Kipor IG1000 Install guide

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KIPOR POWER PRODUCTS CO., LTD.
IG1000 SHOP MANUAL
EPA/CARB/CETL Certified Models
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Kipor Power Systems, Inc.
Revision 4, July, 2011
© 2011 Kipor Power Systems, Inc.

Preface
ers the construction, function and servicing procedures of the KIPOR IG1000.
This manual is applicable to all models certified by the California Air Resources Board (CARB) and
EPA/CETL built from December 2008 onward. The c of both generators is identical but CARB
areful observance of the instructions contained in this manual will result in safe and quality
ll information, illustrations, directions and specifications included in this publication are based on the
UXI KIPOR POWER CO., LTD, reserves the right to make changes without incurring any obligation
This manual cov
onstruction
model fuel systems use certified materials. Procure the correct parts applicable to your model.
Models with production dates of 2011 feature overload reset switches and a parallel version is now
available.
C
maintenance and repair work.
A
latest product information available at the time of approval for printing.
W
whatever. No part of this publication may be reproduced without written permission.
ii
© 2011 Kipor Power Systems, Inc.

CONTENTS
1. SPECIFICATIONS/WIRING DIAGRAM .................................................................................... 1
1.1 SPECIFICATIONS .............................................................................................................. 1
1.2 WIRING DIAGRAMS........................................................................................................... 3
2. SERVICE INFORMATION ........................................................................................................ 6
2.1 THE IMPORTANCE OF PROPER SERVICING.................................................................. 6
2.2 IMPORTANT SAFETY PRECAUTIONS.............................................................................. 6
2.3 SERVICE RULES ............................................................................................................... 5
2.4 ELECTRICAL PRECAUTIONS ........................................................................................... 7
2.5 SERIAL NUMBER AND BARCODE.................................................................................... 8
2.6 MAINTENANCE STANDARDS ........................................................................................... 9
2.7 TORQUE VALUES ............................................................................................................ 10
3. TROUBLESHOOTING............................................................................................................ 11
3.1 GENERAL SYMPTOMS AND CAUSES............................................................................ 11
3.2 HARD STARTING ............................................................................................................. 12
3.3 OIL LEVEL SWITCH ......................................................................................................... 15
3.4 ENGINE STOPS RUNNING.............................................................................................. 15
3.5 ENGINE SPEED UNSTABLE............................................................................................ 16
3.6 ENGINE SPEED TOO HIGH OR LOW ............................................................................. 16
3.7 SMART THROTTLE.......................................................................................................... 17
3.8 LOW OR NO AC OUTPUT................................................................................................ 17
3.9 NO DC OUTPUT............................................................................................................... 17
4. MAINTENANCE .................................................................................................................... 19
4.1 MAINTENANCE SCHEDULE ........................................................................................... 19
4.2 ENGINE OIL ..................................................................................................................... 20
4.3 CHECKING THE LOW OIL ALARM .................................................................................. 20
4.4 AIR CLEANER .................................................................................................................. 21
4.5 SPARK PLUG ................................................................................................................... 22
4.6 VALVE CLEARANCE ........................................................................................................ 23
4.7 FUEL TANK AND FILTER ................................................................................................. 25
4.8 FUEL PUMP AND HOSES................................................................................................ 27
4.9 SPARK ARRESTOR.......................................................................................................... 28
5. MUFFLER ............................................................................................................................. 29
6. AIR FILTER/CARBURETOR ................................................................................................. 28
6.1 AIR FILTER REMOVAL AND INSTALLATION................................................................... 28
6.2 CARBURETOR REMOVAL AND INSTALLATION............................................................. 28
6.3 STEPPING MOTOR REMOVAL AND INSTALLATION ..................................................... 29
6.4 CARBURETOR EXPLODED DRAWING .......................................................................... 30
6.5 INSPECTION .................................................................................................................... 31
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© 2011 Kipor Power Systems, Inc.

