®

Diagnostic
Repair
Manual

iX Series Inverter

models:
iX800
iX1600
iX2000

Portable generators
Foreword

SAFETY Read This Manual Thoroughly

Throughout this publication, DANGER, WARNING, and CAUTION This SERVICE MANUAL has been written and published by
blocks are used to alert the mechanic to special instructions Generac to aid our dealers' mechanics and company service
concerning a particular service or operation that might be personnel when servicing the products described herein.
hazardous if performed incorrectly or carelessly. Observe them It is assumed that these personnel are familiar with the servicing
carefully. Their definitions are as follows: procedures for these products, or like or similar products
manufactured and marketed by Generac. That they have been
trained in the recommended servicing procedures for these
products, including the use of common hand tools and any
 fter this heading, read instructions that, if not strictly complied
A special Generac tools or tools from other suppliers.
with, will result in serious personal injury, including death.
Generac could not possibly know of and advise the service
trade of all conceivable procedures by which a service might
be performed and of the possible hazards and/or results
of each method. We have not undertaken any such wide
 fter this heading, read instructions that, if not strictly complied
A evaluation. Therefore, anyone who uses a procedure or tool not
with, could result in serious personal injury, including death. recommended by Generac must first satisfy themselves that
neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications in this manual
 fter this heading, read instructions that, if not strictly complied
A are based on the latest product information available at the time
with, might result in minor or moderate injury. of publication.
Four commonly used safety symbols accompany the DANGER, When working on these products, remember that the electrical
WARNING and CAUTION blocks. The type of information each system and engine ignition system are capable of violent and
indicates follows: damaging short circuits or severe electrical shocks. If you intend
to perform work where electrical terminals could be grounded
or touched, the battery cables should be disconnected at the
 if not followed, could endanger personal safety and/or
This symbol points out important safety information that,
battery.
property of others. Any time the intake or exhaust openings of the engine are
exposed during service, they should be covered to prevent
accidental entry of foreign material. Entry of such materials will

This symbol points out potential explosion hazard.
result in extensive damage when the engine Is started.
During any maintenance procedure, replacement fasteners must
have the same measurements and strength as the fasteners
that were removed. Metric bolts and nuts have numbers that

This symbol points out potential fire hazard. indicate their strength. Customary bolts use radial lines to
indicate strength while most customary nuts do not have
strength markings. Mismatched or incorrect fasteners can
cause damage, malfunction and possible injury.


This symbol points out potential electrical shock hazard. NOTE: Special NOTES appear in bold type throughout this
publication. While not pertaining to safety, they emphasize
procedures, circumstances or specifications that require
These “Safety Alerts” alone cannot eliminate the hazards that special attention.
they signal. Strict compliance with these special instructions plus
“common sense” are major accident prevention measures.
REPLACEMENT PARTS
When servicing this equipment, it is extremely important that all
components be properly installed and tightened. If improperly
installed and tightened, sparks could ignite fuel vapors from fuel
system leaks.
 Table of Contents

Specifications...................................................................... 2 Section 4 – Troubleshooting and Diagnostic Tests.............. 15

Section 1 – Generator Fundamentals.................................... 6 Test 1 – Check Engine RPM................................... 19
Magnetism.............................................................. 6 Test 2 – Test Sub Coil of Stator.............................. 19
Electromagnetic Fields............................................. 6 Test 3 – Test Main Coil of Stator............................. 19
Electromagnetic Induction........................................ 6 Test 4 – Test DC Circuit Breaker............................. 20
Electrical Units......................................................... 6 Test 5 – Test DC Rectifier....................................... 20
Ohm's Law.............................................................. 7 Test 6 – Test DC Coil on Stator............................... 20
A Simple AC Generator............................................ 7 Test 7 – Test Recoil Function.................................. 21
What is an “iX” Inverter Unit?................................... 8 Test 8 – Test Engine Function................................. 21
iX Inverter System Overview.................................... 8 Test 9 – Check Spark............................................. 21
Why Variable Speed Control?................................... 8 Test 10 – Check Spark Plug................................... 21
Section 2 – Measuring Electricity......................................... 9 Test 11 – Check Fuel Pump.................................... 22
Meters..................................................................... 9 Test 12 – Check Carburetion.................................. 22
The VOM................................................................. 9 Test 13 – Check Engine Compression.................... 23
Measuring AC Voltage.............................................. 9 Test 14 – Test Ignition Trigger Assembly................. 23
Measuring DC Voltage.............................................. 9 Test 15 – Test Ignition Coil..................................... 24
Measuring AC Frequency......................................... 9 Test 16 – Test Fuel Shutoff Switch.......................... 24
Measuring Current................................................... 9 Test 17 – Check Choke Assembly.......................... 25
Measuring Resistance............................................ 10 Test 18 – Test Stepper Motor................................. 25
Section 3 – Major Components.......................................... 11 Test 19 – Test Oil Level Switch............................... 25
Introduction........................................................... 11 Test 20 – Test Ignition Coil Winding........................ 26
UNIT Identification................................................. 11 Test 21 – Test FlexPower Switch............................ 26
Internal Major Engine Components......................... 12 Section 5 – Disassembly................................................... 27
Internal Major Electrical Components..................... 13 Disassembly.......................................................... 27
Operational Analysis.............................................. 14 Section 6 – Electrical Data................................................. 36
Electrical Formulas............................................................ 38

Page 1
Specifications – iX800

Product Series iX800

A/C Rated Output Watts: 800
A/C Maximum Output Watts: 850
A/C Voltage 120
A/C Frequency 60
Rated 120 VAC Amperage 6.6
Max 120 VAC Amperage 7.0
Engine Displacement 38cc
Engine Type 4-stroke OHV
FlexPower Yes
Low Oil Shutdown Method Level
Fuel Tank Capacity (Gal) 0.5
Run Time at 50% (Hours) 3.6
Length (L) 18 inches
Width (W) 10 inches
Height (H) 15 inches
Unit Weight – Dry (lbs) 29
A Spark Plug Type NGK CR7HSA
H Spark Plug Gap 0.030 inch
M Internal - Not Shown Oil Capacity 0.18 qt.

Receptacles
A 2x5-15R

Circuit Breakers
M Internal Overload Protection

Other Features
H FlexPower

Recommended Oil

S A E 30

1 0 W-30

S y n t he ti c 5 W-3 0

Page 2
 Specifications – iX1600

Product Series iX1600

A/C Rated Output Watts 1600
A/C Maximum Output Watts 1650
A/C Voltage 120
A/C Frequency 60
Rated 120 VAC Amperage 13.3
Max 120 VAC Amperage 13.75
Engine Displacement 99cc
Engine Type 4-stroke OHV
FlexPower Yes
Low Oil Shutdown Method Level
Fuel Tank Capacity (Gal) 0.8
Run Time at 50% (Hours) 4.9
Length (L) 21 inches
Width (W) 11 inches
Height (H) 18 inches B
Unit Weight – Dry (lbs) 43.5
Spark Plug Type NGK BPR7HS A
Spark Plug Gap 0.030 inch
Oil Capacity 0.63 qt. H
M Internal - Not Shown

Receptacles
A 2x5-15R
B 1x12VDC

Circuit Breakers
M AC Internal Overload Protection
DC 5 Amp Circuit Breaker

Other Features
H FlexPower

Recommended Oil

SAE 30

10W- 30

S y nt het ic 5W- 30

Page 3
Specifications – iX2000

Product Series iX2000

A/C Rated Output Watts: 2000
A/C Maximum Output Watts: 2200
A/C Voltage 120
A/C Frequency 60
Rated 120 VAC Amperage 16.6
Max 120 VAC Amperage 18.3
Engine Displacement 126cc
Engine Type 4-stroke OHV
FlexPower Yes
Low Oil Shutdown Method Level
Fuel Tank Capacity (Gal) 1.0
Run Time at 50% (Hours) 4.7
Length (L) 22 inches
Width (W) 12 inches
Height (H) 18 inches B
Unit Weight – Dry (lbs) 50
Spark Plug Type NGK BPR6ES A
Spark Plug Gap 0.030 inch
Oil Capacity 0.63 qt. H
M Internal - Not Shown

Receptacles
A (2) 5-20R 120V
B 1x12VDC

Circuit Breakers
M AC Internal Overload Protection
DC 5 Amp Circuit Breaker

Other Features
H FlexPower

Recommended Oil

S A E 30

10W- 30

S y nt het ic 5W- 30

Page 4
NOTES

Page 5
Section 1
Generator Fundamentals

Magnetism
Magnetism can be used to produce electricity and electricity
can be used to produce magnetism.
Much about magnetism cannot be explained by our present
knowledge. However, there are certain patterns of behavior
that are known. Application of these behavior patterns has led
to the development of generators, motors and numerous other
devices that utilize magnetism to produce and use electrical
energy.
See Figure 1. The space surrounding a magnet is permeated
by magnetic lines of force called “flux”. These lines of force
are concentrated at the magnet's north and south poles. They
are directed away from the magnet at its north pole, travel in
a loop and re-enter the magnet at its south pole. The lines of
force form definite patterns which vary in intensity depending Figure 2. The Right Hand Rule
on the strength of the magnet. The lines of force never cross
one another. The area surrounding a magnet in which its lines
of force are effective is called a “magnetic field”. Electromagnetic Induction
Like poles of a magnet repel each other, while unlike poles An electromotive force (EMF) or voltage can be produced in a
attract each other. conductor by moving the conductor so that it cuts across the
lines of force of a magnetic field.
Similarly, if the magnetic lines of force are moved so that they
cut across a conductor, an EMF (voltage) will be produced in
the conductor. This is the basic principal of the revolving field
generator.
Figure 3, below, illustrates a simple revolving field generator.
The permanent magnet (Rotor) is rotated so that its lines of
magnetic force cut across a coil of wires called a Stator. A
voltage is then induced into the Stator windings. If the Stator
circuit is completed by connecting a load (such as a light bulb),
current will flow in the circuit and the bulb will light.

