Kipor IG2000 Shop Manual
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Kipor IG2000 Shop Manual

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

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  • Page 1                                   KIPOR POWER PRODUCTS CO., LTD. IG2000/IG2000P/IG2000S SHOP MANUAL EPA/CARB/CETL Certified Models                        Kipor Power Systems, Inc. Revision 4, July, 2011 ...

  • Page 2: Preface

    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.

  • Page 3: Table Of Contents

    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 ..............
  • Page 4 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.

  • Page 5: Specifications/Wiring Diagram

    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 ...

  • Page 6: Performance Characteristics

    1.2 PERFORMANCE CHARACTERISTICS Model Maximum output AC 2.0KVA Rated output AC 1.6KVA Rated output DC 100W Rated frequency 60HZ Rated voltage AC 120V Rated voltage DC Rated current AC 13.3A Rated current DC 8.3A Power factor Voltage variation rate Momentary 10% max Average 1.5% max...

  • Page 7: Performance Curves

    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.

  • Page 8: Dimensional Drawing

    Unit: mm 1.4 DIMENSIONAL DRAWING...

  • Page 9: Wiring Diagrams

    1.5 WIRING DIAGRAMS a. IG2000 pre 2011 b. IG2000P Pre 2011...
  • Page 10 IG2000 2011 forward...
  • Page 11 d. IG2000P 2011 forward...

  • Page 12: Service Information

    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.

  • Page 13: Service Rules

    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.

  • Page 14: Serial Number And Barcode

    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 2.5 Engine maintenance standards Part Item Standard(mm) Service limit Maximum speed without load 4300±100rpm —...

  • Page 15: Torque Values

    Guide I.D. IN/EX 4.000—4.030 4.06 Seat width IN/EX Valve spring Free length IN/EX 26.4 24.9 Cam wheel Cam height 29.026-29.086 28.5 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...

  • Page 16: Troubleshooting

    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 Trigger faulty or trigger clearance Inspect and replace not start or...

  • Page 17: Hard Starting

    3.2 Hard starting No fuel Check the fuel level in the tank. Add fuel and restart the engine. Sufficient fuel Loosen the drain screw and No fuel indicated Add fuel and restart the engine. check whether fuel reached the carburetor. Good spark Check for blockage in the carburetor Remove the spark plug and...
  • Page 18 缸压计 Pressure gauge 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.
  • Page 19 Measure the spark plug gap and perform the spark plug test. Standard clearance: 0.6—0.7mm No spark Good spark Perform the spark test again using a Replace the spark plug new spark plug No spark Good spark Remove the control panel. Perform Replace the igniter the spark test using a new igniter.

  • Page 20: Oil Alarm

    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...

  • Page 21: Engine Speed Unstable

    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...

  • Page 22: Smart Throttle

    3.7 Smart throttle doesn’t work with zero load, engine speed doesn’t increase with smart throttle on and load connected. Perform generator Abnormal Check the AC output troubleshooting following instruction of “No or low AC output” Normal Abnormal Check the throttle control motor Replace the throttle control motor Normal Abnormal...
  • Page 23 Inverter unit 逆变单元 Main winding/Sub winding 主绕组\副绕组 Measure voltage Phase wire color: Black-Black-Black Model Sub winding color: White-White Item 120V 240V Voltage between ＞30V ＞60V phase wires Sub winding ＞1V voltage Phase sequence arrangement...

  • Page 24: No Dc Output

    ■ Make sure that the parallel output cables are inserted into the parallel cable connectors on the control panel.. ■ Use only KIPOR parallel output cables. ■ Use only the KIPOR parallel output box. ■ Don’t use any control panel receptacles when running in parallel.. ■ Don’t disconnect the parallel cables while either generator is operating.
  • Page 25 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.

  • Page 26: Maintenance

    (1) For commercial use, operation hours are determined by proper maintenance. (2) Service more frequently when operating in dusty areas. (3) Service by an authorized Kipor service center. ■ Checking the oil level Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking.
  • Page 27 维修盖 Maintenance cover Cover screw 螺钉 Upper level 上液面 上限位 Upper limit 机油尺 Oil dipstick 下限位 Lower limit Oil fill port 加油口 ■ Replace the engine oil 1. Disassemble the oil dipstick and oil drain bolt, drain used oil. 2. Tighten the oil drain bolt.. 3.

  • Page 28: Checking The Low Oil Alarm

    4.2 Checking the low oil alarm 1. Disconnect oil alarm connector when the engine is still running, connect the two plugs, be sure that oil alarm lights and engine stops. 橙色 黄绿色 橙色（点火器引出端） Orange (alarm Yellow/ Orange (igniter outlet terminal) outlet terminal) Green the two plugs are connected...

