Clarke IG1000 Spezifikationen

KIPOR POWER PRODUCTS CO., LTD. IG1000 SHOP MANUAL CARB and CETL Models The Coast Distribution System December, 2008

6 • 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 o

72.6 Maintenance standards Part Item Standard(mm) Service limit Engine Maximum speed without load 5500±100 rpm — Cylinder Sleeve I.D. 1.712-1.

83.965—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

93. Troubleshooting This troubleshooting section contains troubleshooting trees organized by common groups of symptoms. Some testing information is

103.2 Hard starting Cylinder compression check 1. Remove the spark plug cap and spark plug. 2. Install a compressio

11 C. Ignition system Fill in oil to the demanded level. Use the genuine spark plug A7RTC. Spark plug inspection 1. Disassemble

12 3.2 Hard Starting Continued Measure the spark plug gap and perform the spark plug test. Gap: 024-028 in

133.3 Engine oil level is low, but engine does not stop. (Defective oil switch) 3.4 Engine stops running (Throttle is at the correct posit

143.5 Engine speed can’t increase or unstable (choke is at the correct position) 3.6 Engine speed too high or too low

153.7 Smart system doesn’t work with zero load or engine speed doesn’t increase with Smart system on and load connected. 3.8 No or lo

iiPreface This manual covers the construction, function and servicing procedure of the KIPOR IG1000. This manual is applicable to all models certi

163.9 No DC output Normal Abnormal

174. Maintenance 4.1 Maintenance schedule Regular service period Each use First month or 20 Hrs. Every 3 months or 50Hrs. Every 6 months or 100 Hrs.

18 3. If the oil level is low, add to the edge of the oil filler port. Replace the engine oil 1. Remove the oil dipstick and oil dra

192. Stop engine, disconnect oil alarm connector, check the connector conduction, no conduct is normal. 3. Drain out the oil inside

20 Caution A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in

21 4) Measure the plug gap with a wire-type feeler gauge. Adjust by bending the side electrode if the measure is not accord with the asked valve. Sp

22 2) Remove the four tighten bolts and disassemble the cylinder cover. Don’t remove the cylinder cover with excessive force as it may deform. Repla

234) Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance. Valve clearance Intake .0031-.0039 in (0.08-0.10m

24 6) Clean the liquid gasket of the cylinder block and cylinder head cover. Apply liquid gasket (Three Bond 1207B or equivalent) to the cylinder

25 4.8 Fuel pump and hoses Caution Gasoline is highly flammable and explosive. You can be burned or seriously injured when han

iiiCONTENTS 1. SPECIFICATIONS/WIRING DIAGRAM ... 1 1.1 SPECIFI

26 4.9 Spark arrestor Caution Make sure the muffler has cooled completely before attempting any maintenance on this part. (1) Remove

275. Muffler Caution Muffler removal/installation must be performed with the engine cold. ● Disassembly/Reassembly

286. Air filter/Carburetor Caution Loosen the drain oil bolt and drain out fuel before disassembly. Keep heat, flame and sparks away. 6.1 Ai

296.3 Stepping motor removal and installtion

306.4 Carburetor exploded drawing Note: With the exception of changing the main jet for altitude compensation, no adjustments to this carburetor ar

316.5 Inspection ● Float height Place the carburetor as the picture shows, measure the float height between float and carburetor block. Height

327. Control panel 7.1 Removal/Installation

337.2 Inspection a. Control panel ● AC receptacle Check the electrode contact disk inside receptacle; if it is burnt or discolored, replace for it.