Figure 1. Magnetic Lines of Force

Electromagnetic Fields
All conductors through which an electric current is flowing
have a magnetic field surrounding them. This field is always at
right angles to the conductor. If a compass is placed near the
conductor, the compass needle will move to a right angle with
the conductor. The following rules apply:
• The greater the current flow through the conductor, the stron-
ger the magnetic field around the conductor.
• The increase in the number of lines of force is directly
proportional to the increase in current flow and the field is Figure 3. A Simple Revolving Field Generator
distributed along the full length of the conductor.
• The direction of the lines of force around a conductor can
be determined by what is called the “right hand rule”. To Electrical Units
apply this rule, place your right hand around the conductor
with the thumb pointing in the direction of current flow. The
fingers will then be pointing in the direction of the lines of AMPERE
force. The rate of electron flow in a circuit is represented by the
NOTE: The “right hand rule” is based on the “current flow” AMPERE. The ampere is the number of electrons flowing past a
theory which assumes that current flows from positive to given point at a given time. One AMPERE is equal to just slightly
negative. This is opposite the “electron” theory, which more than 6.25 x 1018 electrons per second.
states that current flows from negative to positive.

Page 6
 Section 1
Generator Fundamentals
With alternating current (AC), the electrons flow first in one A definite and exact relationship exists between VOLTS, OHMS
direction, then reverse and move in the opposite direction. They and AMPERES. The value of one can be calculated when the
will repeat this cycle at regular intervals. A wave diagram, called value of the other two are known. Ohm's Law states that in
a “sine wave” shows that current goes from zero to maximum any circuit the current will increase when voltage increases but
positive value, then reverses and goes from zero to maximum resistance remains the same, and current will decrease when
negative value. Two reversals of current flow is called a cycle. resistance Increases and voltage remains the same.
The number of cycles per second is called frequency and is If AMPERES is unknown while VOLTS and OHMS are known,
usually stated in “Hertz”. use the following formula:
VOLT AMPERES = VOLTS
The VOLT is the unit used to measure electrical PRESSURE, OHMS
or the difference in electrical potential that causes electrons to
flow. Very few electrons will flow when voltage is weak. More If VOLTS is unknown while AMPERES and OHMS are known,
electrons will flow as voltage becomes stronger. VOLTAGE may use the following formula:
be considered to be a state of unbalance and current flow as
an attempt to regain balance. One volt is the amount of EMF VOLTS = AMPERES x OHMS
that will cause a current of 1 ampere to flow through 1 ohm of
resistance. If OHMS is unknown but VOLTS and AMPERES are known, use
the following:
Conductor of a
OHM - Unit measuring resistance
Circuit

-
or opposition to flow
= VOLTS

+
OHMS AMPERES

A Simple AC Generator
AMPERE - Unit measuring rate of Figure 6 shows a very simple AC Generator. The generator
current flow (number of electrons
past a given point)
consists of a rotating magnetic field called a ROTOR and
a stationary coil of wire called a STATOR. The ROTOR is a
VOLT - Unit measuring force or permanent magnet which consists of a SOUTH magnetic pole
difference in potential and a NORTH magnetic pole.
causing current flow

Figure 4. Electrical Units

OHM
The OHM is the unit of RESISTANCE. In every circuit there
is a natural resistance or opposition to the flow of electrons. STATOR
When an EMF is applied to a complete circuit, the electrons
are forced to flow in a single direction rather than their free
or orbiting pattern. The resistance of a conductor depends on
(a) its physical makeup, (b) its cross-sectional area, (c) its
length, and (d) its temperature. As the conductor's temperature ROTOR
increases, its resistance increases in direct proportion. One (1)
ohm of resistance will permit one (1) ampere of current to flow
when one (1) volt of electromotive force (EMF) is applied.
MAGNETIC FIELD

Ohm's Law Figure 6. A Simple AC Generator

As the MOTOR turns, its magnetic field cuts across the
VOLTS stationary STATOR. A voltage is induced into the STATOR
windings. When the magnet's NORTH pole passes the STATOR,
(E)
current flows in one direction. Current flows in the opposite
direction when the magnet's SOUTH pole passes the STATOR.
This constant reversal of current flow results in an alternating
AMPS OHMS current (AC) waveform that can be diagrammed as shown in
(I) (R) Figure 7.
The ROTOR may be a 2-pole type having a single NORTH and
a single SOUTH magnetic pole. The 2-pole ROTOR must be
Figure 5. Ohm's Law turned at 3600 rpm to produce an AC frequency of 60 Hertz.
Page 7
Section 1
Generator Fundamentals

CURRENT VOLTAGE 3. AC voltage is delivered to the Inverter Assembly from

the Stator which maintains voltage to the 120 VAC
(+) receptacles.
0 180 360 4. AC voltage is delivered to the bridge rectifier from the
DC Charge Coil for the 12VDC outlet available for battery
charging (if equipped).
(-)
5. AC voltage is delivered to the Inverter Assembly from the
ONE CYCLE sub coil for inverter operation.

Figure 7. Alternating Current Sine Wave 6. AC voltage is delivered to the LED module for ignition
spark to the magneto.
What is an “iX” Inverter Unit?
The iX portable is a computer controlled generator that uses Why Variable Speed Control?
an inverter to create a superior sine wave and maintain a Most electrical loads will operate satisfactorily only within a
steady frequency. These units are different from conventional relatively small voltage band. In order to provide useful voltage
generators in that the performance of the engine and AC at larger load currents, it is necessary to increase engine
generator are more accurately matched over a wide range of speed.
power needs. The iX computer controlled generator provides
greater efficiency of both the engine and the generator while In conventional AC generators, some form of voltage regulation
maintaining electrical output within an acceptable voltage range. is needed to provide correct voltage in the full range of load
The frequency is controlled by the inverter and is maintained at current. This is often accomplished by regulating excitation
a steady 60 Hz signal throughout the load range. current to the Rotor (field) which then regulates the strength
of the Rotor’s magnetic field. The voltage induced into the
Computer controlled generator units have the ability to operate Stator windings is proportional to the strength of the Rotor’s
the engine over a wide range of speeds while conventional magnetic field.
generators will deliver correct AC frequency and voltage only
at a fixed RPM. The iX inverter generators use a Rotor having a fixed, permanent
magnetic field. The strength of this magnetic field is fixed and
Unlike conventional AC generators, the iX unit can match engine cannot be regulated.
speed to load requirements. This provides several advantages,
as follows. The output voltage of an iX inverter will tend to droop with
increasing electrical loads. The inverter maintains a constant
• Smaller engines can be used to produce more power than AC output voltage by increasing engine and Rotor speed as the
on a conventional generator, since they can be allowed to load current increases to offset this inherent voltage droop.
run at a higher speed.
• When the load is reduced, the engine can run at slower than
the conventional speeds. This improves fuel economy and LED
MODULE
reduces engine noise.
• The iX unit can be operated closer to its peak power point at IGNITION WINDING
all times, because output voltage and current are a function DC CHARGE WINDING
BRIDGE
of engine speed. This allows for a much more compact ENGINE ROTOR STATOR
RECTIFIER

generator design. MAIN WINDING

INVERTOR
MODULE
SUB COIL WINDING

iX Inverter System Overview

Figure 8 is a block diagram of the iX system. The major elements STEPPER
MOTOR
of the system are represented in the diagram. Operation of the
system may be described briefly as follows:
1. The engine is directly coupled to a permanent magnet type Figure 8. Inverter Block Diagram
Rotor, so the Rotor runs at the same speed as the engine.
2. As the Rotor turns, its magnetic field cuts across the
Stator windings to induce a voltage into the Stator.