  • Page 29: Air Cleaner

    Igniter outlet terminal 点火器引出端 Alarm outlet terminal 报警器引出端 check the conductivity 测量两线间的通断 between the two wires 3. Drain out the oil inside engine and check the conductivity, conducivity is normal. 4.3 Air cleaner Inspection/Cleaning: 1) Loosen the cover screw and remove the maintenance cover. 2) Disengage the locking tab by pushing it, and remove the air cleaner cover.
  • Page 30 Maintenance cover 维修盖 螺钉 Cover Filter element 精滤芯 screw 空滤器盖 Air filter cover Fixed bolt 紧固螺栓 粗滤芯 Filter element 洗净 Wash 拧干后晾干 Dip in engine oil 浸入机油 Squeeze firmly 挤出机油 Sealing strip 海绵密封条 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.

  • Page 31: Spark Plug

    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. 3) Measure the plug resistance; replace the spark plug if the measure is not accordance with the specification.

  • Page 32: Valve Clearance

    0.6-0.7 5). Install the plug finger tight to seat the washer, then tighten with a plug wrench. Torque valve is 13~15 N.m 4.5 Valve clearance Caution ■ Valve clearance inspection and adjustment must be performed with the engine cold. Inspection/Adjustment: 1) Remove the following parts: ―Front cover, control panel ―Rear cover...
  • Page 33 气缸盖罩 Cylinder cover 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 and exhaust valves are closed. 正时标记...
  • Page 34 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.

  • Page 35: Fuel Tank And Filter

    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...

  • Page 36: Fuel System

    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 Vent Hose Washer Fuel Tank Certification No. Cotter Pin Retention Hook Fuel Hose Vent Hose Fuel Tank Negative Pressure Hose Fuel Hose Fuel Hose...

  • Page 37: Fuel Pump And Hoses

    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...

  • Page 38: Exhaust System

    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 。 消声器垫片 Muffler gasket 火星捕捉器 Spark Arrestor 组装：...

  • Page 39: Exhaust Tube/Secondary Air Injection Valve

    5.2 Exhaust tube, secondary air injection valve ● Disassembly/Reassembly 排气管 Exhaust tube Secondary air injection valve 二次补气阀垫片 gasket Second air injection valve 二次补气阀组件 5.3 Spark Arrestor Caution ■ Do maintenance after engine has cooled completely. (1) Remove the rear cover (2) Disassemble the spark arrestor from the muffler (3) Remove the carbon from the spark catcher steel net, check for damage, and replace if necessary.

  • Page 40: Intake System

    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 tube 通气管 Diaphragm tube 碳罐负压管 紧固螺钉 Fixed screw 化油器垫片 Carburetor gasket Installation: check 安装：...

  • Page 41: Carburetor Removal And Installation

    6.2 Disassembly/Installation of Carburetor Diaphragm tube 负压管 化油器垫片A Carburetor gasket A Installation: check the 安装： 应当先确认垫片有无 gasket for damage 破损再进行安装。 before installation Air filter shell 空滤器壳 进气管垫片 Inlet pipe gasket: Installation: check the gasket 安装： 应当先确认垫片有无弯 Carburetor stud For distortion or damage, 化油器螺柱...
  • Page 42 ● Disassembly/Installation of Stepping motor 步进电机机盖 Stepping motor cover 步进电机 Stepping motor 步进电机座 Stepping motor seat 拔叉弹簧 Fork spring 拔叉 Disassembly: Fork 拆卸： 拆卸时用手捏牢， Hold the spring 以防弹簧丢失。 拔叉 firmly to avoid Fork 油门杆 Throttle lever dropping it. Fork spring 拔叉弹簧...
  • Page 43 ● 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 混合比调节螺丝 mixture adjusting screw 出厂前位置已确 (sealed) 定，不可调节 Needle seat 针座 Foam tube 泡沫管 控油针 Installation: clear foreign Fuel control needle 组装：...

  • Page 44: Inspection

    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...
  • Page 45 ● 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.

  • Page 46: Control Panel

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

  • Page 47: Removal And Installation

    ●IG2000\IG2000S Igniter 点火器 交流插座 AC receptacle smart开关 Smart throttle switch 直流插座 DC receptacle 接地端 Ground terminal 7.2 Inspection a. Control panel ● AC receptacle Check the electrode contact disk inside receptacle, if it is burnt or the discolored, replace it.
  • Page 48 ● 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...
  • Page 49 ● Engine switch Check the continuity of connector, there should be continuity when depressing the micro switch. Press down 压下...
  • Page 50 ● 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 黑色 红色 黄色 兰色 Black Yellow Blue Conducted between 同序号相通...
  • Page 51 Parallel connection communication interface 并联通讯接口 (aero receptacle) （航空插头） Conducted 同序号相通 between same series number ● Parallel output receptacle Check the continuity between the two terminals of parallel output receptacle. ● Parallel output cable 1. Check the AC receptacle output terminal, there should be no continuity between two terminals. 2.
  • Page 52 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 Parallel connection plug 接地端 Grounding terminal Grounding terminal 接地端 Grounding terminal 接地端 输出端 Output terminal 交流插座...
  • Page 53 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.

