
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between the plug orange wire and ground.
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Sufficient fuel
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Check the fuel switch and fuel filter for Blocked Clear the fuel switch and fuel
blockage filter
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Blocked Clear or replace the fuel supply

Check the fuel supply pipe for blockage
pipe
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No blocked
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Check the fuel switch and fuel filter for Blocked

Disassemble and clear
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blockage
No blocked
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Check sealing of inlet gasket and carburetor Abnormal Tighten nut or replace the
heat insulation block gasket
Normal 1. Check the valve clearance

Abnormal 2. Check the carbon deposit in
Measure the cylinder compression combustion chamber
3. Check the piston, piston ring
Normal and cylinder for damage
Abnormal
Check the trigger clearance Readjust the trigger clearance
Normal
Perform the throttle control system test
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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 Abnormal Clear electrode, adjust clearance
electrode clearance for carbon deposit or replace the spark plug
Normal
Check the carburetor and nozzle for Blocked
blockage Clean or replace
No blockage
Tighten the nut, and/or replace
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Check sealing of inlet line gasket and Abnormal
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the gasket or heat insulation
carburetor heat insulation block
block
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1. Check the valve clearance
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Abnormal 2. Check the carbon deposit in
Measure the cylinder compression
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combustion chamber
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Normal and cylinder for damage
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Perform the throttle control system test

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3.6 Throttle control system test

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1. Engine speed too high or too low

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Abnormal Perform the generator

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Check the AC output troubleshooting following the

instruction of “No or low AC output”
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Normal
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Abnormal
Check the throttle control motor Replace the throttle control motor
Normal
Replace the inverter unit
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3.7 Smart throttle doesn’t work with zero load, engine speed doesn’t increase with smart
throttle on and load connected.
Abnormal Perform the generator

Check the AC output troubleshooting following the
instruction of “No or low AC output”
Normal
Abnormal
Check the throttle control motor Replace the throttle control motor
Normal
Abnormal
Check the Smart switch Replace the smart switch
Normal
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Abnormal
Check Smart switch connection wire Repair or replace the wire harness
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3.8 No or low AC output
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ON Disconnect the load, and restart the

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Is the overload indicator light ON? engine

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OFF
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Is the engine speed normal? Abnormal

Smart switch Perform the throttle control system
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ON: 3200±100rpm test

OFF:4300±100rpm
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Normal
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Stop the engine and check the AC Abnormal

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receptacle Replace the AC receptacle
Normal
Disconnect the 6P connector on inverter
unit, pull the recoil starter with force and
measure the AC voltage between the
black terminal and white terminal. 1. Check and repair stator wire
120V type: Abnormal harness or replace stator
Black-Black: ＞30V 2. Rotor inner magnetism
White-White: ＞1V decreases, replace the rotor
Normal

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Inverter unit
逆变单元
Main winding/Sub winding

主绕组\副绕组
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Measure voltage
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Phase wire color: Black-Black-Black
Model
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Sub winding color: White-White
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Item 120V 240V
Voltage
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between ＞30V ＞60V

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phase wires
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Sub winding
＞1V
voltage
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Phase sequence arrangement

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3.9 No DC output
Abnormal Perform the throttle control system

Is the engine speed normal? test.
Normal
Abnormal
Check the DC output* Replace the DC receptacle
Normal
Abnormal
Check the DC output Replace the rectifier.
Normal
Measure the resistance between the Abnormal Check the wire harness, or replace
blue terminals of the rectifier. the stator.
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Resistance: 0.12~0.15Ω
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Normal
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Rotor losses magnetism and replace the
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rotor.
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*later models had a fuse in the receptacle. Check the fuse before replacing the receptacle.
3.10 No Parallel Output (prior to 2011 model year)
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■ Make sure that the parallel output cables are inserted into the parallel cable connectors on the
control panel..
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■ Use only KIPOR parallel output cables.

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■ Use only the KIPOR parallel output box.

■ Don’t use any control panel receptacles when running in parallel..
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■ Don’t disconnect the parallel cables while either generator is operating.

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Check whether the two generators could Abnormal Perform single generator
work well separately. troubleshooting
Normal
Is one of the over load indicating light Off 1. Check the parallel output cable
on? 2. Check the parallel output terminal
On
Check the paralleled I/O communication Abnormal Replace the parallel I/O
wire communication wire
Normal
Check the paralleled I/O communication Abnormal Replace the parallel I/O
receptacle communication receptacle
Normal
23

3.10 No parallel output- 2011 forward
This model year featured the elimination of the communication cable connecting the two
generators. Additionally, two generators of different sizes can be run in parallel. The new IG2000P
model cannot be paralleled with an older model. Troubleshooting remains basically the same. A
new parallel box is available with two circuit breakers. If there is no output at either receptacle on
the parallel box and both generators are indicating normal output, test the circuit breaker(s).
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24

4. MAINTENANCE
4.1 Maintenance schedule

Regular service period(1)
First Every 3 Every 6 Every
Item perform at every indicated
Each use month or months or months or year or
month or operating hour interval,
20 Hrs. 50Hrs. 100 Hrs. 300 Hrs.
whichever comes first
Check ●
Engine Oil
Replace ● ●
Check ●
Air filter
Clean ●②
.
Spark plug Clean-Adjust ●
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Spark catcher Clean-Adjust ●
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Valve clearance Check-Adjust ●③
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Fuel tank and filter Clean ●③
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Fuel line Check
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Every 2 year (Replace if necessary)
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Note:
(1) For commercial use, operation hours are determined by proper maintenance.
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(2) Service more frequently when operating in dusty areas.