Page 8
 Section 2
Measuring Electricity

Meters 1. Always read the generator's AC output voltage only at the

Devices used to measure electrical properties are called meters. unit's rated operating speed and AC frequency.
Meters are available that allow one to measure (a) AC voltage, (b) 2. The generator's Voltage Regulator can be adjusted for
DC voltage, (c) AC frequency, and (d) resistance in ohms. The correct output voltage only while the unit is operating at
following apply: its correct rated speed and frequency.
• To measure AC voltage, use an AC voltmeter.
3. Only an AC voltmeter may be used to measure AC voltage.
• To measure DC voltage, use a DC voltmeter.
DO NOT USE A DC VOLTMETER FOR THIS PURPOSE.
• Use a frequency meter to measure AC frequency in “Hertz”
or “cycles per second”.
* DANGEROUS VOLTAGES. CONTACT WITH HIGH VOLTAGE
DANGER! GENERATORS PRODUCE HIGH AND
• Use an ohmmeter to read circuit resistance, in “Ohms”.
TERMINALS WILL RESULT IN DANGEROUS AND
The VOM POSSIBLY LETHAL ELECTRICAL SHOCK.
A meter that will permit both voltage and resistance to be read
is the “volt-ohm-milliammeter” or “VOM”.
Measuring DC Voltage
Some VOMs are of the “analog” type (not shown). These meters
display the value being measured by physically deflecting a A DC voltmeter or a VOM may be used to measure DC voltages.
needle across a graduated scale. The scale used must be Always observe the following rules:
interpreted by the user. 1. Always observe correct DC polarity.
“Digital” VOMs (Figure 9) are also available and are generally a. Some VOMs may be equipped with a polarity switch.
very accurate. Digital meters display the measured values
directly by converting the values to numbers. b. On meters that do not have a polarity switch, DC
polarity must be reversed by reversing the test leads.
NOTE: Standard AC voltmeters react to the AVERAGE value 2. Before reading a DC voltage, always set the meter to a
of alternating current. When working with AC, the effective
value is used. For that reason a different scale is used on higher voltage scale than the anticipated reading. If in
an AC voltmeter. The scale is marked with the effective or doubt, start at the highest scale and adjust the scale
“rms” value even though the meter actually reacts to the downward until correct readings are obtained.
average value. That is why the AC voltmeter will give an
incorrect reading if used to measure direct current (DC). 3. The design of some meters is based on the “current flow”
theory while others are based on the “electron flow”
theory.
a. The “current flow” theory assumes that direct current
flows from the positive (+) to the negative (-).
b. The “electron flow” theory assumes that current
flows from negative (-) to positive (+).
NOTE: When testing generators, the “current flow” theory
is applied. That is, current is assumed to flow from positive
(+) to negative (-).

Measuring AC Frequency
VOM’s may also measure the frequency of an AC voltage (if
equipped). The iX Inverter will produce AC frequencies that are
exactly 60Hz. Since the inverter module controls the frequency,
their will not be any direct relation to the speed of the engine
and the output of the unit.

Measuring Current
Figure 9. Digital VOM
Clamp-on
Measuring AC Voltage To read the current flow, in AMPERES, a clamp-on ammeter
may be used. This type of meter indicates current flow through
An accurate AC voltmeter or a VOM may be used to read the a conductor by measuring the strength of the magnetic field
generator's AC output voltage. The following apply: around that conductor. The meter consists essentially of
a current transformer with a split core and a rectifier type
instrument connected to the secondary. The primary of the
Page 9
Section 2
Measuring Electricity
current transformer is the conductor through which the current In Figure 12 the control wire to a relay has been removed. The
to be measured flows. The split core allows the instrument to meter is used to connect and supply voltage to the relay to
be clamped around the conductor without disconnecting it. energize it and measure the amperes going to it.
Current flowing through a conductor may be measured safely
and easily. A line-splitter can be used to measure current in a
cord without separating the conductors.
1.00 A
BATTERY
- + RELAY

Figure 12. A VOM as an In-line meter

Measuring Resistance
The volt-ohm-milliammeter may be used to measure the
Figure 10. Clamp-On Ammeter resistance in a circuit. Resistance values can be very valuable
when testing coils or windings, such as the Stator and Rotor
windings.
When testing Stator windings, keep in mind that the resistance
of these windings is very low. Some meters are not capable
of reading such a low resistance and will simply read
CONTINUITY.
If proper procedures are used, the following conditions can be
detected using a VOM:
• A “shor t-to-ground” condition in any Stator or Rotor
winding.
• Shorting together of any two parallel Stator windings.
• Shorting together of any two isolated Stator windings.
• An open condition in any Stator or Rotor winding.
Figure 11. A Line-Splitter Component testing may require a specific resistance value
or a test for INFINITY or CONTINUITY. Infinity is an OPEN
NOTE: If the physical size of the conductor or ammeter capac- condition between two electrical points, which would read as
ity does not permit all lines to be measured simultaneously, no resistance on a VOM. Continuity is a CLOSED condition
measure current flow in each individual line. Then, add the between two electrical points, which would be indicated as very
individual readings.
low resistance or “ZERO” on a VOM.
In-Line
Alternatively, to read the current flow in AMPERES, an in-line
ammeter may be used. Most Digital Volt Ohm Meters (VOM)
will have the capability to measure amperes.
This usually requires the positive meter test lead to be
connected to the correct amperes plug, and the meter to be
set to the amperes position. Once the meter is properly set
up to measure amperes the circuit being measured must be
physically broken. The meter will be in-line or in series with the
component being measured.

Page 10
 Section 3
Major Components

Introduction 20. Ground (Earth) Connection Lug: Grounding point for the
The unit components and the major internal components of generator; consult state and local electrical codes before
the generator are discussed in this section. Unit identification use (floating ground).
is broken down into two basic categories; items located that 21. 120 VAC Receptacles: Two (2) receptacles for connecting
are visual from the outside and items located on the electrical accessories.
control panel. The internal major components are grouped into 1 2
two separate categories; mechanical and engine related items
13
and electrical items. 2
4
3
UNIT Identification 4 5
1. Carrying Handle: Lift the generator by this handle only.
5
2. Spark Plug Cover: Allows access to the engine spark plug.
3. Fuel System Primer: Used to prime the fuel system for
starting.
4. Fuel Cap Pressure Valve: Allows air to enter the fuel tank
to equalize pressure.
5. Fuel Tank Cap: Access to fuel tank for filling. 6 7

6. Control Panel: location of generator controls and output 6 7

receptacles.
7. Air Intake Slats: Allows for cooling air to enter the
housing.
8. Muffler: Lowers engine exhaust noise. 8
13
9. Choke: Cold engine starting aid 8

10. Left Side Service Cover: Allows access to air filter, fuel
filter and oil fill.
11. Vent Hoses: Allow venting of the carburetor.
12
12. Fuel Shutoff: Controls fuel supply to the carburetor. 11
13. Starter Rope: Pull rope for starting engine. 911
10

10
Control Panel 9

14. Low Oil Level LED (yellow): Lights up when oil level is Figure 13. Unit Identification
below safe operating level and the engine shuts down.
15. Overload LED (red): Lights up if the generator experiences
iX1600
a load greater than the rated output, low voltage, overheats iX800
iX2000
or the powered circuit experiences a short. TheiX1600
output is 14 16
iX800
stopped even though the engine keeps running. iX2000
14 15 16 15
16. Ready LED (green): Indicates output from the generator
unless there is a low oil or overload condition. 15 16 15 14

17. 12 VDC Plug (if equipped): Connection for re-charging

16 14
12VDC automotive-style batteries while generator is in 17
operation.
17
18. FlexPower™ Switch: This switch slows the engine speed
18
when the load is reduced to save fuel and engine wear.
19. 12 VDC Circuit Breaker (if equipped): Overload protection
18
for the 12 VDC charging system.
19 20 21

19 20Figure 14.21Control Panel Identification

Page 11
Section 3
Major Components

Internal Major Engine Components Ignition Shutoff Switch

The ignition shutoff switch is mechanically connected to the
Engine fuel shutoff valve. The internal contacts of the ignition shutoff
A 4 stroke engine attached to the rotor creates the mechanical switch are open when the fuel shutoff valve is in its ON position.
energy necessary to maintain current flow at the receptacles. The contacts are closed when the fuel shutoff valve is in its OFF
position. When the contacts are closed it completes a path to
ground to the LED module that will inhibit spark and shutdown
Ignition Coil
the engine.
The ignition coil provides spark for the engine. Spark timing
is determined by LED module and the Trigger Assembly (Hall
Effect Sensor). IGNITION SHUTOFF
SWITCH
IGNITION COIL

Figure 17.

Low Oil Level Switch

The low oil level switch is a float type switch located inside
the engine on the bottom of the crank case casting. When the
Figure 15. Ignition Coil internal contact is closed it completes a path to ground to the
LED module that will inhibit spark and shutdown the engine.
Trigger Assembly (Hall Effect Sensor)
The trigger assembly is located directly underneath the stator.
The stator sends timing pulses to the trigger assembly, SWITCH OPEN
depending on the position of the engine, to determine the
correct timing for spark. This voltage is delivered to the LED
module.
SWITCH CLOSED

Figure 18.

Carburetor
The carburetor provides a sufficient air/fuel mixture to the engine
to maintain the required speed. A stepper motor incorporated
in the carburetor allows the engine to run at variable speeds.
The speed of the engine is maintained by the inverter which
TRIGGER ASSEMBLY will increase or decrease speed to maintain the output current
necessary for loads.
Figure 16. The Trigger Assembly
Page 12
 Section 3
Major Components
Fuel Pump
The mechanical fuel pump is located on the exterior of the plastic
housing around the engine and is accessible by removing the
side panels. Changes in pressure from the crankcase actuates
a diaphragm inside the pump which then supplies fuel to the
carburetor.