  • Page 54: Inspection Of Components

    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...

  • Page 55: Housing Disassembly

    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 cross 右机壳十 protection frame 字保护架 Side door 侧门组件 开口挡圈 逆变单元 Inverter unit Spilt washer Protection sleeve 保护套...
  • Page 56 ● Left housing case 左机壳 Left housing case 燃油泵 Fuel pump 油开关手柄 Fuel switch lever 油开关 Fuel switch 微动开关 Micro switch 微动开关挡板 baffle Fuel pump 燃油泵 油管 Fuel hose 左机壳 Left housing case 负压管 Diaphragm tube 油管 Fuel hose 油箱 Fuel tank 油开关...

  • Page 57: Fuel Tank Assembly

    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 Gauge 油标...

  • Page 58: Fan Housing/Engine Mounting Plate

    8.4 Fan shield/Engine mounting plate Fan shield 导风罩 减震套 Shock pad 45cc碳罐 45cc carbon canister 空心轴 Hollow shaft 发动机固定板焊合 Mounting plate...

  • Page 59: Evaporative Control System

    8.5 Evaporative control system 进气系统 Inlet system Connected to 接碳罐负压管 diaphragm tube 碳罐负压管 Diaphragm tube 油箱通气管 Ventilation tube 45cc碳罐 Carbon canister Curved hose 大气弯管...

  • Page 60: Guide Plate

    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 下气道导流板 Lower air duct guide plate...

  • Page 61: Recoil Starter/Air Conduct Cover/Igntion Coil

    9. Recoil starter/ Air conduct cover/ Ignition coil 9.1 Disassembly/Reassembly 密封套 Seal sleeve Ignition coil 点火线圈 导风罩 Air conduct cover Recoil starter 反冲启动器 Rectifier bracket 整流桥支架 整流桥 Rectifier 起动拉绳 Starter rope Assembly: check the starter 组装： 安装前应检查起动拉绳是否 rope damage before 反冲起动器弹簧...

  • Page 62: Recoil Starter Installation

    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 (2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw.
  • Page 63 (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. (5) Install the starter pawl and fix it with bolts.

  • Page 64: Inspection

    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 ● Attach one lead of the meter to each terminal of primary coil plugs of ignition coil and the other lead to the spark plug cap，then measure the secondary resistance of the ignition coil.
  • Page 65 （1）负极引脚（-） （2）交流引脚（ ） Negative (-) AC (～) （4）交流引脚（ ） （3）正极引脚（+） AC (～) Positive (+)

  • Page 66: Alternator/Trigger

    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： 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 M12 X 1.25 70-80 N.m M12X1.25 70-80 N.m 风叶轮 Fan pressure plate 风叶轮压板 启动拉轮 Pull wheel Pulse coil (trigger) 脉冲线圈 （触发头）...

  • Page 67: Trigger Adjustment

    (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 10.3 Adjustment Adjust the clearance between trigger and the projection part of rotor. Trigger clearance 0.50-0.75mm Insert a feeler gauge between the trigger and the projection part of the rotor;...

  • Page 68: Cylinder Cover/Rocker Arm

    11. Cylinder cover/ Rocker arm 11.1 Disassembly/ Reassembly Cylinder cover 气缸盖罩 Valve clearance adjusting nut 气门间隙调节螺母 Adjusting screw 气门间隙调节螺钉 Rocker shaft 摇臂轴 进气门摇臂 Rocker arm of intake valve Rocker arm of exhaust valve 排气门摇臂 Breather cover 呼吸器盖板焊接件 Sealant: 1mm diameter 直径1mm密封胶...

  • Page 69: Inspection

    11.2 Inspection ● Rocker arm outer diameter Standard(mm) Service limit(mm) 5.972-5.980 5.965 ● Rocker arm inner diameter of inlet/exhaust valve Standard(mm) Service limit(mm) 6.000-6.012 6.037...
  • Page 70 ● Inner diameter of rocker arm bearing Standard(mm) Service limit(mm) 6.000-6.012 6.037...

  • Page 71: Crankcase Cover/Camshaft Drive Chain

    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 传动轴 Driving shaft 曲轴箱盖 Crankcase cover O形密封圈 O-seal ring 卡块 Block 曲轴箱盖定位销 Location pin of crankcase cover 销...