34 ● Engine switch Check the continuity of connector, there should be continuity when the micro switch is depressed. ● Rectifie

358. Housing / Fuel tank 8.1 Housing disassembly and reassembly ● Left housing case

iv 7. CONTROL PANEL ... 32 7.1 REMO

36 8.2 Fuel tank assembly Caution Gasoline is highly flammable and explosive. You can be burned or seriously injured when handing fuel. Keep heat

379. Recoil starter/ Air conduct cover/ Ignition coil/ Air conduct plate 9.1 Disassembly/Reassembly

389.2 Air conduct plate Disassembly/ Reassembly

399.3 Disassembly and reassembly of recoil starter (1) Set the spring into the starter reel, and hang the spring outer hook inside the reel groov

40(2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the reel anticlockwise to hang the spring inner ho

41(4) Pull rope through from starter outer shell hole completely; pass it through the handle and make a figure eight knot, then turn off handle cove

429.4 Ignition Coil ● Attach the two leads of tester to the primary coil plug of ignition coil, and measure the primary resistance of the ignition

4310. Alternator/Trigger 10.1 Alternator Disassembly/Reassembly 10.2 Inspection (1) Ignition winding Measure the resistance between the green termi

44 (5) Trigger Attach the two test leads to the trigger and measure the resistance. Trigger resistance 80-130 Ω 10.3 Trigger adjustment Ad

4511. Cylinder cover/ Rocker arm 11.1 Disassembly/ Reassembly

11. SPECIFICATIONS and WIRING DIAGRAM 1.1 SPECIFICATIONS Dimensions and weights Model IG1000 Overall Length in (mm) 18.1 (460) Overall Width in (

4611.2 Inspection ● Rocker arm outer diameter Standard in (mm) Service limit in (mm) 0.1570-0.1573 (3.988-3.996) 0.1555 (3.950) ● Rocker a

4712. Crankcase cover/ Camshaft drive chain 12.1 Disassembly 12.2 Crankcase oil tray disassembly and reassembly 1. Clean any remaining g

482. Apply a 0.040~0.059 in (1~1.5 mm) layer of liquid gasket material [1207B or equivalent] evenly on the sealing face of the crankcase oil tray.

4912.4 Crankcase cover assembly 1. Remove any remaining gasket material on the cylinder block and crankcase cover. 2. Apply a 0.040~0.059 in (1~1.5

50 ● Cam height Standard in (mm) Service limit in (mm) 1.101-1.103 (27.97-28.03) 1.062 (26.97) ● Cam inner diameter Standard in (mm) Servi

51 ●Valve tappet inner diameter Standard in (mm) Service limit in (mm) 0.1968-0.1975 (5.000~5.018) 0.1988 (5.050)

52 13. Crankshaft/ Piston 13.1 Disassembly/Reassembly

5313.2 Piston Assembly of piston ring Caution ● Set the manufacture label up. ● Pay careful attention not to mi

54● There may be two different kinds of piston rings for the same model generator. They can be distinguished by different manufacture labels. Don’t

55● Valve stem outer diameter Standard in (mm) Service limit in (mm) Intake valve 0.156-0.157 (3.965-3.980) 0.1535 (3.900) Exhaust valve 0.15

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

56● Cylinder inner diameter Standard in (mm) Service limit in (mm) 1.712-1.714 (43.500-43.520) 1.716 (43.595) ● Piston skirt outer diameter St

57● Piston skirt outer diameter Standard(mm) Service limit(mm) 57.960-57.980 57.850 ● Clearance between piston and cylinder Standard in (mm)

58● Piston ring height Standard in (mm) Service limit in (mm) The 1st ring 0.0030-0.031 (0.77-0.79) 0.028 (0.70) The 2nd ring 0.038-0.039

59● Clearance between piston pin and piston pin hole Standard in (mm) Service limit in (mm) 0.00008-0.00055 (0.002-0.014) 0.00314 (0.080) ● Con

60● Crankshaft neck outer diameter Standard in (mm) Service limit in (mm) 0.5896-0.5899 (14.975-14.985) 0.5866 (14.900) ● Connecting rod

61 ● Oil film clearance of connection rod big end (1) Wipe all oil from the surface of the crankshaft neck. (2) Set the plastic wire feeler at t

62●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (cylinder block) Standard in mm） Service limit in (mm) 0.1976~0.1988 (5.02

63● Bearing vibration Clean the bearing and dry it. check the clearance between crankshaft journal and connecting rod big end by rotating the bea

31.2 WIRING DIAGRAM

42. SERVICE INFORMATION 2.1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of

52.3 Service rules • Use genuine KIPOR or KIPOR-recommended parts and lubricants or their equivalents. Parts that do not meet Kipor’s design speci