7. CONTROL PANEL ................................................................................................................ 32
7.1 REMOVAL AND INSTALLATION....................................................................................... 33
7.2 INSPECTION .................................................................................................................... 33
8. HOUSING/FUEL TANK ......................................................................................................... 35
8.1 HOUSING DISASSEMBLY ............................................................................................... 35
8.2 FUEL TANK ASSEMBLY ................................................................................................... 36
9. RECOIL STARTER/AIR CONDUCT COVER/IGNTION COIL/AIR CONDUCT PLATE ......... 37
9.1 DISASSEMBLY AND REASSEMBLY................................................................................ 37
9.2 AIR CONDUCT PLATE ..................................................................................................... 38
9.3 RECOIL STARTER ........................................................................................................... 39
9.4 IGNITION COIL................................................................................................................. 42
10. ALTERNATOR/TRIGGER ..................................................................................................... 43
10.1 ALTERNATOR................................................................................................................. 43
10.2 INSPECTION .................................................................................................................. 43
10.3 TRIGGER ADJUSTMENT ............................................................................................... 44
11. CYLINDER COVER/ROCKER ARM....................................................................................... 45
11.1 DISASSEMBLY/REASSEMBLY ...................................................................................... 45
11.2 INSPECTION .................................................................................................................. 46
12. CRANKCASE COVER/CAMSHAFT DRIVE CHAIN ............................................................. 47
12.1 DISASSEMBLY ............................................................................................................... 47
12.2 CRANKCASE OIL TRAY ASSEMBLY AND DISASSEMBLY ........................................... 47
12.3 CRANKSHAFT INSTALLATION ...................................................................................... 48
12.4 CRANKCASE COVER ASSEMBLY ................................................................................ 49
12.5 INSPECTION .................................................................................................................. 49
13. CRANKSHAFT/PISTON AND CONNECTING ROD ............................................................. 52
13.1 DISASSEMBLY ............................................................................................................... 52
13.2 PISTON........................................................................................................................... 53
13.3 INSPECTION .................................................................................................................. 54
13. APPENDIX A- CAPACITOR .................................................................................................. 66
13. APPENDIX B- CARB CERTIFIED UNITS ............................................................................. 68
13. APPENDIX C- PARALLEL OPERATION .............................................................................. 69
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1
1. SPECIFICATIONS and WIRING DIAGRAM
1.1 SPECIFICATIONS
Dimensions and weights
Model IG1000/IG1000P
Overall Length in (mm) 18.1 (460)
Overall Width in (mm) 9.8 (248)
Overall Height in (mm) 15.6 (395)
Net Weight in (Kg) 30.8 (14)
Engine
Model KG144
Type 4-stroke,OHV, single cylinder, Gasoline engine
Displacement cu in. (cc) 3.3 (53.5)
Maximum horsepower/rpm 1.3/5500
Compression ratio 8.5:1
Cooling system Forced air-cooled
Ignition system T.C.I
Ignition timing 29°B.T.D.C
Spark plug UR5
Carburetor Float type, Horizontal, butterfly valve type
Air cleaner Semi-dry type
Governor Electronic control
Lubrication system Forced splash
Oil capacity qt (L) .19 (0.22)
Starting system Recoil starter
Stopping system Primary circuit ground
Fuel Automotive unleaded gasoline 87 octane
Alternator
Model KD10
Generator type Multi pole rotation
Generator structure Self-ventilation drip-proof alternator
Excitation Self-excitation (Magnet type)
Voltage regulation system Plush width modulation
Phase Three phase
Rotating direction Clockwise (Viewed from the generator)
Frequency regulation AC-DC-AC conversion
© 2011 Kipor Power Systems, Inc.

2
Performance
Model IG1000
Maximum output AC 1.0KVA
Rated output AC 0.9KVA
Rated output DC 100W
Rated frequency 60HZ
Rated voltage AC 120V
Rated voltage DC 12V
Rated current AC 7.5A
Rated current DC 8.3A
Power factor 1.0
Voltage variation rate Momentary
Average
Averagetime
10%max.
1.5%max.
3 sec. max.
Voltage stability ±1%
Frequency variation rate Momentary
Average
Averagetime
1%max.
1%max.
1 sec. max.
Frequency stability ±0.1%
Insulation resistance 10MΩmin.
AC circuit protector 8.8 A
DC circuit protector 10 A
Fuel tank capacity-gal (L) .69 (2.6)
Operating hours 4
Noise level NL-FL @ 23’ (7 m) 60-65 dB
© 2011 Kipor Power Systems, Inc.

1.2 WIRING DIAGRAM IG1000 through 2010 Model Year
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© 2011 Kipor Power Systems, Inc.

IG1000 2011 Forward
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© 2011 Kipor Power Systems, Inc.

IG2000P 2011 forward
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© 2011 Kipor Power Systems, Inc.