(3) Service by an authorized Kipor service center.
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■ Checking the oil level

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Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking.
1. Loosen the screws of the maintenance cover and remove the cover.
11
2. Remove the oil filler cap and check for the oil level.
20
3. If the oil level is low, add to the edge of the oil fill port.
©
25

维修盖
Maintenance cover
Cover
螺钉screw
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Upper level
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上液面
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上限位
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机油尺
Oil dipstick
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下限位
Lower limit
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Oil 加油口
fill port
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■ Replace the engine oil

20
1. Disassemble the oil dipstick and oil drain bolt, drain used oil.
2. Tighten the oil drain bolt..
©
3. Refill with clean oil. (Oil capacity is 0.4L)

※ Recommended oil: SAE10W-30 or SAE30, API Service Classification SE, SF or SG.
4. Check the oil level; fill to the upper limit level if necessary.
5. Tighten the oil dipstick.
■ Please dispose of the used motor oil in a manner that is compatible with the environment. We
suggest you take used oil in a sealed container to your local recycling center or service station for
reclamation. Do not throw it in the trash; pour it on the ground, or down a drain.
■ Drain the used oil while the engine is warm. Warm oil drains quickly and completely.
26

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4.2 Checking the low oil alarm
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1. Disconnect oil alarm connector when the engine is still running, connect the two plugs, be sure
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that oil alarm lights and engine stops.
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橙色 (alarm
Orange 黄绿色
Yellow/ 橙色（点火器引出端）
Orange (igniter outlet terminal)
outlet terminal)
(报警器引出端） Green the two plugs are connected
两个插孔相互短接
2. Stop engine, disconnect oil alarm connector, check the connector conduction, no conduct is
normal.
27

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Igniter outlet terminal
点火器引出端
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Alarm
报警器引出端outlet terminal
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check the
测量两线间的通断 conductivity
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between the two wires
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3. Drain out the oil inside engine and check the conductivity, conducivity is normal.
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4.3 Air cleaner

Inspection/Cleaning:
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1) Loosen the cover screw and remove the maintenance cover.

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2) Disengage the locking tab by pushing it, and remove the air cleaner cover.
3) Remove the element from the air cleaner case.
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4) Clean the element in warm soapy water, rinse and allow to dry thoroughly, or clean with a high
20
flash point solvent and allow to dry.

©
Dip the element in clean engine oil and squeeze out the excess oil.
Excess oil will restrict air flow through the foam element and may smoke at engine start.
5) Install the air cleaner element in the air cleaner case.
6) Clean the air cleaner sealr and the air cleaner case if necessary. Be sure that the air cleaner
cover seals are set securely..
7) Install the maintenance cover securely.
28

Maintenance
维修盖cover
螺钉
Cover
Filter element
screw 精滤芯
Air空滤器盖
filter cover
Fixed
紧固螺栓 bolt
粗滤芯
Filter element
洗净
Wash 拧干后晾干
Dry Dip浸入机油
in engine oil 挤出机油
Squeeze firmly
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Sealing
海绵密封条 strip
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20
©
Caution
■ A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If the
engine is operated in dusty areas, clean the air cleaner more often than specified in the
Maintenance Schedule.
■ Never run the engine in case there is no element or the filter is damaged, as it will do great
harm to the engine.
29

4.4 Spark plug
Inspection/Cleaning:
1) Remove the spark plug cap and remove the spark plug.
2) Remove carbon or other deposits with a plug cleaner or stiff ire brush. Check the sealing
washer for damage.
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3) Measure the plug resistance; replace the spark plug if the measure is not accordance with the
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specification.
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Spark plug resistance 3~9KΩ
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4) Measure the plug gap with a feeler gauge. Adjust by bending the side electrode if the reading is
20
not within the specification..

Spark plug clearance 0.6~0.7mm
©
Standard spark plug UR5
30

0.6-0.7
5). Install the plug finger tight to seat the washer, then tighten with a plug wrench.
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Torque valve is 13~15 N.m
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4.5 Valve clearance
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Caution
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■ Valve clearance inspection and adjustment must be performed with the engine cold.
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Inspection/Adjustment:
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―Front cover, control panel
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―Rear cover
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―Right/left side covers

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―Fuel tank
―Inverter unit, engine bed
20
―Recoil starter, fan cover

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―Inlet/Exhaust side baffle

2) Remove the four bolts and disassemble the cylinder cover. Don’t remove the valve cover with
excessive force or it will deform. Replace the valve cover if it is deformed.
31

气缸盖罩
Cylinder cover
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3) Turn the rotor to set the piston at top dead center of the compression stroke.
Timing line of camshaft driving chain should align with the cylinder head seal. Insure the intake
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正时标记
Timing mark
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Exhaust valve
排气门
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Inlet valve
进气门
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旋转方向
Revolve direction
Caution
■ If the intake valve is open, turn the rotor again to align the timing line with the cylinder head
seal and both the inlet and exhaust valves should be closed.
4) Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance.
IN 0.06mm
Valve clearance
EX 0.08mm
32

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.
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塞尺gauge
Feeler
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6) Clean the liquid gasket of the cylinder block and cylinder head cover. Apply the liquid gasket
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(Three Bond 1207B or equivalent) to the cylinder block installation surface as shown.
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Liquid gasket 1.5-2.0 in diameter
直径1.5-2mm密封胶
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7) Install the removed parts in the reverse order of removal.
33

4.6 Fuel tank/Fuel filter EPA/CETL Models
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 solvent and allow the fuel tank to dry thoroughly.
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5) After cleaning, install the fuel tank and set the fuel filter in the tank. Connect the fuel tube.
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6) Install the removed parts in the reverse order of removal.
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Ventilation hose st
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油箱通气管
Fuel tank
燃油箱
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燃油滤网
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Fuel filter
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抱箍
Clamp
油管
Fuel hose
34