STEPPER MOTOR

INVERTER

CARBURETOR

FUEL PUMP

Figure 19.
Figure 20.
Stepper Motor
The Stepper Motor consists of a motor along with a gear and LED Module
cam arrangement which allows motor movement to change the The LED module receives inputs from the inverter assembly to
engine carburetor throttle setting. The Motor is controlled by monitor an Overload condition. It also illuminates the Green
output signals from the inverter assembly, which calculates the Ready light when unit is producing voltage and ready to accept
number of steps the stepper needs to take and generates the load. An AC voltage is delivered to the module from the stator
required signals to the Motor. The inverter signals the Motor for firing of the ignition coil. The module determines when to
to actuate in response to changes in AC output voltage. Thus, deliver spark to the ignition coil by receiving timing pulses from
in response to decreasing AC output voltages, the Motor will the trigger assembly and fires the coil using the voltage from
increase the throttle setting and engine speed will increase. the stator winding.
Conversely, increasing AC output voltages will cause the Motor
to decrease throttle setting and engine speed will decrease.

Recoil Assembly
The recoil assembly connected directly to the crank shaft of
the engine and allows the engine to spin over when pulled and
reach a speed that allows the engine to maintain that speed.

Internal Major Electrical

Components
Inverter Module
The inverter module receives voltage from two windings in
the stator and produces a sine wave where the voltage is
120 VAC and the frequency is 60 Hz. It is also responsible
for maintaining the correct engine speed needed to maintain
current flow to the connected loads. Figure 21.

Page 13
Section 3
Major Components
Permanent Magnet Rotor Operational Description
Sixteen permanent magnets have been affixed to the Rotor. The 1. The iX inverter units are computer controlled generators
Rotor and Hub are balanced at the factory as an assembly and that use an inverter to create a superior sine wave and
must be replaced as an assembly. maintain a steady frequency of 60 Hz. The PERMANENT
MAGNET ROTOR is directly coupled to the ENGINE and
Stator
rotates at the same speed as the engine.
The stator has 4 separate windings that provide AC voltage
to several different components. The DC Coil provides AC 2. As the ROTOR turns, its magnetic field cuts across a
voltage to the bridge rectifier where 12 VDC is provided for number of STATOR windings, to induce a voltage into
charging. The Main Coil provides voltage to the inverter which those windings as follows:
provides the 120 VAC to the receptacles. The Sub Coil provides a. The MAIN COIL WINDING provides the AC voltage
operating voltage to the Inverter for operation. Finally, the necessary for the inverter to supply rated output voltage
Ignition winding provides AC voltage to the LED module which to the receptacles.
triggers the ignition coil to fire at the correct position.
b. The SUB COIL WINDING provides the AC voltage
needed to operate the Inverter.
Operational Analysis c. The DC COIL WINDING provides the AC voltage
necessary to provide the DC Charging outlet with 12
VDC.
General
d. The IGNITION WINDING provides the voltage needed for
Figure 22, below is a block diagram of the iX inverter generator. the LED module to fire the ignition coil.
The diagram is intended only for the purpose of illustrating
generator operation. Refer to the actual wiring diagram for 3. While the unit is running it continues to monitor the current
wiring interconnections. on the receptacles and make the needed adjustments to
the engine speed by changing the output signals to the
STEPPER MOTOR to either increase or decrease engine
speed based on load demand.

TRIGGER LED OUTLET

ASSEMBLY MODULE

IGNITION
COIL
MAGNETIC
FIELD

IGNITION WINDING
BRIDGE
DC CHARGE WINDING
RECTIFIER
ENGINE ROTOR STATOR
MAIN WINDING
INVERTOR
MODULE
SUB COIL WINDING

MAGNETIC
FIELD OUTLETS
STEPPER
MOTOR

Figure 22. iX Inverter Operating Diagram

Page 14
 Section 4
Troubleshooting and Diagnostic Tests

Problem 1 – No AC Output

IS THE OVERLOAD IS THE GREEN STATUS REMOVE RECEPTACLE PANEL AND

LIGHT ON WHILE OFF LIGHT ON WHILE ON VERIFY CONNECTIONS OF
ENGINE IS RUNNING? ENGINE IS RUNNING? RECEPTACLES AND WIRING

OFF
BAD
GOOD
TEST 1 –
ON BAD CHECK
ENGINE RPM REPAIR OR REPLACE
COMPONENT
GO TO GOOD
“PROBLEM 6”

TEST 2 – TEST TEST 3 – TEST

IS THE LOAD SUBCOIL OF MAIN COIL OF GOOD
NO
CONNECTED? STATOR STATOR

YES REPLACE
GOOD
INVERTER
BAD BAD
MODULE

DISCONNECT THE LOAD, REPLACE

THEN RESTART THE INVERTER
CHECK HARNESS FOR
ENGINE AND CHECK THE MODULE
GOOD CONNECTIONS
AC OUTPUT AGAIN

GOOD BAD

REPLACE REPAIR OR
STATOR REPLACE WIRE

Problem 2 – No DC Output

TEST 1 – TEST 4 – CHECK

TEST 5 – TEST
CHECK GOOD THE DC CIRCUIT GOOD GOOD
DC RECTIFIER
ENGINE RPM BREAKER

BAD
BAD
BAD

REPLACE DC
GO TO REPLACE DC CIRCUIT RECTIFIER
“PROBLEM 6” BREAKER

TEST 6 – TEST
CHECK HARNESS FOR GOOD DC COIL ON
GOOD CONNECTIONS
STATOR

GOOD BAD BAD

REPLACE REPAIR OR REPLACE
STATOR REPLACE WIRE INVERTER
MODULE

Page 15
Section 4
Troubleshooting and Diagnostic Tests

Problem 3 – Overload Light is On

IS THE LOAD
YES DISCONNECT THE LOAD, THEN RESTART THE
CONNECTED?
ENGINE AND CHECK THE AC OUTPUT AGAIN

NO

GO TO “PROBLEM 1, TEST 2”

Problem 4 – Engine Will Not Pull Start

TEST 7 – TEST 8 – TEST VISUALLY INSPECT FOR OBSTRUCTIONS

TEST RECOIL GOOD ENGINE GOOD THAT WOULD CAUSE BINDING OF THE
FUNCTION FUNCTION RECOIL ONCE INSTALLED

BAD BAD

REPLACE VISUALLY INSPECT EXTERNAL

COMPONENTS FOR A FAILURE NOTHING AN INTERNAL ENGINE FAILURE
THAT WOULD CAUSE THE FOUND HAS POSSIBLY OCCURRED
ENGINE TO BE SIEZED

BAD REPLACE COMPONENT

Problem 5 – Flex Power Feature is Not Responding

TEST 21 – TEST REPLACE

FLEX POWER GOOD INVERTER
SWITCH MODULE

BAD

REPLACE
SWITCH

Page 16
 Section 4
Troubleshooting and Diagnostic Tests

Problem 6 – Engine Will Not Start

CHECK FUEL CHECK FUEL TEST 17 – TEST 9 –
QUALITY AND GOOD SHUTOFF GOOD CHECK CHOKE GOOD CHECK GOOD
SUPPLY VALVE ASSEMBLY SPARK

BAD OFF BAD

BAD

REPLENISH FUEL TURN ON REPLACE CHOKE

SUPPLY

TEST 15 – TEST 14 – TEST TEST 16 – TEST

TEST IS “LOW OIL”
GOOD TRIGGER GOOD FUEL SHUTOFF OFF
IGNITION LIGHT ON?
ASSEMBLY SWITCH
COIL

BAD BAD
BAD ON
REPLACE

REPLACE
IGNITION COIL
GOOD CHECK OIL
GO TO “PROBLEM 8” GOOD
LEVEL

BAD
TEST 20 – GOOD REPLACE LED MODULE REPLENISH OIL TEST 10 –
TEST CHECK
IGNITION SPARK PLUG
WINDING BAD REPLACE STATOR
REPAIR OR REPLACE BAD

GOOD

TEST 13 – CHECK TEST 12 – TEST 11 –

ENGINE GOOD CHECK GOOD CHECK FUEL
COMPRESSION CARBURETOR PUMP

BAD BAD BAD

REPLACE
ENGINE

GOOD
REPLACE REPLACE FUEL
CARBURETOR PUMP

CONTACT TECHNICAL
SERVICE

Page 17
Section 4
Troubleshooting and Diagnostic Tests

Problem 7 – Engine Hunts / Erratic Idle or Will Not Come Up to Speed

IS THE UNIT IS THE ENGINE TEST 17 – TEST 11 –

PRODUCING YES RUNNING YES CHECK CHOKE GOOD CHECK FUEL
AC POWER? ERRATICALLY? ASSEMBLY PUMP

NO BAD BAD GOOD

GO TO “PROBLEM 1” NO
REPLACE CHOKE REPLACE FUEL
ASSEMBLY PUMP

REPLACE TEST 18 – TEST TEST 9 – TEST 12 –

INVERTER GOOD STEPPER GOOD CHECK CHECK
MODULE MOTOR SPARK CARBURETOR

BAD BAD
BAD – ENGINE MISS
APPARENT
REPLACE REPLACE
STEPPER CARBURETOR
MOTOR

TEST 14 – TEST
TRIGGER BAD REPLACE
ASSEMBLY

GOOD

REPLACE TEST 15 – TEST REPLACE

LED GOOD IGNITION COIL BAD IGNITION
MODULE COIL

Problem 8 – Unit Shuts Down for Low Oil

TEST 20 – TEST
CHECK OIL REPLACE
GOOD OIL LEVEL BAD
LEVEL ENGINE
SWITCH

BAD
GOOD
REPLACE
LED
MODULE
REPLENISH OIL

Page 18
 Section 4
Troubleshooting and Diagnostic Tests

Test 1 – Check Engine RPM

Tools Required
Small Engine Tachometer 1 – GRAY
2 – EMPTY 1 2 3
Procedure 3 – ORANGE
4 – GRAY
1. With the engine running connect the engine tachometer
according to the manufactures instructions and record the
5 – ORANGE
6 – ORANGE 4 5 6
engine RPM.

