Kipor IG2000 Install guide

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KIPOR POWER PRODUCTS CO., LTD.
IG2000/IG2000P/IG2000S SHOP MANUAL
EPA/CARB/CETL Certified Models
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Kipor Power Systems, Inc.
Revision 4, July, 2011

1
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
incurring any obligation.
No part of this publication may be reproduced without written permission.
© 2011 Kipor Power Systems, Inc.

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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
2.2 IMPORTANT SAFETY PRECAUTIONS ............................................................................11
2.3 SERVICE RULES ............................................................................................................. 12
2.4 ELECTRICAL PRECAUTIONS ......................................................................................... 13
2.5 SERIAL NUMBER AND BARCODE.................................................................................. 13
2.6 MAINTENANCE STANDARDS ......................................................................................... 14
2.7 TORQUE VALUES............................................................................................................ 14
3. TROUBLESHOOTING ........................................................................................................... 15
3.1 GENERAL SYMPTOMS AND CAUSES ........................................................................... 15
3.2 HARD STARTING............................................................................................................. 16
3.3 OIL ALARM ....................................................................................................................... 19
3.4 ENGINE STOPS RUNNING ............................................................................................. 19
3.5 ENGINE SPEED UNSTABLE ........................................................................................... 20
3.6 THROTTLE CONTROL SYSTEM ..................................................................................... 20
3.7 SMART THROTTLE.......................................................................................................... 21
3.8 LOW OR NO AC OUTPUT ............................................................................................... 21
3.9 NO DC OUTPUT............................................................................................................... 22
3.10 NO PARALLEL OUTPUT ................................................................................................ 23
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
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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
9. RECOIL STARTER/AIR CONDUCT COVER/IGNTION COIL .................................................. 60
9.1 DISASSEMBLY AND REASSEMBLY................................................................................ 60
9.2 RECOIL STARTER INSTALLATION ................................................................................. 61
9.3 INSPECTION.................................................................................................................... 63
10. ALTERNATOR/TRIGGER ..................................................................................................... 65
10.1 ALTERNATOR................................................................................................................. 65
10.2 INSPECTION.................................................................................................................. 65
10.3 TRIGGER ADJUSTMENT............................................................................................... 66
11. CYLINDER COVER/ROCKER ARM....................................................................................... 67
11.1 DISASSEMBLY/REASSEMBLY ...................................................................................... 67
11.2 INSPECTION .................................................................................................................. 68
12. CRANKCASE COVER/CAMSHAFT DRIVE CHAIN ............................................................. 70
12.1 DISASSEMBLY............................................................................................................... 70
12.2 CRANKCASE COVER REASSEMBLY........................................................................... 71
12.3 ROLLER CHAIN REASSEMBLY .................................................................................... 71
12.4 CHAIN SUPPORT PLATE/PRESSURE PLATE.............................................................. 73
12.5 CRANKCASE COVER ASSEMBLY ................................................................................ 75
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
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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
Model KG158
Type 4-stroke,OVC, single cylinder, Gasoline engine
Displacement 105 cc
Horsepower/RPM 2.2/4500
Compression ratio 8.5:1
Cooling system Forced air-cooled
Ignition system T.C.I
Ignition timing 27°B.T.D.C
Spark plug UR5
Carburetor Float type, Horizontal, butterfly valve
Air cleaner Semi-dry
Governor Electronically controlled
Lubrication system Splash
Oil capacity qt (L) .35 (0.4)
Starting system Recoil starter
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)
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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
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 10 MΩmin
AC circuit protector 17.9A @120V
DC circuit protector 10A
Fuel tank capacity gal (L) .9 (3.5 )
Operating hours (at rated load) 4
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
b. IG2000P Pre 2011
© 2011 Kipor Power Systems, Inc.

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c. IG2000 2011 forward
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d. IG2000P 2011 forward
© 2011 Kipor Power Systems, Inc.