4.6 Fuel tank/Fuel filter CARB Models
Fuel System
Fuel Indicator Gas Cap
Strainer Washer
Gas Cap
Sleeve
Sleeve Gasket
Fuel Tank Cover Bushing
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Vent Hose
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Fuel Tank Washer
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Certification No. Cotter Pin
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Fuel Hose
Vent Hose
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Fuel Tank
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Negative Pressure Hose
Fuel Hose
Fuel Hose
Curved Hose
35

4.7 Fuel hose/ Fuel pump/Diaphragm tube
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) Check the fuel tube for deterioration, cracks and gasoline leakage. If there is any abnormality in
the fuel tube, replace the tube.
3) Check the diaphragm tube for deterioration, crack and gasoline leakage. If there is any
abnormality in the diaphragm tube, replace the tube.
4) Check to see whether water or foreign material has been accumulated in the fuel pump.
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If there is water or foreign material accumulated in the pump, replace the fuel pump.
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5) Check the fuel switch and fuel duct, blow away any foreign matter with compressed air with fuel
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switch turned on.
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6) After assembly, check for gasoline leakage from each component.
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燃油真空泵
Fuel pump
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油管
Fuel tube
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Diaphragm
负压管 tube
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至化油器
to Carburetor
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至负压口
to pressure port
11
Fuel油箱
tank
20
©
油开关
Fuel switch
Fuel 油管
tube
36

5. EXHAUST SYSTEM
Caution: Muffler removal/installation must be performed with the engine cold.

5.1 Muffler
Disassembly/Reassembly
消声器
Muffler
组装：
Installation: remove the
安装前用橡胶锤轻
carbon deposits by
轻敲打除去内部积
lightly tapping with
.
碳，再安装
a rubber hammer 。
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火星捕捉器消声器垫片
Muffler gasket
Spark Arrestor
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组装：
Installation: remove the
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安装前用刷子等清
carbon deposit by
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a brush
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除积碳再安装。
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后罩壳密封条
Seal strip of rear cover
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后罩壳
Rear cover
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Muffler mark “T”

安装有三元催化的
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消声器标识符号
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“T”
20
©
37

5.2 Exhaust tube, secondary air injection valve
● Disassembly/Reassembly
排气管
Exhaust tube
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Secondary
二次补气阀垫片 air injection valve
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gasket
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Second st
air injection valve
二次补气阀组件
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Caution
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■ Do maintenance after engine has cooled completely.

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(1) Remove the rear cover

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(2) Disassemble the spark arrestor from the muffler

(3) Remove the carbon from the spark catcher steel net, check for damage, and replace if
11
necessary.
20
(4) Install the removed parts in the reverse order of removal.

©
38

6. INTAKE SYSTEM
Caution
■ Loosen the drain olt and drain out fuel before disassembly.
■ Keep heat, flame and sparks away.
6.1 Disassembly/Installation of air filter
Ventilation
通气管tube
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Diaphragm
碳罐负压管 tube
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紧固螺钉
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Fixed screw
化油器垫片
Carburetor gasket
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Installation:
安装： check the
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gasket for
应当先确认垫片有无弯 deflection and
11
Air空滤器壳
filter shell damage.
折、破损等，同时应注 Pay attention to
意内外侧方向。
the inner and outer direction
20
Fine filter element

精滤芯
©
Rough
粗滤芯 filter element
Air 空滤器盖
filter cover
39

6.2 Disassembly/Installation of Carburetor
Diaphragm
负压管 tube
化油器垫片A
Carburetor gasket A
Installation:
安装： check the
应当先确认垫片有无
gasket for damage
破损再进行安装。
before installation
Air空滤器壳
filter shell
进气管垫片
Inlet pipe gasket:
Installation:
安装： check the gasket
Carburetor
化油器螺柱 stud 应当先确认垫片有无弯
For distortion or damage,
.
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折、破损等，同时应请
化油器绝缘块
Insulation block 注意内外侧方向。
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Installation:
安装： check the
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block for damage
应当先确认绝缘块有
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Oil inlet
进油管 tube 无破裂再进行安装。
before installation
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©
40

● Disassembly/Installation of Stepping motor
步进电机机盖
Stepping motor cover
步进电机
Stepping motor
Stepping motor seat

步进电机座
拔叉弹簧
Fork spring
Disassembly:
拆卸：拔叉
Fork
拆卸时用手捏牢，
Hold the spring
以防弹簧丢失。
.
firmly to avoid 拔叉
Fork
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油门杆
Throttle lever
dropping it.
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Fork spring
拔叉弹簧
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Idle adjusting cap
怠速调整限位帽
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©
41

● Disassembly/Installation of Carburetor
阻风门杆
Choke valve
Fork
拨叉
拨叉弹簧
Fork spring
阻风门片
Choke valve plate
怠速调整限位帽
Idle adjusting cap
Carburetor block
本体
mixture混合比调节螺丝
adjusting screw
(sealed) 出厂前位置已确
定，不可调节
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Needle seat
针座
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Foam tube
泡沫管
Installation: clear foreign 控油针
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组装：
Fuel control needle
material with compressed 组装：
Installation: check the end
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先用压缩空气清除通
先对端部的磨损、弹簧的动
air 路中的脏物再安装。
before installation.
st and spring before installation
作进行检查，再进行安装。
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注意安装方向。
控油针弹簧
Fuel control needle
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Main metering jet 主量孔

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Installation: clear foreign

组装： material Sealing ring of bowl
油杯密封圈
with compressed 先用压缩空气
air before
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清除通路中的浮子销
installation. Pay attention to the Float pin
脏物再安装。
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installation direction
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浮子
11
组装：
Float
安装后应当用手指触
20
动，对其动作确认。
©
油杯
Bowl
油杯锁紧螺丝密封圈
Sealing ring of carburetor bowl
油杯螺栓油杯放油螺栓
Bowl drain bolt
Bowl bolt 组装：
组装： Installation: check for
Installation:
安装后确认没有燃油check for 安装后确认没有燃油
fuel leakage ater
fuel leakage
漏出。 after 漏出。
installation
installation
42