  • Page 72: Crankcase Cover Reassembly

    机油报警器 Oil alarm O型密封圈 O-seal ring Oil gear shaft 甩油齿轮轴 Crankcase cover 曲轴箱盖 Gasket 限速齿轮垫片 甩油齿轮 Oil gear 挡圈 Retainer ring 12.3 Reassembly of roller chain 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 crankcase.
  • Page 73 Timing mark 正时标记 装配密封面 Seal face 正时标记 Timing mark 箱体上的正时标记 Timing mark...

  • Page 74: Chain Support Plate/Pressure Plate

    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.
  • Page 75 用尖嘴钳夹紧 Clamp 弹簧使其卡在 spring to seize 档块上 the block...

  • Page 76: Crankcase Cover Assembly

    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.

  • Page 77: Inspection

    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 block 机体 直径1.5-2mm密封胶 Sealant: 1-1.5mm diameter 12.6 Inspection ● Inspection of oil alarm (1) Stand the oil alarm, check the oil alarm output wire and copper earth wire, there should be no continuity.
  • Page 78 ● Cam height Standard(mm) Service limit(mm) 29.026-29.086 29.15 ● Cam inner diameter Standard(mm) Service limit(mm) 9.000-9.015 9.035 ● Camshaft outer diameter Standard(mm) Service limit(mm) 8.966-8.975 8.920...
  • Page 79 ● 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...

  • Page 80: Crankshaft/Piston And Connecting Rod

    13. Crankshaft/ Piston 13.1 Disassembly/ Reassembly 气门弹簧座 Valve spring 气门弹簧 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 按下并朝旁孔 the spring seat slightly and 移位卸下。 disassemble it Cylinder block 机体 活塞 Piston Installation: install 组装：...

  • Page 81: Piston/Connecting Rod

    13.2 Piston/Connecting Rod 厂家标记 Label 第一道环 1st ring 第二道环 2nd ring Oil ring 油环 活塞 Piston 活塞销 Piston pin 活塞销卡环 Piston pin clip 组装： Installation: set the front end in the 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。 end. Install the ring clip by revolving. 不要使卡环的开口对着活塞销孔的缺...

  • Page 82: Inspection

    Assembly of piston rings Caution ● Set the manufactory label upwards. ● Pay attention not to mix the location of the 1 ring and 2 ring. ● Check the piston ring for flexibility after installation. ● Stagger each piston ring opening apart piston pin for 120°. ring 第一道环（有镀铬）...
  • Page 83 ● Valve rod outer diameter Standard(mm) Service limit(mm) Inlet valve 3.965-3.980 3.90 Exhaust valve 3.955-3.970 3.90 ● Valve guide pipe inner diameter Standard(mm) Service limit(mm) Inlet/Exhaust valve 4.000-4.030 4.060...
  • Page 84 ● Clearance between valve rod and valve guide pipe Standard(mm) Service limit(mm) Inlet valve 0.020-0.065 0.10 Exhaust valve 0.030-0.075 0.12 ● Cylinder inner diameter Standard(mm) Service limit(mm) 58.000-58.020 58.105 ● Piston skirt outer diameter Standard(mm) Service limit(mm) 57.960-57.980 57.850 10mm ●...
  • Page 85 ● Side clearance of piston ring Standard(mm) Service limit(mm) 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. Standard(mm) Service limit(mm) 0.15-0.25...
  • Page 86 ● Piston ring height Standard(mm) Service limit(mm) The 1 ring 0.97-0.99 0.87 The 2 ring 1.17-1.19 1.107 ● Piston pin outer diameter Standard(mm) Service limit(mm) 12.994-13.000 12.950...
  • Page 87 ● Piston pin hole inner diameter Standard(mm) Service limit(mm) 13.002-13.008 13.050 ● Clearance between piston pin and piston pin hole Standard(mm) Service limit(mm) 0.002-0.014 0.080 ● Connection rod small end inner diameter Standard(mm) Service limit(mm) 13.006-13.017 13.080...
  • Page 88 ● Connection rod big end inner diameter Standard(mm) Service limit(mm) 24.020-24.033 24.090 ● Crankshaft neck outer diameter Standard(mm) Service limit(mm) 23.967-23.980 23.900...
  • Page 89 ● Connection rod big end side clearance Standard(mm) Service limit(mm) 0.1-.0.4 ● Oil film clearance of connection rod big end (1) Wipe off the oil on the surface of crankshaft neck. (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.
  • Page 90 ● Bearing vibration Clean the bearing and check the clearance between the crankshaft journal and connecting rod big end by revolving bearing by hand. Replace the bearing if there is abnormal noise or vibration. Clearance 游隙 Clearance 游隙 Axial direction Circle direction 轴向...

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