2. SERVICE INFORMATION
2.1 The importance of proper servicing
Proper servicing is essential to the safety of the operator and the reliability of the generator. Any error
or oversight made by the technician while servicing can easily result in faulty operation and/or damage to
the equipment or injury to the operator.
Improper servicing can cause an unsafe condition that can lead to serious injury or death.
Follow the procedures and precautions in this shop manual carefully.
Some of the most important precautions are stated below.
2.2 Important safety precautions
Be sure you have a clear understanding of all basic shop safety practices and that you are wearing
appropriate clothing and safety equipment. When performing maintenance or repairs, be especially
careful of the following:
•Read the instructions before you begin, and be sure you have the tools and skills required to
perform the tasks safely.
•Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the
possibility of several hazards:
- Carbon monoxide poisoning from engine exhaust.
- Burns from hot parts.
- Injury from moving parts.
•Do not run the engine unless the instructions tell you to do so. Keep your hands
and clothing away from rotating parts.
•To reduce the possibility of fire or explosion, exercise extreme caution when
working around gasoline. Use only a nonflammable solvent, not gasoline, to clean
parts. Keep cigarettes, sparks and flames away from all fuel-related parts.
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© 2011 Kipor Power Systems, Inc.

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2.3 Service rules
•Use genuine KIPOR or KIPOR-recommended parts and lubricants or their equivalents. Parts that
do not meet Kipor’s design specifications may damage the engine.
•Use the special tools designed for the product.
•Always install new gaskets, O-rings, etc. when reassembling components.
•Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before
reassembly. After reassembly, check all parts for proper installation and operation.
•Many screws used in this machine are self-tapping. Be aware that cross-threading or over
tightening these screws will strip the threads and ruin the hole.
•Use only metric tools when servicing this engine. Metric bolts, nuts and screws are not
interchangeable with non metric fasteners. The use of incorrect tools and fasteners will damage
the engine.
2.4 Electrical precautions
•Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire
harness. To disconnect the locking connector, be sure to unlock first, and then disconnect.
•Check the connector terminals for bend, excessive extrusion, missing terminals, or other
abnormalities before connecting the connector.
•To connect, insert the connector as far as it goes. If the connector is a locking type, be sure that it
is locked securely.
•Check the connector cover for breakage and check whether the connector female terminal is not
opened excessively. Then, connect the connector securely. Check the connector terminal for rust.
Remove the rust using an emery paper or equivalent material before connecting the connector.
•Set the harness clips in the specified places of the frame securely, and secure the wire
harnesses.
•Clamp the cables securely.
•Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving
parts and hot parts.
•Route and connect the wire harnesses properly. Be sure that the harnesses are not slack,
twisted or pulled overly taut.
•Route the wire harnesses properly so that they do not contact sharp edges and corners and the
end of the bolts and screws on the body.
© 2011 Kipor Power Systems, Inc.

•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
The generator serial number identifies your particular unit and is important when ordering parts and
accessories. It is also used by your dealer and distributor for warranty administration.
The generator serial number is stamped on the engine block to the right of the oil dipstick. It is also on a
label on both ends of the generator carton as well as the certificate of quality.
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© 2011 Kipor Power Systems, Inc.

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2.6 Maintenance standards
Part Item Standard(mm) Service limit
Engine Maximum speed without load 5500±100 rpm —
Cylinder Sleeve I.D. 1.712-1.714 in 1.716 in
43.500-43.520 mm 43.595 mm
Piston
Skirt O.D 1.711-1.712 in 1.707 in
43.460-43.480 mm 43.350 mm
Pin bore I.D. 0.3937-0.3940 in 0.3955 in
10.002-10.008 mm 10.050 mm
Piston pin O.D 0.3934-0.3937 in 0.3920 in
9.994-10.000 mm 9.950 mm
Piston ring
1st ring
Height 0.030-0.031 in 0.028 in
0.77-0.79 mm 070 mm
Ring side clearance 0.0008-0.0024 in 0.0059 in
0.02-0.06 mm 0.15 mm
Ring end clearance 0.0039-0.0098 in 0.0314
0.10-0.25 mm 0.80 mm
Width 0.063-0.071 in 0.055 in
1.60-1.80 mm 1.40 mm
2nd ring
Height 0.038-0.039 in 0.0354 in
0.97-0.99 mm 0.90 mm
Ring side clearance 0.0008-0.0024 in 0.0059 in
0.02-0.06 mm 0.15 mm
Ring end clearance 0.0039-0.0098 in 0.0314
0.10-0.25 mm 0.80 mm
Width 0.071-0.078 in 0.063 in
1.80-2.00 mm 1.60 mm
Oil ring
Height 0.053-0.058 in 0.049 in
1.35-1.48 mm 1.25mm
Ring side clearance 0.0008-0.0067 in 0.0090 in
0.02-0.17 mm 0.23 mm
Ring end clearance 0.0079-0.1180 in 0.0354 in
0.20-0.30 mm 0.90 mm
Width 0.3942-0.3946 in 0.3965 in
2.00-2.40 mm 1.80 mm
Connecting
rod
Small end I.D 0.3942-0.3946 in 0.3965 in
10.012-10.024 mm 10.070 mm
Big end I.D 0.5911-0.5915 in 0.5937 in
15.015-15.025 mm 15.080 mm
Crankshaft Crank pin O.D. 0.5896-0.5899 in 0.5866 in
14.975-14.985 mm 14.900 mm
Valves
Valve
clearance
Intake 0.0031-0.0039 in ---
0.08-0.10 mm ---
Exhaust 0.0039-0.0059 in ---
0.10-0.15 ---
Stem O.D. Intake 0.156-0.157 in 0.1535 in
© 2011 Kipor Power Systems, Inc.