Results
Figure 24. C4 Connector Pin Locations, Male Side
1. If the engine rpm was 3000 ±200 rpm it is running within
rated specs, refer back to flow chart. 5. Set VOM to measure resistance.
2. If the engine rpm was outside the range of 3000 ±200 6. Disconnect the C4 connector. On the female side of
rpm, go to Problem 7. the connector connect one meter test lead to Pin 1 and
connect the other meter test lead to Pin 4. Measure and
record the resistance.
Test 2 – Test Sub Coil of Stator
Results
Procedure
1. The resistance measured between Pin 1 and Pin 4 should
1. Stop the engine. be as follows:
2. Drain the fuel from the tank.
iX 800 0.5 Ohms
iX 1600 0.7 Ohms
iX 2000 0.3 Ohms


 asoline is highly flammable and explosive. You can
G
be burned or seriously injured when handling fuel. 2. If the resistance measured is between the specified
Keep heat, sparks, and flame away. Wipe up spills values, refer back to flow chart.
immediately. Be careful not to touch the muffler while 3. If the resistance reading is outside the tolerance, replace
it is HOT. stator.
3. Remove the electrical box assembly and back window
and upper enclosure half. Test 3 – Test Main Coil of Stator
4. Take out the C4 connector.
Procedure
Note: Do not remove the harness of the control panel.
1. Stop the engine.
C4 CONNECTOR
2. Drain the fuel from the tank.

 be burned or seriously injured when handling fuel.

Gasoline is highly flammable and explosive. You can

Keep heat, sparks, and flame away. Wipe up spills

immediately. Be careful not to touch the muffler while
it is HOT.
3. Remove the electrical box assembly and back window
and upper enclosure half.
4. Take out the 6 pin connector
Note: Do not remove the harness of the control panel.
5. Set VOM to measure resistance.
Figure 23. C4 Connector Pin Locations, Male Side
Page 19
Section 4
Troubleshooting and Diagnostic Tests
6. Disconnect the C4 connector. On the female side of Results
the connector connect one meter test lead to Pin 3 and 1. If CONTINUITY is measured across the circuit breaker,
connect the other meter test lead Pin 5, measure and refer back to flow chart.
record the resistance.
2. If the circuit breaker reads open, replace the DC circuit
7. Repeat Step 6 between the following test points: breaker and re-test.
• Pin 3 and Pin 6
• Pin 6 and Pin 5
Test 5 – Test DC Rectifier
Results
Procedure
1. The resistance measured between the all tests points
should be as follows: 1. With the electrical panel still exposed remove the wires on
the DC rectifier and mark the location of each wire on the
iX 800 2.1 Ohms ± 0.3 Ohms rectifier.
iX 1600 TBA ± 0.3 Ohms
2. Set VOM to the Diode test feature (marked on most meters
iX 2000 2.5 Ohms ± 0.3 Ohms by the diode symbol ).
2. If the resistance measured is within the specified values, 3. Connect the meter test leads according to the chart below
refer back to flow chart. and record the results.
3. If the resistance reading is outside the tolerance, replace
the stator. 1 2

Test 4 – Test DC Circuit Breaker

3 4
Procedure
1. Remove the electrical panel so that the DC circuit breaker
is exposed and remove both wires from the breaker. (+) Test Lead
1 2 3 4
Ensure that the breaker is reset from the front of the panel (-) Test Lead
and is not tripped. 1 INFINITY INFINITY INFINITY
2. Set VOM to measure resistance. 2 CONTINUITY INFINITY INFINITY
3 CONTINUITY INFINITY INFINITY
3. Connect one meter test lead to one side of the breaker
and the other meter test lead to the other side of the 4 CONTINUITY CONTINUITY CONTINUITY
breaker and measure resistance. CONTINUITY should be
measured. Results
1. If the meter indicated the correct readings at all test points
refer back to flow chart.
DC BREAKER 2. If the meter indicated any reading other than what was
specified, replace the rectifier.

Test 6 – Test DC Coil on Stator

Procedure
1. Locate the two white wires coming from the stator. One
of them will be located on the DC circuit breaker and the
DC BRIDGE RECTIFIER other one will be located on the rectifier.
2. Set VOM to measure resistance.
Figure 25. DC Breaker and DC Bridge Rectifier 3. Connect one meter lead to one wire and the other meter
lead to the other wire. Measure and record the resistance.

Page 20
 Section 4
Troubleshooting and Diagnostic Tests
Results 2. Attach the high tension lead to the spark tester terminal.
1. The resistance measured between the all tests points 3. Ground the spark tester clamp by attaching it to the
should be as follows: cylinder head (see Figure 26).

iX 1600 0.2 Ohms 4. Attempt to pull start the engine. If spark jumps the tester
iX 2000 0.3 Ohms
gap, the ignition system is working properly.
Note: The fuel shutoff switch should be in the closed position
2. If the resistance measured is within the specified values,
refer back to flow chart. Note: It may take several start attempts before a good
spark is noticed in the tester
3. If the resistance reading is outside the tolerance, replace
the stator.

Test 7 – Test Recoil Function

Procedure
1. Attempt to pull start the engine and make the following
observations while doing so.
• Does the cord pull easily and smoothly?
• Does the cord return with no assistance?
• Does the engine turn over as the cord is pulled?

Results
If the recoil did not perform as the observations are stated
above, possible problems that could be present are: Figure 26.
• The engine could be seized.
• The recoil could have become detached from the flywheel. Results
• The recoil mechanism could be broken and not retracting
properly. 1. Refer back to flow chart

Test 8 – Test Engine Function Test 10 – Check Spark Plug

Procedure PROCEDURE
1. Remove the recoil and front cover assembly. Remove spark plug. Clean with a commercial solvent. DO
NOT BLAST CLEAN SPARK PLUG. Replace spark plug if badly
2. Remove the spark plug from the unit. fouled, if ceramic is cracked, or if badly worn or damaged.
3. Attempt to turn the engine over by hand. Refer to specifications in the front of this manual for proper
replacement spark plugs and spark plug gaps.
Results
1. If the engine can not turn over freely with the spark plug
removed, the engine has suffered some type of internal
failure that has seized it and is inhibiting it from running.
2. Refer back to flow chart.

Test 9 – Check Spark

PROCEDURE
A commercially available spark tester may be used to test the
engine ignition system. Figure 27. Setting Spark Plug Gap
1. Disconnect the spark plug lead from the spark plug.

Page 21
Section 4
Troubleshooting and Diagnostic Tests

NORMAL MISFIRES

CARBURETOR

FUEL PUMP

PRE-IGNITION DETONATION

Figure 28. Spark Plug Conditions Figure 29.

RESULTS
Test 12 – Check Carburetion
1. Clean and regap or replace sparks plug as necessary.
Before checking the carburetor, be sure the fuel tank has an
2. Refer back to the Flow Chart. ample supply of fresh, clean gasoline. Check that all shutoff
valves are open and fuel flows freely through the fuel line. Make
sure the choke operates properly. If the engine will not start,
Test 11 – Check Fuel Pump remove and inspect the spark plug.

Procedure If the spark plug is wet, look for the following:

• Over choking.
1. Open up the side panel that exposes the carburetor and
• Excessively rich fuel mixture.
fuel pump.
• Water in fuel.
2. Carefully remove the fuel line from the filter on the inlet • Intake valve stuck open.
side of the carburetor. • Needle/float stuck open.
If the spark plug is dry look for the following:
• Leaking carburetor mounting gaskets.
• Intake valve stuck closed.
 be burned or seriously injured when handling fuel.
Gasoline is highly flammable and explosive. You can
• Inoperative fuel pump.
Keep heat, sparks, and flame away. Wipe up spills • Plugged fuel filter(s).
immediately. • Varnished carburetor
3. Using a suitable container to catch fuel, slowly pull on • Check that the choke is working properly.
the recoil cord and turn the engine over. Fuel should flow 1. Remove the fuel line at the carburetor and ensure
from the fuel line. If fuel does not flow, verify that fuel that there is an adequate amount of fuel entering the
is available to the pump. If fuel is available to the pump carburetor.
inspect the fuel filter and pulse line. 2. Remove the float bowl and check to see if there is any
foreign matter in the bottom of the bowl.
RESULTS
3. Remove the plastic float to gain access to the needle.
1. If fuel does not flow, replace the fuel pump.
4. Remove the needle so it can be cleaned.
2. If fuel flow has been verified proceed to Test 12.
Page 22
 Section 4
Troubleshooting and Diagnostic Tests
5. Use a suitable carburetor cleaner to clean the carburetor Test 14 – Test Ignition Trigger
before reassembly. Assembly
6. After cleaning the carburetor, blow dry with compressed
air and reassemble. Procedure
Note: The shelf life of gasoline is about 30 days. Proper 1. Remove the electrical panel so that the LED module is
procedures need to be taken so that the fuel doesn’t var- exposed and disconnect the J1 connector.
nish over time. A fuel stabilizer should be used at all times
in order to ensure that the fuel stays fresh. 2. Set VOM to measure resistance.
3. Locate Pin 3 on the J1 connector. Connect one meter
RESULTS
test lead to Pin 3 and the other meter test lead to engine
1. If carburetor is varnished, clean or replace. Refer to back ground. Measure and record the resistance.
to Flow Chart.