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 drawing is for information only. Kipor will not supply any
carburetor parts other than stepping motors and main jets
6.3 Inspection
● Float height
Place the carburetor on a level surface as shown; measure the float height between the float and
carburetor block.
Height 12mm
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Replace the carburetor if the float height is not correct.
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43

● Stepping motor
Measure the resistance of stepping motor connection to the inverter.
Between 1and 3：45~55Ω

Standard resistance
Between 2 and 4：45~55Ω
Replace the stepping motor if the resistance excesses the above range.
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44

7. Control panel
7.1 Disassembly/Installation
前罩壳
Front cover
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控制面板
Control panel
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插件
Plug
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45

●IG2000\IG2000S
Igniter
点火器
交流插座
AC receptacle
smart开关
Smart throttle switch
直流插座
DC receptacle
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接地端
Ground terminal
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7.2 Inspection
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a. Control panel
11
● AC receptacle
20
Check the electrode contact disk inside receptacle, if it is burnt or the discolored, replace it.
©
● DC receptacle
Connect both terminals of the receptacle with a jumper wire to short. There must be continuity
between the lead wire terminals with the circuit protector ON. Replace the DC receptacle if there
is no continuity.
● Smart switch
There should be continuity with the switch ON, and no continuity with the switch OFF.
46

● Igniter (Ignition module)
Pull off the 10P receptacle from the module. Measure the resistance by connecting one test lead
with the metal outer case of the engine and the other lead with the 10P connector.
Color Circuit unit Standard resistance
Blue Primary coil of the ignition coil 0.8-1.3Ω
There should be no continuity with correct
Orange Oil level alarm
oil level
Yellow Trigger coil 80-130Ω
Yellow/Green Ground wire Continuity
Green Igniter unit power coil winding 0.26-0.28Ω
.
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There should be no continuity with the
Red Engine switch
switch ON, continuity with the switch OFF
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黄黄绿
兰橙 Yellow
Blue Orange 红Red
Green
Yellow/
绿
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Green
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熄火开关
Engine
11
(油开关)
switch
20
ON
©
OFF
47

● Engine switch
Check the continuity of connector, there should be continuity when depressing the micro switch.
Press down
压下
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©
48

● Aero receptacle (parallel I/O communication port)
Check the continuity between connector and aero receptacle, there should be continuity between
the two terminals with the same serial number.
8P连接器
8P connector
航空插座
Aero receptacle
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9 8 6 3 st
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黑色
Black 红色Red 黄色
Yellow兰色Blue 1 2
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Conducted between
同序号相通
same series number
6 7
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白色 Purple 橙色
White 紫色绿色
Orange Green
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1 2 4 7
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8P连接器
8P connector 航空插座
Aero receptacle
20
©
● Aero plug (Parallel I/O communication data wire)

Check the continuity of aero plugs, there should be continuity between two plugs with the same
serial numbers.
49

Parallel connection
communication
并联通讯接口interface
(aero（航空插头）
receptacle)
2 1 7 4
4 1 8
3
Conducted
同序号相通
.
between same
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7 6 2 9
series number
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9 8 6 3
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● Parallel output receptacle
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Check the continuity between the two terminals of parallel output receptacle.
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©
● Parallel output cable

1. Check the AC receptacle output terminal, there should be no continuity between two terminals.
2. Connect the AC receptacle output terminal with one lead, check the parallel plug; there should
50

be continuity among the four plugs.
3. There should be continuity between the cable earth terminal and AC receptacle earth terminal.
并联插头
Parallel connection plug
并联插头plug
Parallel connection
接地端terminal
Grounding
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Grounding
接地端 terminal
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Grounding terminal
接地端输出端
st Output terminal
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交流插座
AC Receptacle
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● Capacitor
Beginning with models built in December 2007 and ending in July, 2008, a capacitor was added to
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reduce electro-mechanical interference and eliminate problems with some digital clocks not displaying
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the time properly. This was an interim solution and all later models had an inverter module modification
11
to eliminate the capacitor.

20
1. LOCATION
The capacitor was placed in the output lines between the inverter and the AC receptacles. It is
©
physically located inside the service door to the right of the oil dipstick. It is mounted on a bracket that
bolts to the base plate. The base plate was modified to accept the new bracket. There is a 2p
connection behind the receptacles.
51

2. TROUBLESHOOTING AND TESTING
Check the capacitor when troubleshooting issues regarding digital clock displays. Should the capacitor
fail, there will be no impairment of any other generator function or output. As the capacitor is connected
directly to the output power supply, it has the potential to store a high voltage charge and should be
discharged prior to testing. Unplug the 2p connector and short circuit the capacitor by placing the end
of an insulated screwdriver across the two terminals.
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Term
Do not touch the exposed terminals nor attempt to take any measurements
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before discharging the capacitor.

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Use the capacitance checking mode of a multimeter. Replace the capacitor if any reading is outside the
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standard value of 10uF±5%.