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3.965—3.980 mm 3.900 mm
Exhaust 0.1557-0.1562 in 0.1540 in
3.955—3.970 mm 3.900 mm
Guide I.D. IN/EX 0.1575-0.1579 in 0.2598 in
4.000—4.012 mm 4.060 mm
Valve spring Free length IN/EX 0.925 in 0.866 in
23.5 mm 22 mm
Cam wheel Cam height 1.101-1.103 in 1.062 in
27.97-28.03 mm 26.97 mm
Camshaft
O.D 0.1963-0.1967 in 0.1949 in
4.988-4.996 mm 4.950 mm
Camshaft bearing I.D. 0.1976-0.1988 in 0.2008
5.02-5.05 mm 5.10 mm
Rocker arm
I.D(Rocker arm) 0.1575-0.1579 in 0.2598 in
4.000-4.012 mm 4.050 mm
O.D.(Rocker arm shaft) 0.1574-0.1579 in 0.1590 in
3.988-3.996 mm 3.950 mm
I.D.(Rocker arm shaft bearing) 0.1574-0.1579 in 0.1594 in
4.000-4.012 mm 4.050 mm
Spark plug Gap 0.024-0.028 in —
0.6—0.7 mm —
Ignition coil Resistance Primary side 0.8—1.3 Ω—
Second side 15 —21 kΩ—
Pulse coil
(Trigger)
Air gap 0.020-0.0295 in —
0.5-0.75 mm —
Resistance 80～130Ω—
Part Item Type Standard (Ω)
Ignition winding Resistance Green-Yellow/Green 0.50-0.70
Outer charging
winding Resistance Blue--Blue 0.16-0.20
Sub winding Resistance White—White 0.25-0.35
Main winding Resistance Black—Black 2.0-3.0
2.7 Torque values
Item Specification Tightening torque
Ft lb. N·m
Connection rod bolt M5X0.8X25 5.9-7.4 8-10
Spark plug M10X1.0X13 11-13
Flywheel nut M10X1.25 48-52
Standard torque M5 Bolt, nut 4.4-6.0 6-8
M6 Blot, nut 5.9-7.4 8-10
Note: Use standard torque values for fasteners that are not listed in this table.
© 2011 Kipor Power Systems, Inc.

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3. Troubleshooting
This troubleshooting section contains troubleshooting trees organized by common groups of symptoms.
Some testing information is contained in these sections. The following chapters of this manual focus on
individual components and sub assemblies which will give you the assembly and reassembly
procedures along with detailed specifications and testing procedures.
3.1 General symptoms and possible causes
Engine does
not start or
hard starting
Fuel filter clogged Clean
Fuel tank tube clogged Clean
Fuel switch clogged Clean
Carburetor faulty Readjust and clean
Ignition coil faulty Inspect and replace
Spark plug faulty Inspect and replace
Trigger faulty or trigger clearance
faulty
Inspect and replace
Spark plug cap looses Fix it securely
Low oil alarm faulty Inspect and replace
Ignitor faulty Inspect and replace
Ignition winding faulty Inspect and replace
Throttle opening fault Set in fully close or half close position
Engine speed
does not
stabilize, too
high or too low
Carburetor faulty Adjust and/or disassemble and clean
Throttle control motor (stepping
motor) faulty
Inspect and replace
Inverter unit faulty Inspect and replace
Valve clearance misadjusted Readjust
© 2011 Kipor Power Systems, Inc.