Test 13 – Check Engine Compression

Discussion
Most engine problems may be classified as one or a combination
of the following:
• Will not start.
• Starts hard.
• Lack of power.
• Runs rough.
• Vibration.
• Overheating.
• High oil consumption.
Figure 30. J1 Connector on LED Module
Check Compression
Table 1. J1 Connector Pin Chart
To check engine compression, remove the spark plug. Insert an
automotive type compression gauge into the spark plug hole. Location Function Wire Color
Crank the engine until there is no further increase in pressure. Pin 1 Ignition Coil Blue
The highest reading obtained is the engine compression
pressure. Pin 2 Low Oil Switch Yellow
Pin 3 Trigger Assembly White
Minimum allowable compression Pin 4 Ground Pink
60 psi
pressure cold engine
Pin 5 Ignition Winding Red
If compression is poor, look for one or more of the following
causes: Pin 6 Fuel Shutoff Switch Gray

• Loose cylinder head bolts. Pin 7 Inverter Purple

• Failed cylinder head gasket. Pin 8 Inverter Yellow
• Burned valves or valve seats. Pin 9 Inverter White
• Insufficient valve clearance. Pin 10 Inverter Green
• Warped cylinder head.
• Warped valve stem. Results
• Worn or broken piston ring(s). 1. If the meter reading is within ± 5 ohms of the correct
• Worn or damaged cylinder bore. resistance, refer back to flow chart.
• Broken connecting rod.
• Worn valve seats or valves. iX 800 30 Ohms
• Worn valve guides. iX 1600 30 Ohms
iX 2000 129 Ohms
2. If the meter did not indicate the correct resistance, replace
trigger assembly.

Page 23
Section 4
Troubleshooting and Diagnostic Tests

Test 15 – Test Ignition Coil

Procedure
1. Open up the electrical panel so that the control panel
wiring is exposed.
2. Disconnect the J1 connector and disconnect the ignition
coil boot from the spark plug.
3. Set VOM to measure resistance.
4. Connect one meter test lead to ground and connect
the other meter test lead to Pin 1 on the J1 connector.
Measure and record the resistance.

Figure 32.
Figure 31.
5. Connect one meter test lead to the spark plug wire and Test 16 – Test Fuel Shutoff Switch
connect the other meter test lead to engine ground.
Procedure
Measure and record the resistance.
1. Open up the electrical panel so that the control panel
Results wiring is exposed.

1. Refer to the following chart. If the correct values were 2. Set fuel shutoff valve to the CLOSED position.
measured in Steps 4 and 5, refer back to flow chart. 3. Disconnect the J1 connector from the LED module.
4. Set VOM to measure resistance.
Pin 1 to Ground 1.7 Ohms ± 0.5 Ohms
5. Connect one-meter test lead to J1 Pin 6 and the other test
Spark Plug to Ground 12.5K Ohms ± 2K Ohms lead to ground. Measure and record the resistance.
6. Set fuel shutoff valve to the OPEN position
2. If the incorrect values were measured in Steps 4 and 5, 7. Repeat Step 5.
inspect ignition coil connector for bad connection. If the
connection is verified good, replace ignition coil. Fuel Shutoff Valve Position Fuel Shutoff Switch Reading
3. If the incorrect value was measured in Step 5 then inspect CLOSED OPEN (INFINITY)
the ground connection on Pin 2 of the C2 connector going OPEN CLOSED (CONTINUITY)
to the ignition coil.
Results
1. If INFINITY was measured when the shutoff valve was
CLOSED, and CONTINUITY was indicated when the valve
was OPEN, refer back to flow chart.
2. If CONTINUITY to ground was not measured when the
valve was in the OPEN position, verify the mechanical
Page 24
 Section 4
Troubleshooting and Diagnostic Tests
connection between the valve and the switch. If d. Pin 2 and Pin 3 – approximately 50 ohms should be
mechanical connection is good, replace switch. measured.
e. Pin 2 and Pin 4 – INFINITY should be measured.
3. If the meter read CONTINUITY when the shutoff valve was
in either the open or closed position, verify mechanical f. Pin 3 and Pin 4 – INFINITY should be measured.
connection between the valve and the switch. If
Results
mechanical connection is good replace shutoff switch.
1. If the values in steps 3a through 3f are good, refer back to
Note: A fuel shutoff switch that does not read INFINITY
when the fuel shutoff valve is in the closed position will flow chart.
cause a no spark condition. 2. If any one of the values in steps 3a through 3f tested bad,
replace stepper motor.
Test 17 – Check Choke Assembly
iX1600, iX2000 Procedure
Procedure
1. Disconnect the C3 connector (Stepper motor) from the
1. If the generator is surging it may have a carburetion Inverter module.
problem. A lean condition can cause erratic RPM. Slowly
2. Set VOM to measure resistance.
slide the choke to see if surging stops. If it does stop,
carburetion should be checked. 3. Connect a VOM test leads across the following test points
2. Verify the mechanical connection to the carburetor and a. Pin 1 to Pin 5 – approximately 195 ohms should be
measured.
that the choke is functioning properly.
b. Pin 2 to Pin 5 – approximately 195 ohms should be
measured.
Results
c. Pin 3 to Pin 5 – approximately 195 ohms should be
1. If the choke is functioning correctly, refer back to flow measured.
chart. d. Pin 4 to Pin 5 – approximately 195 ohms should be
2. If the choke is not functioning correctly, replace the choke measured.
assembly.

Test 18 – Test Stepper Motor

1 2 3 4 5
iX800 Procedure
1 – RED 4 – YELLOW
1. Disconnect the J2 connector (Stepper Motor) from the
2 – ORANGE 5 – BLUE
Inverter module.
3 – WHITE
2. Set VOM to measure resistance.
Figure 34. C3 Connector Female Side, iX1600, iX2000

Results
1. If the values in steps 3a through 3d are good, refer back
1 – PINK
2 – YELLOW 1 2 to flow chart.
3 – BLUE 2. If any one of the values in steps 3a through 3d tested bad,
4 – ORANGE replace stepper motor.
3 4
Test 19 – Test Oil Level Switch
Figure 33. C3 Connector Female Side, iX800 Procedure
3. Connect VOM test leads across the following test points: 1. Verify that the engine is filled with the appropriate amount
a. Pin 1 and Pin 4 – approximately 50 ohms should be of oil.
measured. 2. Locate the low oil shutdown wire on the engine and isolate
b. Pin 1 and Pin 3 – INFINITY should be measured. it from the rest of the harness.
c. Pin 1 and Pin 2 – INFINITY should be measured. 3. Set VOM to measure resistance.
Page 25
Section 4
Troubleshooting and Diagnostic Tests
4. Connect one meter lead to the wire that runs through the Results
plastic engine housing to the oil level switch and the other 1. Refer to the following chart. If the meter reading is within
test lead to engine frame ground. Measure and record the ± 0.2 ohms, refer back to flow chart.
resistance.
iX 800 0.8 Ohms
Results iX 1600 0.5 Ohms
1. If oil level was good and the meter indicated an open iX 2000 0.7 Ohms
circuit, check for a short to ground on the wire between
the low oil level switch and the LED module.
2. If oil level was good and the meter indicated a closed
circuit to ground, replace the engine. Test 21 – Test FlexPower Switch
Procedure
Test 20 – Test Ignition Coil Winding 1. Disconnect the orange and brown wires from the
FlexPower switch (FPS).
Procedure
2. Set VOM to measure resistance.
1. Remove the electrical panel so the components are
exposed. 3. Set FPS to “ECO” position.

2. Disconnect the J1 Connector. 4. Connect one meter test lead to Pin 1 and the other meter
test lead to Pin 2. Measure resistance and record results.
3. Set VOM to measure resistance.
5. Set FPS to “HIGH” position.
4. Connect one meter lead to Pin 5 of the J1 connector and
the other meter test lead to ground. Measure and record 6. Repeat Step 4. Measure resistance and record results.
the resistance. Refer to Table 1 on Page 23.

3 2 1

1 – ORANGE
2 – BROWN
3 – EMPTY

Figure 36. FlexPower Switch Test Points

Test Points ECO HIGH

Pin 1 to Pin 2 INFINITY CONTINUITY

Results
Figure 35. J1 Connector on LED Module
1. If INFINITY was measured in Step 4 and CONTINUITY in
Step 5, replace inverter module.
2. If either CONTINUITY was measured in Step 4 or INFINITY
in Step 5, replace FPS switch.

Page 26
 Section 5
Disassembly
Discussion
During the process of tearing the unit apart it is critical to make
special notes as to the way the different parts are located
inside. There is no room for error when putting the unit
back together. When re-assembling the unit, it is good to be
proactive and always thinking about the next step to eliminate
back tracking. It is also a good idea to continually re-check
what parts are left for reassembly to ensure that no parts are
forgotten during the process.