11
20
©
52

8. Light Kit/ Housing / Fuel tank/ Fan housing/ Inverter unit
8.1 Disassembly and installation of accessory lamp

Caution: Stop the engine and let the lamp cool completely before disassembly.
Handle
灯壳手柄
Mounting pad
灯壳手柄石绵垫
灯壳
Lamp shell
Fixed seat
灯丝固定座
反射镜
.
Reflector
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玻璃
Glass
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Lamp bulb
灯管
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Sealing ring
灯壳密封圈
Mounting pad
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灯壳转头石绵垫
灯盖
Lamp cover
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Right
灯壳右固定架bracket
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螺母
Nut
20
Switch
开关 Screw
螺杆
©
B" B
A
A"
Left bracket
灯壳左固定架
Lamp shell swivel
灯壳转头
A
53

8.2 Disassembly and installation of housing case
Top cover
天门
Right housing case
右机壳
油箱盖
Fuel tank cover
油箱口垫
Filling port gasket
插件
Plug
Left housing case

左机壳
Right
右机壳十 cross
.
nc
protection
字保护架 frame
I
Side侧门组件
door
s,
e m
开口挡圈
Spilt
st
washer 逆变单元
Inverter unit
Sy
Protection
保护套 sleeve
逆变单元
er
Inverter mounting pad

减震垫
Left cross
左机壳十
ow
protection
字保护架
rP
frame
po
手拉柄固
Guard Foot
脚垫
Ki
定座
11
20
©
54

● Left housing case
Left左机壳
housing case
燃油泵
Fuel pump
油开关手柄
Fuel switch lever
油开关
Fuel switch
.
nc
微动开关
Micro switch
I
微动开关挡板
baffle
s,
em
st
Sy
er
ow
Fuel pump
燃油泵油管
Fuel hose
左机壳
Left housing case
rP
负压管
Diaphragm tube
po
Ki
油管
Fuel hose
11
20
©
Fuel tank
油箱
油开关
fuel switch
油管I
Fuel hose 卡箍
Clamp
55

8.3 Fuel tank- CARB
Caution
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handing
fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. Loosen the drain screw to
drain the carburetor thoroughly before removal.
Fuel
油标 Gauge
Filter
滤杯
cup
.
Fuel
油箱盖 tank cover
nc
油箱盖内棘爪
I
Pallet
Gasket
油箱口垫
s,
Thread sleeve
油箱盖内螺纹套
m
Groove
凹槽卡在凸缘处 Seal gasket
e
油箱盖密封垫
st Bushing
油箱盖内称套
Sy
燃油箱
Fuel tank Washer
垫圈
容量：3.4L
Capacity: 3.4L Washer
垫圈
er
组装：
Installation: clear the Hook
防掉倒钩
ow
先清除底部的脏污或
fuel水，然后再进行安装。
tank before
rP
installation
po
Filter strainer
滤网
Ki
Clamp
抱箍右机壳十字保护架
Cross protection frame for
11
Cross protection
左机壳十字保护架frame for 油管左右装配不能混淆
Fuel hose right housing case
20
left housing case

©
56

8.4 Fan shield/Engine mounting plate
Fan shield
导风罩
.
Inc
s,
减震套pad
Shock
e m
45cc 45cc碳罐
carbon
st
Sy
canister
空心轴
Hollow shaft
er
ow
发动机固定板焊合
Mounting plate
rP
po
Ki
11
20
©
57

8.5 Evaporative control system
进气系统
Inlet system
Connected to
接碳罐负压管
diaphragm
.
tube
nc
碳罐负压管
I
Diaphragm tube
s,
em
油箱通气管
Ventilation tube
st
Sy
er
ow
45cc碳罐
Carbon canister
rP
po
Curved hose
大气弯管
Ki
11
20
©
58

8.6 Guide Plate
Exhaust tube
排气管
Exhaust tube gasket
排气管垫片
排气侧导流板
Exhaust guide plate
Inlet guide plate

进气侧导流板
.
I nc
s,
e m
st
Sy
er
ow
rP
Lower air duct guide plate

下气道导流板
po
Ki
11
20
©
59

9. Recoil starter/ Air conduct cover/ Ignition coil
9.1 Disassembly/Reassembly
密封套
Seal sleeve
Ignition
点火线圈 coil
导风罩
Air conduct cover
Recoil
反冲启动器 starter
.
I nc
s,
e m
st
Sy
er
Rectifier bracket
整流桥支架
ow
整流桥
Rectifier
rP
起动拉绳
Starter rope
po
Assembly:
组装： check the starter
安装前应检查起动拉绳是否
rope for damage before
Ki
起动手柄盖
Handle cover
反冲起动器弹簧
绽裂或磨损，再进行安装。
installation
11
拆卸：
起动手柄
Handle 拆卸时应当戴上手套操作，小心不要使弹簧弹出。
20
起动器外壳
Starter shell 组装：spring
Starter
将外侧的钩挂在卷轴槽内，内侧的钩挂在外壳的卡爪上。
©
Disassembly: put on the gloves when disassembly
起动器卷轴
Starter reel
组装：
Assembly: install the starter to the reel
先将起动器弹簧安装到卷轴上，
first, and then install the reel to the starter
再把卷轴安装到起动器外壳上。
Friction
磨擦弹簧 spring
棘爪导板
Conduct plate
棘爪弹簧
Pallet spring
Pallet棘爪
60

9.2 Installation of recoil starter
(1) Set the spring into the starter reel, and hang the spring outer hook inside the reel groove.
弹簧
Spring
起动器卷轴
Starter reel
.
I nc
s,
(2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the
m
reel anticlockwise to hang the spring inner hook on the starter outer shell claw.
e
st
Sy
起动器卷轴 Starter reel
er
ow
Starter shell
起动器外壳
rP
po
Ki
11
20
©
(3) Make a knot at one end of the rope, pass the other end through the reel hole. Wind the reel
anticlockwise 4 turns to fix the reel.
61

(4) Pull out rope thrum from starter outer shell hole completely, pass it through the handle and
make a knot, then turn the handle cover. Loosen the reel to untension the spring, taking care not
to allow the reel to pop out.
.
I nc
s,
e m
st
Sy
er
ow
rP
po
(5) Install the starter pawl and fix it with bolts.