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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
every conceivable hazard that can arise in performing maintenance or repairs. Only you can
decide whether you should perform a given task.
■Failure to follow maintenance instructions and precautions can cause you to be seriously hurt
or killed. Follow the procedures and precautions in this shop manual carefully.
2.2 Important safety precautions
Be sure you have a clear understanding of all basic shop safety practices and that you are
wearing appropriate clothing and safety equipment. When performing maintenance or repairs, be
especially careful of the following:
■Read the instructions before you begin, and be sure you have the tools and skills required to
perform the tasks safely.
■Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the
possibility of several hazards:
Be careful for carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you run the engine.
Be careful for burns from hot parts.
Let the engine cool before you touch it.
Be careful for injury from moving parts.
■Do not run the engine unless the instruction tells you to do so. Even then, keep your hands,
fingers, and clothing away.
■To reduce the possibility of a fire or explosion, be sure when working around gasoline, use only
a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away
from all fuel-related parts.
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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
the engine.
9. Follow the instructions represented by these symbols when they are used.
■Electric precautions
1. Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire
harness. To disconnect the locking connector, be sure to unlock first, and then disconnect.
2. Check the connector terminals for bend, excessive extrusion, missing terminal, or other
abnormalities before connecting the connector.
3. To connect, insert the connector as full as it goes. If the connector is a locking type, be sure that
it is locked securely.
4. Check the connector cover for breakage and check whether the connector female terminal is
open excessively. Then, connect the connector securely. Check the connector terminal for rust.
Remove the rust using an emery paper or equivalent material before connecting the connector.
5. Set the harness clips in the specified places of the frame securely, and clamp the wire
harnesses.
6. Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving
parts and the hot parts.
7. Route and connect the wire harnesses properly. Be sure that the harnesses are not slack,
twisted or pulled taut.
8. Route the wire harnesses properly so that they do not contact with the shape edges and
corners, and the end of the bolts and screws on the body.
9. If a wire harness contacts the end of the bolts/screws or sharp edges and corners, protect the
contact part of the harness with a tube or by winding with an electrician’s insulating tape. If the
wire harness has a grommet, set the grommet securely.
10. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has
the damaged insulation, repair by winding with the electrician’s insulating tape.
11. Read the tester manufacture’s operation instructions carefully before operation with tester.
Follow the instructions of the Service Manual. Be sure that the battery built in a tester is fully
charged and check the meter before inspection using the tester.
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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.
序列号位置
2.5 Engine maintenance standards
Part Item Standard(mm) Service limit
Engine Maximum speed without load 4300±100rpm —
Compress force 0.45Mpa/800rpm —
Cylinder Sleeve I.D. 58.000-58.020 58.105
Piston Skirt O.D 57.960-57.980 57.85
Pin bore I.D. 13.002-13.008 13.05
Piston pin O.D 12.994－13.000 12.95
Piston ring
1st ring
Height h 0.97-0.99 0.87
Ring side clearance 0.02-0.06 0.15
Ring end clearance 0.15-0.25 1.0
Width t 1.95-2.15 1.75
2nd ring
Height h 1.17-1.19 1.07
Ring side clearance 0.02-0.06 0.15
Ring end clearance 0.15-0.25 1.0
Width t 2.4-2.6 2.2
Oil ring
Height h 1.85-1.98 1.75
Ring side clearance 0.03-0.18 0.24
Ring end clearance 0.20-0.50 1.0
Width t 2.3-2.7 2.2
Connecting
rod
Small end I.D 13.006—13.017 13.08
Big end I.D 24.020—24.033 24.09
Crankshaft Crank pin O.D. 23.967-23.980 23.90
Valves
Valve
clearance
IN 0.10±0.02 ---
EX 0.15±0.02 ---
Stem O.D. IN 3.965—3.980 3.90
EX 3.955—3.970 3.90
Serial number
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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
Camshaft O.D 8.966-8.975 8.92
Camshaft bearing I.D. 9.000-9.015 9.035
Rocker arm
I.D(Rocker arm) 6.000-6.012 6.037
O.D.(Rocker arm shaft) 5.972-5.980 5.965
I.D.(Rocker arm shaft bearing) 6.000-6.012 6.037
Carburetor
Main jet 0.60 —
Float height 12 —
Pilot screw opening 2 turns out —
Spark plug Gap 0.6—0.7 —
Ignition coil Resistance Primary side 0.8—1.3Ω—
Second side 15 —21kΩ—
Pulse coil
(Trigger)
Air gap 0.5-0.75 —
Resistance 80～130Ω—
2.6 Alternator
Part Item Type Standard(Ω)
120V 240V