3.2 Hard starting
Install the spark plug and ground
the electrode. Check the spark.
Install a compression gauge in
the spark plug hole and check the
cylinder compression by pulling
the recoil starter rope several
times
Normal
Install the spark plug securely.
Restart the engine according to
the starting procedure.
Normal
com
p
ression
Low cylinde
r
compression 1. Check the valve clearance
2. Check for carbon deposits in the
combustion chamber.
3. Check for worn guides and seals.
4. Check for worn piston, piston ring
or cylinder.
No spark o
r
weak spark
Perform the ignition system
troubleshooting
Clean the electrode and restart,
Ensure the choke is not closed. I
f
flooding is severe, check the
carburetor float valve.
Wet
Check the fuel level in the tank.
Loosen the drain screw and
check whether fuel reached the
float chamber and the oil level.
Remove the spark plug and
check for wet or fouled electrode.
Dry Check for blockage in the carbureto
r
intake port and nozzle.
Normal
Abnormal Check the fuel lines for blockage.
Sufficient fuel
No fuel
A
dd fuel and restart the engine.
■Cylinder compression check
1. Remove the spark plug cap and spark plug.
2. Install a compression gauge in the spark plug hole. Pull the recoil starter rope several times with force
and measure the cylinder compression.
Cylinder compression 80 psi/0.55Mpa
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© 2011 Kipor Power Systems, Inc.

C. Ignition system
■Fill in oil to the required level.
■Use spark plug UR5.
■Spark plug inspection
1. Disassemble spark plug
2. Install spark plug onto spark plug cap.
3. Set the oil switch to the “ON” position. Ground the negative (—) electrode (i.e. threaded part) of the
spark plug against the shroud and pull the recoil starter rope to check the spark plug. Normally you
should see the spark jump the electrode gap when the plug is firing.
13
■Don’t pull the recoil starter while touching the high tension wire with wet hands. High voltage
generates, which is very dangerous.
■Fire may be caused if fuel spilled around the spark plug, so make sure that you test after draining off
fuel completely.
■Fuel inside cylinder will be burnt if the spark plug is near the hole, so please turn off the engine first.
Pull the recoil starter several times to release the unborn gas in the cylinder.
© 2011 Kipor Power Systems, Inc.

3.2 Hard Starting Continued
14
Measure the spark plug gap and
perform the spark plug test. Gap:
024-028 in
(
0.6—0.7mm
)
Perform the spark test again using a
new spark plug
Good spark Replace the spark plug
No spark
No spark
Check the trigger Abnormal Replace the trigger or readjust
trigger clearance
Check the ignition coil resistance
and high pressure cable, high
pressure insulation cap.
Inspection or replace wire harness.
Abnormal
Replace the ignition coil
Normal
Check the resistance of motor
ignition winding Replace the motor stator
Abnormal
Replace the engine switch
No spark
Check the engine switch Good spark
Replace the low oil alarm
Disconnect the low oil alarm and
perform spark test
Good spark
No spark
Remove the control panel. Perform
spark test with a new ignition module.
Good spark Replace the ignition module
No spark
Normal
Normal
© 2011 Kipor Power Systems, Inc.

3.3 Engine oil level is low, but engine does not stop. (Defective oil switch)
Drain out oil completely, disconnect alarm
connection wire, and check the continuity
between alarm outlet terminal and ground. Replace the oil level alarm
Ignition module fault: replace module.
Continuity
Reset the alarm connection wire, disconnect
ignition module and check the continuity
between the plug orange wire and ground.
No continuity Repair or replace the wire
harnesses
Continuity
No continuity
3.4 Engine stops running (Throttle is at the correct position)
Check the oil level and oil alarm Fill in oil and restart the engine
Sufficient oil
Oil alarm
Check whether there is enough fuel in the
fuel tank.
A
dd fuel and restart the engine
No fuel
Sufficient fuel
Check the fuel switch and fuel filter fo
r
blockage
Check the fuel supply line for blockage Clear or replace the fuel supply
line
Blocked
No blocked
Clean or replace carburetor
Blocked
Check the carburetor nozzles for blockage
No blocked
Blocked Clear the fuel switch and fuel
filter
Not blocked
Check seal between inlet gasket and
carburetor heat insulation block
Normal
Measure the cylinder compression
1. Check the valve clearance
2. Check the carbon deposit in
combustion chamber
3. Check the piston, piston ring
and cylinder for damage
Abnormal
Tighten nuts and/or replace
gasket.
Abnormal
Normal
Check the trigger clearance Abnormal
Normal
Perform the throttle control system test
Readjust the trigger clearance
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© 2011 Kipor Power Systems, Inc.