Ki
11
20
©
Pawl
棘爪
Pawl plate
棘爪导板
背面涂敷润滑脂
紧固螺栓
Fixed bolt
涂敷螺纹止动剂
棘爪弹簧
Pawl spring
磨擦弹簧
Friction spring
(6) Pull the starter for several times, and check the ratchet wheel returning.
62

9.3 Inspection
(1) Ignition coil
● Attach the two leads of meter to the primary coil plug of ignition coil and measure the primary
resistance of the ignition coil.
Primary resistance 0.8—1.3Ω
.
nc
I
● Attach one lead of the meter to each terminal of primary coil plugs of ignition coil and the other
s,
lead to the spark plug cap，then measure the secondary resistance of the ignition coil.
m
Secondary resistance 15—21kΩ
e
st
Sy
er
ow
rP
po
Ki
11
(2) Rectifier
20
Measure the on or off (positive pressure fall) of rectifier with control potentiometer , the
©
measurement should agree with the standard as shown in the chart.
Positive
1 2 3 4
Negative
1 OFF OFF OFF
2 ON OFF OFF
3 ON ON ON
4 ON OFF OFF
63

（1）负极引脚（-）
Negative (-) （2）交流引脚（
AC (～) ）
~
（4）交流引脚（）（3）正极引脚（+）
AC (～)
~ Positive (+)
.
nc
I
s,
em
st
Sy
er
ow
rP
po
Ki
11
20
©
64

10. Generator/ Trigger
10.1 Alternator
Disassembly/Reassembly
半圆键
组装：电机转子
检查安装是否正确，组装：
Key
注意不要漏装。安装电机转子时清除
锥面部分油污和脏物。
Rotor
Stator
电机定子
飞轮螺母
Flywheel nut
M12X1.25 70-80
70-80N.m
.
M12X1.25 N.m
nc
风叶轮
I
Fan
s,
m
风叶轮压板
Fan pressure plate
e
st 启动拉轮
Pull wheel
Sy
Pulse coil 脉冲线圈
(trigger)
（触发头）
er
ow
电机线密封圈
Seal ring
rP
po
Ki
11
10.2 Inspection
20
(1) Ignition winding

©
Measure the resistance between the green terminal and yellow/green terminal.
Resistance 0.40-0.55Ω
(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.
White-White
Resistance
0.15~0.30
65

(4) Main winding
Measure the resistance among the main winding terminals.
Black-Black-Black
Resistance
1.35~1.75
(5) Trigger
Attach the two testers in the trigger, and measure its resistance.
Trigger resistance 80-130Ω
.
ncI
s,
e m
st
Sy
er
ow
10.3 Adjustment
rP
Adjust the clearance between trigger and the projection part of rotor.
po
Ki
Trigger clearance 0.50-0.75mm

11
20
©
Insert a feeler gauge between the trigger and the projection part of the rotor; loosen the trigger
fixed plate bolt to adjust the clearance slightly. Never move the plastic part of trigger.
66

11. Cylinder cover/ Rocker arm
11.1 Disassembly/ Reassembly
Cylinder
气缸盖罩 cover
.
nc
Valve clearance adjusting nut
气门间隙调节螺母
I
Adjusting
气门间隙调节螺钉screw
s,
e m
st
Sy
Rocker shaft
摇臂轴
er
Rocker arm 进气门摇臂

of intake valve
ow
Rocker arm of exhaust valve

排气门摇臂
rP
po
Ki
11
Breather
呼吸器盖板焊接件cover
20
Sealant: 1mm diameter

直径1mm密封胶
©
气缸盖罩
Cylinder cover
67

11.2 Inspection
● Rocker arm outer diameter
Standard(mm) Service limit(mm)

5.972-5.980 5.965
.
nc
● Rocker arm inner diameter of inlet/exhaust valve
I
s,
m
e
6.000-6.012 6.037
st
Sy
er
ow
rP
po
Ki
11
20
©
68

● Inner diameter of rocker arm bearing

6.000-6.012 6.037
.
Inc
s,
e m
st
Sy
er
ow
rP
po
Ki
11
20
©
69

12. Crankcase cover/ Cam timing drive chain
12.1 Disassembly
火花塞
Spark plug
链条压板
Chain press plate
Spring
张紧弹簧
Retainer
挡块
凸轮正时传动链轮
Camshaft timing driving chain
Roller chain
滚子链
.
nc
传动轴
Driving shaft
I
O形密封圈曲轴箱盖
Crankcase cover
s,
O-seal ring
e m
st
Sy
卡块
er
Block
Location曲轴箱盖定位销
ow
pin of crankcase cover 销

Pin 张紧弹簧销轴
Spring pin roll
rP
链条托板
Chain plate
po
Ki
11
20
©
70

机油报警器
Oil alarm
O型密封圈
O-seal ring
.
Oil gear shaft
甩油齿轮轴
I nc
s,
Crankcase
曲轴箱盖 cover
em
Gasket
限速齿轮垫片
st
Sy
甩油齿轮
Oil gear 挡圈
Retainer ring
er
ow
12.3 Reassembly of roller chain

rP
po
1. Install the crankshaft, piston and connection rod assembly on the cylinder block.
2. Revolve the crankshaft; align the timing mark of crankshaft timing shaft with the timing mark of
Ki
crankcase. (Step 1)
11
3. Install the roller chain on the cam timing drive chain, level the timing mark upward. (Step 2)
20
4. Put the roller chain into the crankcase, set the end of roller chain to the crankshaft timing gear.
(Step 3) straighten the chain to align the timing mark of cam timing drive chain with cylinder head
©
sealing face.
Caution
Don’t remove the timing mark of crankshaft timing gear during installation. If the timing mark of
cam timing drive chain is not parallel with cylinder head sealing face, adjust the meshing of chain
and cam.
5. Install the O-seal ring into the drive shaft, and then assemble the drive shaft. (Step 4) Pay
attention that the opening of drive shaft should upward.
6. Install chain pressure plate. (Step 5)
71