Disassembly
Muffler Removal
1. Drain all fuel and oil from unit.
2. Remove four (4) Phillips screws located on the black
Figure 38.
exhaust cover.
3. Remove the rubber muffler gasket and note orientation of 5. Remove the retaining clip underneath the fuel fill cap
the seal before removing. cover.

Enclosure Removal
4. Remove one (1) flat head screw holding the service
access panel.

Figure 39.
6. Remove four (4) Phillips screws holding the control panel
to the housing.

Figure 37.
The following items are able to be serviced and replaced at
this point:
• Fuel Pump
• Stepper Motor
• Carburetor
• Air Filter

Figure 40.

Page 27
Section 5
Disassembly
7. Disconnect the connectors and ground wires and remove • Lower and Upper Enclosures
control panel. • Ignition Coil
8. Remove one (1) Phillips screw to remove the fuel shutoff • Recoil Assembly
knob.
Engine Housing Removal
9. Remove one (1) Phillips screw from recoil access area.
19. Remove one (1) Phillips screw from the fuel pump
10. Remove three (3) Phillips screws located on the handle. housing.
(two on iX 800)
20. Remove two (2) 8 mm nuts from the carburetor plastic
11. Carefully orient the assembly so that the side with the intake assembly and remove the fuel pump and the
access cover is facing down. See Figure 38. carburetor as one assembly and isolate the fuel hose from
12. Remove two (2) Phillips bolts on the underside of the the fuel shutoff valve.
plastic housing. Note: Keep the two spacers with the housing once it has
been removed.
13. The side with the spark plug access should be facing up
21. Remove ten (10) Phillips screws around the top and
at this point, remove this half of the enclosure.
bottom seams of the housing. There are two different
sizes of screws. Make note of which one is which for
reassembly.
22. Isolate the wiring harness from the housing and remove
the low oil plug and pull the wire through for removal.
23. Separate the two housings to expose the engine.

Figure 41.
14. Disconnect the fuel tank by removing the hose clamp and
removing the hose from fuel shutoff valve.
15. Remove one (1) Phillips screw from the fuel shutoff valve
so it is isolated from the enclosure.
Note: Make note of the orientation of the fuel shutoff valve
for re-assembly.
16. On the iX 1400, iX 1600 and iX 2000 disconnect Figure 42.
connectors and remove inver ter. On the iX 800 the
inverter is connected to the fuel shutoff switch and can Time to reach this point: 25 minutes
not be removed. The following items are able to be serviced at this point
17. Feed the recoil cord through the lower enclosure piece. • Engine
• Rotor
18. The engine assembly should be able to be lifted out of the
• Stator
unit and set aside.
• Low Oil Switch
Time to reach this point: 15 minutes • Fan
The following items are able to be serviced and replaced at • Trigger Assembly
this point The following items are able to be replaced at this point
• Inverter Assembly • Low Oil Switch
• Fuel Shutoff Valve • Trigger Assembly
• Fuel Shutoff Switch
Page 28
 Section 5
Disassembly
Rotor/Stator Removal
24. Remove the 8mm bolt in the center of the recoil jaw.

Figure 45.
29. Remove two (2) 8mm bolts holding stator to engine
casting.
Figure 43.
30. Remove stator.
25. Remove two 8mm bolts from the starting jaw seat.
• Time to reach this point: 45 minutes
26. Remove the fan. • The following items are able to be replaced at this point
27. Remove the 15mm nut in the center of the rotor by • Engine
inserting the socket wrench first and install a steering • Stator
wheel puller over the socket wrench as shown in Figure • Rotor
41. Use an adjustable wrench to counter the torque from
the socket to break the nut free. Reassembly Notes
• The above procedure should be reversed to re-assemble unit
• Order of reassembly
1. Engine
2. Stator
3. Rotor
4. Engine Housing
5. Fuel Pump
6. Carburetor
7. Place Engine Housing in lower Enclosure
Note: Be sure to locate all harnesses and fuel lines to
ensure they will not be obstructed during the reassembly
process. The stepper motor harness must be able to reach
the inverter
8. Fuel Shutoff Switch
Note: Test Fuel Switch for correct orientation before putting
the two halves together.
9. Fuel Tank
10. Inverter
Figure 44.
11. Upper Enclosure
28. With the nut removed install the steering puller with the
center bolt tight against the center shaft and remove the 12. Retaining Clip below fuel cap
rotor assembly 13. Receptacle panel

Page 29
Section 5
Disassembly

Exploded View – iX800

Page 30
 Section 5
Disassembly

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 1 ENGINE ASSY. 39 2 DAMPING RING, POTHOOK 80 3 SCREW, M4X12
2 1 SUPERCHARGED CAP ASSY, 40 2 STUD BOLT 81 1 CASING, ENGINE UPPER
FUEL TANK
41 1 GASKET, POTHOOK 82 4 SCREW, TAPPING, CROSS,
3 1 FUEL FILLER INLET RUBBER RING RECSD, P/HEAD(ST4.2X13)
42 1 POTHOOK
4 8 CLAMP, FUEL HOSE 83 1 PUMP ASSY. FUEL
43 2 PIN, HOLLOW FIXED POSITION
5 1 CUP, FUEL FILTER 84 1 GASPIPE, FUEL PUMP
44 1 BLOCK, CARBURETOR CUSHION
6 1 TANK, FUEL 85 1 OUTLET PIPE, FUEL PUMP
45 2 SEAL GASKET, CARBURETOR (IN)
7 4 SHOCK ABSORBER BLOCK 86 1 SCREW, PHILIPS, ST4.8X19
46 1 CARBURETOR REGULATING
8 2 SCREW, CROSS RECESSED PAN ASSY. 87 1 SHELL, LOWER
HEAD, M6X120
47 1 SEAL GASKET, CARBURETOR (IN) 88 1 SWITCH, IGNITION ON/OFF
9 1 COVER, UPPER SHELL
48 1 FILTER ADAPTER BOX 89 1 COVER, SWITCH
10 1 SHELL, UPPER (BREATHER)
90 2 SCREW, TAP/CRS/
11 2 SCREW, CROSS RECESSED PAN 49 1 TUBE, BREATHER RECSD(ST4.8X19)
HEAD, M6X14
50 2 CIRCLIP, ADAPTER 91 1 SWITCH/VALVE. FUEL
12 8 LOCK SLICE/SCREW CLIP
51 1 SLEEVE, FILTER ADAPTER 92 1 PIPE, OUTLET
13 2 ALIGNMENT PIN
52 2 ALIGNMENT PIN, ADAPTER BOX 93 1 PIPE, INLET, FUEL PUMP
14 4 FEET, VIBRATION MOUNTS
53 3 NUT, HEX FLANGE FACE 94 1 SCREW, TAP,CRS,RECD(ST6.3X16)
15 4 BOLT, HEX, FLANGE FACE (M6X12)
54 1 STARTER ASSY. 95 1 KNOB, ON/OFF FUEL SWITCH
16 1 LOWER CASING, ENGINE
55 3 SAFEGUARD TUBE 96 1 CONNECTION-PEG, GROUNDED
17 2 BOLT, HEX, FLANGE FACE (M5X16)
56 3 REC. PAN HEAD SCREW/WASHER 97 1 COVER, LOWER SHELL
18 4 WASHER ASSY.(M5X12)
98 1 SEAL, LOWER SHELL COVER
19 4 SLEEVE, DAMPING/VIBRATION 57 1 HANDLE PANEL
MOUNTS 99 1 SCREW(M6X14)
58 1 RECESSED HEAD BOLT &
20 1 KEY, WOODRUFF--3X5X13 WASHER ASSY. 100 6 SCREW, TAP/CRS/REC/(ST4.2X16)

21 1 STATOR ASSY. 59 1ea HANDLE, RECOIL ASSY 101 1 WASHER, FLAT

22 2 BOLT, HEX, FLANGE FACE (M5X25) 59a 1ea STARTER HANDLE HOOD 102 1 SHIM, MUFFLER

23 1 FLYWHEEL ROTOR ASSY. 60 1 CORD, RECOIL ASSY 103 1 MUFFLER ASSY.