Ignition winding Resistance Green-Yellow/Green 0.40-0.55
Outer charging
winding Resistance Blue--Blue 0.12-0.15
Sub winding Resistance White-White (IG)
White-White (CG) 0.15-0.30
Main winding Resistance
Black—Black-Black
(IG)
Black-Yellow/Black-Gr
een/Black-Red
(CG)
1.35-1
.75 5.0-5.5 0.18-0.
21
0.65-0.
90
2.7 Torque values
Item Specification Tightening torque
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
Standard torque
M5 Bolt, nut 5-7 0.5-0.7
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
Engine does
not start or
hard starting
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
Trigger faulty or trigger clearance
faulty
Inspect and replace
Spark plug cap loose. Install securely
Low oil alarm faulty Inspect and replace
Igniter faulty Inspect and replace
Ignition winding faulty Inspect and replace
Throttle opening fault Set in fully closed or half closed position
Engine speed
does not
stabilize, too
high or too low
Carburetor faulty Clean or replace
Throttle control motor (stepping
motor) faulty
Inspect and replace
Inverter unit faulty Inspect and replace
Valve clearance misadjusted Readjust
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3.2 Hard starting
■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
Check the fuel level in the tank.
A
dd fuel and restart the engine.
No fuel
Sufficient fuel
Loosen the drain screw and
check whether fuel reached the
carburetor.
A
dd fuel and restart the engine.
No fuel indicated
Good spark
Remove the spark plug and
check for wet or fouled electrode.
Check for blockage in the carbureto
r
port and nozzle.
Dry
Wet
Clean the electrode and restart,
taking care that the choke is no
t
closed too much. If flooding is severe,
chec
k
the carburetor float valve.
Remove the spark plug and
check for wet or fouled electrode. Perform the ignition system
troubleshooting
No spark o
r
weak spark
Install a compression gauge and
check ylinder compression b
y
pulling the recoil starter rope
several times
1. Check the valve clearance
2. Check for carbon deposits in the
combustion chamber.
3. Check for valve cone and base.
4. Check for worn piston, piston ring
or cylinder.
Low cylinde
r
compression
Normal
com
p
ression
Install the spark plug securely.
Restart the engine according to
the starting procedure.
Good spark
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缸压计
c. Ignition system
■Fill in oil to the demanded level.
■Use specified UR5 spark plug
■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. You
should see a clear spark.
■Don’t pull the recoil starter while touching the high tension wire with wet hands. High voltage is
generated and very dangerous.
■Drain the gasoline from the fuel tank and carburetor.
■Pull the recoil starter several times to release the unburned gas in the cylinder with the engine
switch OFF.
Pressure gauge
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Measure the spark plug gap and
perform the spark plug test.
Standard clearance: 0.6—0.7mm
Perform the spark test again using a
new spark plug Replace the spark plug
Remove the control panel. Perform
the spark test using a new igniter. Replace the igniter
Check the resistance of motor
ignition winding
Replace the engine switch
No spark
Good spark
No spark
Good spark
No spark
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
Abnormal Replace the motor stator
Check the trigger Abnormal Replace the trigger or readjust
trigger clearance
Normal
Check the ignition coil resistance
and high pressure cable, high
pressure insulation cap.
Abnormal
Replace the ignition coil
Normal
Inspection or replace wire harness.
Normal
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3.3 Engine oil level is low, but engine does not stop. (Defective oil alarm device)
3.4 Engine stops running (Throttle is at the correct position)
Drain out oil completely, disconnect alarm
connection wire, and check the continuity
between alarm outlet terminal and ground. Replace the oil level alarm
Continuity
No continuity
Reset the alarm connection wire, disconnect
igniter plug, and check the continuity
between the plug orange wire and ground.
Repair or replace the wire
harnesses
No continuity
Continuity
Igniter fault, replace the igniter.
Check the oil level and oil alarm Fill oil and restart the engine
Sufficient oil
Oil alarm
Reset the alarm connection wire, disconnect
igniter plug, and check the continuity
between the plug orange wire and ground.
Fill in fuel and restart the engine
No fuel
Sufficient fuel
Check the fuel switch and fuel filter fo
r
blockage Clear the fuel switch and fuel
filter
Blocked
Check the fuel supply pipe for blockage Clear or replace the fuel supply
pipe
Blocked
No blocked
No blocked
Check the fuel switch and fuel filter fo
r
blockage Disassemble and clear
Blocked
No blocked
Check sealing of inlet gasket and carbureto
r
heat insulation block Tighten nut or replace the
gasket
Abnormal
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
Normal
Check the trigger clearance Readjust the trigger clearance
Abnormal
Normal
Perform the throttle control system test
© 2011 Kipor Power Systems, Inc.