Timing
正时标记 mark
装配密封面
Seal face
.
nc
4
I
s,
me
st
Sy
er
ow
rP
po
正时标记
Timing mark
Ki
11
20
箱体上的正时标记
Timing mark
©
72

12.4 Assembly of chain support plate/pressure plate
● Chain support plate
1. Put the upper groove of chain support plate into block; press the other end to seize the support
plate fully.
2. Insert the location pin into cylinder block location hole and align them, set the support plate and
clip block into cylinder block. Adjust the clip block location to align the clip bolt with cylinder block
bolt.
3. Install inner hexagonal bolt and tighten hard.
用力压入
Press
.
I nc
s,
e m
1 st 2
Sy
er
ow
rP
po
Ki
11
Location
定位销
20
pin
©
3 4
● Chain pressure plate
1. Install the spring pin shaft, spring and chain pressure plate as the picture shows.
2. Insert the spring into block location hole, set the chain pressure plate into cylinder block and
spring into location hole. Pay attention that the spring pin should be inserted as far as location.
3. Adjust the block location to align the block bolt hole with cylinder block bolt hole.
4. Install the inner hexagonal bolt and tighten it.
5. Hold the spring free end to seize the block (as picture shows), knock the spring pin with copper
hammer.
73

.
nc
I
s,
me
st
Sy
er
ow
rP
po
用尖嘴钳夹紧
Clamp the
Ki
弹簧使其卡在
spring to seize
11
档块上
the block
20
©
74

12.5 Assembly of crankcase cover
1. Clean any remaining sealant on the cylinder block and crankcase cover with cloth.
2. Apply gasket sealant on the cylinder block sealing face, as shown.
3. Reassemble the crankcase cover in the opposite direction of disassembly.
Caution
Install the crankcase cover on the cylinder block within three minutes after applying sealant.
Revolve the crankshaft if necessary.
.
I nc
s,
e m
st
Sy
er
ow
rP
po
Ki
11
20
©
75

4. Tighten the crankcase cover bolt slowly to the prescribed torque.
5. Wait 20 minutes after installation before filling with oil and starting the engine
Cylinder
机体 block 直径1.5-2mm密封胶
Sealant: 1-1.5mm diameter
.
I nc
s,
12.6 Inspection
e m
● Inspection of oil alarm st
Sy
(1) Stand the oil alarm, check the oil alarm output wire and copper earth wire, there should be no
er
continuity.
ow
(2) Bottom up the oil alarm; check again, there should be continuity.
(3) Bottom up the oil alarm completely in the oil, check the float, there should be no continuity.
rP
po
Ki
11
20
©
76

● Cam height
29.026-29.086 29.15
.
nc
● Cam inner diameter
I
s,
m
9.000-9.015 9.035
e
st
Sy
er
ow
rP
po
Ki
11
20
©
● Camshaft outer diameter

8.966-8.975 8.920
77

● Decompression block
Check the return spring for damage and weary, make sure the decompression block could
perform well.
Depression block
减压飞块
Return spring
回位弹簧
.
I nc
s,
em
st
Sy
er
ow
rP
po
Ki
11
20
©
78

13. Crankshaft/ Piston
13.1 Disassembly/ Reassembly
气门弹簧座
Valve
气门弹簧 spring
拆解：
Valve spring seat
将弹簧座稍稍
Disassembly: press down Oil seal of inlet valve
进气门导管油封
the 按下并朝旁孔
spring seat slightly and
移位卸下。
disassemble it Cylinder
机体 block
活塞
Piston
.
nc
Installation:
组装： install the
I
piston
将活塞顶部的“ with “ ▽ ”标记 ” label
s,
朝向电机侧安装。
towards inlet valve
e m
曲轴
Oil油封
seal 轴承
Bearing
st Crankshaft:
组装：
Sy
Semicircle
Installation: pay attention
装安装时注意不要将油封
半圆键
key
not to hurt the oil seal
碰伤，一直推入直到轴承
er
接触到轴承座底部为止。
during installation
ow
进气门座
Inlet valve
传动齿轮
Driving gear
rP
seat
排气门
Inlet
进气门 valve Timing gear
曲轴正时齿轮
po
Exhaust valve
组装：
Installation: check for damage
Ki
检查锥面有无缺损、
before installation.
积碳是否过多后再进行Don’t mix the
Connection rod连杆盖
11
cover
inlet valve安装。
and exhaust valve
连杆螺栓
Connection rod bolt
20
安装时进排气门不要
Inlet valve: ￠22 M5X0.8X25
M5X0.8X258-10N.m
混淆。
Exhaust valve: ￠20
©
锥面直径： 8-10M.m
进气门： 22
排气门： 20
79

13.2 Piston/Connecting Rod
厂家标记
Label
第一道环
1st ring
第二道环
2nd ring
Oil油环
ring
.
I nc
s,
me
活塞
Piston
st
Sy
er
ow
活塞销
Piston pin
rP
活塞销卡环
Piston pin clip
po
组装：
Installation: set the front end in the
Ki
将前端置于活塞的槽处，用尖嘴钳夹
piston groove, and clamp the other
住另一端，边转动边安装到槽内。
11
end. Install the ring clip by revolving.

不要使卡环的开口对着活塞销孔的缺
Pay
口处。 attention that the opening should
20
not face the gap of piston pin hole

连杆
©
Connection
组装： rod
将大端部较长的一侧朝向活塞的
Installation: the connection
卡环 “ ”指向的右侧装入活塞。
rod big end points to the right
Clip ring
side of piston △ label
80

Assembly of piston rings
Caution
● Set the manufactory label upwards.
● Pay 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 apart piston pin for 120°.
st
1 ring
第一道环（有镀铬）
2nd ring
第二道环（表面磷化）
油环
Oil ring
.
I nc
13.3 Inspection
s,
m
● Free length of valve spring
e
st
Sy
26.4 24.9
er
ow
rP
po
Ki
11
20
● Valve seat width

©

0.7 1.8
81

● Valve rod outer diameter

Inlet valve 3.965-3.980 3.90
Exhaust valve 3.955-3.970 3.90
.
ncI
s,
e m
● Valve guide pipe inner diameter st
Sy
er

ow
Inlet/Exhaust valve 4.000-4.030 4.060

rP
po
Ki
11
20
©
82

● Clearance between valve rod and valve guide pipe

Inlet valve 0.020-0.065 0.10
Exhaust valve 0.030-0.075 0.12
● Cylinder inner diameter

58.000-58.020 58.105
.
ncI
s,
e m
st
Sy
er
ow
rP
po
● Piston skirt outer diameter

Ki

11
57.960-57.980 57.850
20
10mm
©
● Clearance between piston and cylinder

0.020-0.042 0.120
83

● Side clearance of piston ring

0.02-0.06 0.15
● Piston ring end clearance
.
Locate the piston ring into cylinder with piston top, and measure the piston end clearance.
I nc
s,
m
0.15-0.25 1.0
e
st
Sy
er
ow
rP
po
Ki
11
20
©
84

● Piston ring height

st
The 1 ring 0.97-0.99 0.87
nd
The 2 ring 1.17-1.19 1.107
.
ncI
s,
e m
● Piston pin outer diameter
st
Sy
er
12.994-13.000 12.950
ow
rP
po
Ki
11
20
©
85

● Piston pin hole inner diameter

13.002-13.008 13.050
.
Inc
s,
e m
st
Sy
er
● Clearance between piston pin and piston pin hole

ow
rP

0.002-0.014 0.080
po
Ki
● Connection rod small end inner diameter

11
20

©
13.006-13.017 13.080
86

● Connection rod big end inner diameter

24.020-24.033 24.090
.
Inc
s,
m
● Crankshaft neck outer diameter
e
st
Sy
23.967-23.980 23.900
er
ow
rP
po
Ki
11
20
©
87

● Connection rod big end side clearance

0.1-.0.4 0.8
.
I nc
s,
e m
st
Sy
● Oil film clearance of connection rod big end
er
(1) Wipe off the oil on the surface of crankshaft neck.

ow
(2) Set the plastic wire feeler at the crankshaft neck and install the connection rod. Tighten the bolt
to the prescribed torque, pay attention that don’t revolve the crankshaft. The tighten torque is 8 to
rP
10N.m.
po
(3) Disassemble the connection rod, measure the plastic wire feeler thickness.
Ki
(4) Replace the connection rod if the clearance exceeds the service limit and measure the
clearance again. Grind the crankshaft neck if the new clearance still exceeds the service limit, and
11
use the connection rod less than the standard valve.

20
©

0.040-0.066 0.120
塑料线塞尺
Plastic gauge
88

.
nc
● Bearing vibration
I
Clean the bearing and check the clearance between the crankshaft journal and connecting rod big
s,
end by revolving bearing by hand. Replace the bearing if there is abnormal noise or vibration.
e m
st
Sy
er
Clearance
游隙
ow
Clearance
游隙
rP
po
Ki
11
20
Axial轴向
direction Circle
圆周方向direction
©
89

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KIPOR POWER PRODUCTS CO., LTD.

IG2000/IG2000P/IG2000S SHOP MANUAL

Kipor Power Systems, Inc.

Revision 4, July, 2011

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The manual is applicable to EPA, CARB, and CETL models.

All information, illustrations, directions and specifications included in this publication

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3.2 HARD STARTING ............................................................................................................. 16

3.3 OIL ALARM ....................................................................................................................... 19

3.4 ENGINE STOPS RUNNING ............................................................................................. 19

3.6 THROTTLE CONTROL SYSTEM ..................................................................................... 20

3.7 SMART THROTTLE.......................................................................................................... 21

3.8 LOW OR NO AC OUTPUT ............................................................................................... 21

3.10 NO PARALLEL OUTPUT ................................................................................................ 23

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10.3 TRIGGER ADJUSTMENT ............................................................................................... 66

11. CYLINDER COVER/ROCKER ARM....................................................................................... 67

11.1 DISASSEMBLY/REASSEMBLY ...................................................................................... 67

12. CRANKCASE COVER/CAMSHAFT DRIVE CHAIN ............................................................. 70

12.1 DISASSEMBLY ............................................................................................................... 70

12.3 ROLLER CHAIN REASSEMBLY .................................................................................... 71

12.4 CHAIN SUPPORT PLATE/PRESSURE PLATE .............................................................. 73

12.6 INSPECTION .................................................................................................................. 76

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Dimensions and weights

Ignition system T.C.I

Ignition timing 27°B.T.D.C

Carburetor Float type, Horizontal, butterfly valve

Air cleaner Semi-dry

Governor Electronically controlled

Oil capacity qt (L) .35 (0.4)

Starting system Recoil starter

Fuel used Automotive unleaded gasoline 87 octane

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Frequency stability ±0.1%

Insulation resistance 10 MΩ min

AC circuit protector 17.9A @120V

DC circuit protector 10A

Operating hours (at rated load) 4

Noise level NL-FL @23’ (7 m) 54-59

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The curves show performance of the generator under average conditions.

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a. IG2000 pre 2011

b. IG2000P Pre 2011

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2.1 The importance of proper servicing

2.2 Important safety precautions

perform the tasks safely.

Be careful for carbon monoxide poisoning from engine exhaust.

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abnormalities before connecting the connector.

parts and the hot parts.

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Cylinder Sleeve I.D. 58.000-58.020 58.105