24 1 NUT, HEX FLANGE 61 1 INVERTER 104 2 BOLT, HEX, FLANGE FACE(M6X50)

FACE(M10x1.25-8) 105 3 WASHER, FLAT
66 1 FRAME, FRONT PANEL
25 1 FAN 106 1 BOLT, HEX (M5X70)
67 1 PANEL, IC
26 1 SEAT, STARTING JAW 107 1 GASKET, RUBBER, BACK WINDOW
68 1 ADAPTER SLEEVE, RESPIRATOR
27 2 BOLT, HEX , FLANGE FACE(M6X14) 108 1 WINDOW, BACK
69 1 IGNITER (WITH INDICATOR)
28 1 JAW, STARTING 109 4 SCREW, PH RECESSED M5X20
70 1 BACKOIL ASSY. RESPIRATOR
29 1 WASHER (6) 110 1 SEAL COVER, OIL SENSOR
71 4 SCREW, CROSS RECESSED PAN
30 1 BOLT, HEX, FLANGE FACE(M6X18) HEAD (M5X12) 111 3 GASKET, SHAFT
31 1 COWLING & INLET COVER ASSY. 72 7 WASHER, FLAT(5) 112 1 O-RING
32 2 SCREW, CROSS RECESSED PAN 73 1 SWITCH, FLEXPOWER 113 1 DIPSTICK/COVER, OIL
HEAD TAPPING
74 1 IC SCREEN 114 2 NUT, HEXAGONAL
33 1 COIL, IGNITION
75 2 NUT, I TYPE HEX.(M4) 115 1 SPRING WASHER, STANDARD
34 1 SLEEVE, RUBBER (HIGH VOLTAGE) TYPE
76 8 WASHER, FLAT, M4
35 2 SPONGE, AIR FILTER 116 1 PANEL ASSY., CONTROL
77 8 WASHER, LOCK, M4
36 1 COVER, AIR FILTER
78 6 SCREW, CROSSED RECESSED
37 1 ALIGNMENT PIN PAN HEAD
38 2 WASHER 79 1 OUTLET ASSY 120V

Page 31
Section 5
Disassembly

Exploded View – iX1600

Page 32
 Section 5
Disassembly

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 1 ENGINE 38 1 GASKET, CARBURETOR (B) OUT 74 1 FILTER, FUEL
2 1 CAP ASSY., FUEL TANK 39 1 BLOCK, CARBURETOR SPACER 75 1 PIPE, FUEL PUMP OUTLET
(CUSHION)
3 1 COVER, FUEL FILLER PORT 76 1 GASPIPE, FUEL PUMP
40 1 CARBURETOR, SEAL GASKET
4 1 CUP, FUEL FILTER A (OUT) 77 1 PIPE-B, FUEL PUMP INLET
5 1 TANK, FUEL 41 1 REGULATING ASSY. CARBURETOR 78 1 PUMP ASSY., FUEL
6 4 BLOCK, SHOCK ABSORBER 42 1 GASKET, CARBURETOR IN 79 1 SCREW, PAN HEAD , RECESSED,
7 1 COVER, LOWER SHELL 43 2 NUT, HEX/ FLANGED, M5 80 10 CLAMP, FUEL HOSE
8 1 SHELL, LOWER 44 2 WASHER, FLAT 81 1 CASING, UPPER ENGINE
9 8 CLIP, SCREW 45 2 SPACER, FILTER CASE LINER 82 4 SCREW, TAPPING-PAN HEAD
RECESSEDST4.2X16
10 4 FEET, VIBRATION MOUNTS 46 1 CASE ASSY., FILTER
83 1 SLEEVE, RESPERATOR ADAPTOR
11 5 RECESSED PAN HEAD SCREW, 47 2 SPRING CLIP
ST6. 3X19 84 1 SHIM, MUFFLER
48 1 FILTER, ADAPTER SLEEVE
12 2 ALIGNMENT PIN 85 1 MUFFLER ASSY.
49 STARTER, RECOIL ASSY.
13 2 BOLT, HEX, W/ FLANGE M6X12 86 3 BOLT, HEX HEAD, FLANGED,
50 1 BOLT, HEX HEAD W/WASHER, M6X55
14 1 CASING, LOWER, ENGINE M5X12
87 1 RUBBER SEAL, BACK WINDOW
15 4 WASHER 51 1 INVERTER ASSY
88 1 WINDOW, BACK (EXHAUST
16 4 SLEEVE, DAMPING 52 1 FRAME, FRONT PANEL COVER)
17 1 SEAL COVER, OIL SENSOR 353 1 PLATE ASSY, CONTROL 89 4 SCREW, RECESSED PAN HEAD/
18 1 KEY, WOODRUFF, 3X5X13 M5X20
54 4 SCREW, PAN HEAD, RECESSED,
19 1 STATOR ASSY. M5X25 90 1 RETAINING CLIP, SHELL

20 2 BOLT, HEX, W/ FLANGE M5X30 55 4 WASHER, FLAT 5 91 1 BAFFLE, THERMAL

21 1 FLYWHEEL/ROTOR ASSY. 56 2 SCREW, PAN HEAD RECESSED,

M6X120
22 1 NUT, HEX/FLANGED M10X1.25-8 CONTROL PLATE ASSEMBLY
57 1 SEAL COVER, LOWER SHELL
23 1 FAN 1 3 NUT, HEX/ FLANGED, M5
58 1 SCREW, M6X14
24 1 JAW SEAT, STARTING 2 1 IGNITION .LED INDICATOR
59 1 COVER, UPPER SHELL
25 5 BOLT, HEX, FLANGED, M6X16 3 1 RECTIFIER 1010A
60 1 SCREW, PAN HEAD M4X12
26 1 COUPLER, STARTING JAW 4 1 BOLT, IGNITION APPARATUS
61 1 SWITCH, FUEL ON/OFF
27 1 BOLT, HEX/FLANGED, M8X14 5 1 BOLT, HEX, WITH FLANGE
62 3 SCREW, PAN HEAD, RECESSED,
28 1 COVER ASSY, COWLING AND M6X14 6 1 BOLT, HEX, WITH FLANGE
INLET 7 1 CONTROL PLATE ASSEMBLY
63 1 SHELL, UPPER
29 1 PLUG, RUBBER 8 2 WASHER, FLAT
64 1 SWITCH, IGNITION, ON/OFF
30 1 O-RING, RUBBER, 20X1.8 9 1 SCREW, RECESSED PAN HEAD
65 1 COVER, SWITCH
31 1 COIL, IGNITION 10 1 12VDC PLUG ASSY.
66 2 SCREW, RECESSED PAN HEAD/
32 2 TAPPING SCREW, RECESSED ST4.2X9.5 TAPPING 11 1 SWITCH, FLEXPOWER
PAN/HD STR. 8X14
67 1 VALVE, FUEL 12 1 120V OUTLET ASSY.
33 1 PIN, MOUNTING (POTHOOK
PILLAR) 68 1 HOSE, OIL DISCHARGE 13 3 NUT, I- TYPE HEX
34 1 POT HOOK 69 1 SHIELD, PIPE SPRING 14 3 WASHER, SPRING, STANDARD
35 1 CLEANER, AIR 70 1 HOSE, FUEL PUMPI OIL INJ. 15 3 WASHER, FLAT, M4
36 1 COVER, AIR FILTER 71 1 O-RING 16 1 PEG, GROUND CONNECTION
37 6 SCREW, PAN HEAD, TAPPING 72 1 COVER, OIL W/DIPSTICK 17 1 DECAL, CONTROL PLATE
STR.8X32 73 2 STUD/BOLT

Page 33
Section 5
Disassembly

Exploded View – iX2000

Page 34
 Section 5
Disassembly

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 1 ENGINE ASSEMBLY 38 1 CARBURETOR ASSY. HOSE, FUEL PUMP OIL INJEC-
75 1
TION B
2 1 CAP, FUEL FILLER 39 1 GASKET, CARBURETOR (IN)
76 1 FUEL PUMP ASSY.
3 1 COVER, FUEL FILLER PORT 40 6 NUT, HEX. WITH FLANGE, M6
77 1 SCREW, PHILIPS, ST4.8X19
4 1 CUP, FUEL FILTER 41 2 SPACER, OIL SPLASH COVER
78 1 WRAPPER, ENGINE, UPPER
5 1 TANK, FUEL 42 1 OIL SPLASH SUB-ASSY.
79 6 SCREW, PHILIPS, ST4.2X13
6 4 BLOCK, SHOCK ABSORBER 43 2 CLIP, SPRING
80 1 REDUCER
7 1 COVER, UPPER SHELL 44 1 AIR TUBE
81 1 GASKET, MUFFLER
8 1 SHELL, UPPER 45 1 HANDLE , RECOIL ASSY.
82 1 MUFFLER ASSY.
9 8 CLIP, SCREW 46 1 CORD, RECOIL ASSY.
BOLT, HEX HEAD W/FLANGE,
SHOCK ABSORBER, FOOT OF 47 1 STOP, HANDLE 83 2
10 4 M6X60
CHASSIS
48 1 RECOIL ASSY. 84 1 SEAL, EXHAUST COVER
11 5 SCREW, PHILIPS, ST6, 3X19
49 1 INVERTER SUB ASSY 85 1 COVER, EXHAUST
12 2 MOUNTING PIN, BOTTOM
50 1 BRACE, CONTROL PANEL 86 4 SCREW, CROSS PAN HEAD, M5X20
BOLT, HEX HEAD W/FLANGE
13 5 51 1 CONTROL PANEL W/ DECAL
M6X12 87 1 CLIP, RETAINING, CHASSIS
14 1 WRAPPER, SIDE SCREW, CROSSED PAN HEAD, 88 1 O-RING, RUBBER
52 4
M5X25
15 4 GASKET 89 2 WASHER
53 4 WASHER
16 4 REDUCER RING, VIBRATION 90 10 CLIP, HOSE, FUEL
SCREW, CROSSED PAN HEAD,
54 2
17 1 KEY, WOODRUFF, 3X5X13 M6X130 BOLT, HEX HEAD W/FLANGE,
91 1
M6X80
18 1 STATOR ASSY. 55 1 SEAL, COVER
SCREW, PHILIPS W/WASHER,
BOLT, HEX HEAD W/FLANGE 56 1 SCREW, M6X14 92 1
19 4 M5X12
M5X30
57 1 COVER, UPPER SHELL 93 2 PIN, GUIDE, A
20 1 FLYWHEEL ROTOR ASSY
58 1 SCREW, CROSS PAN HEAD, M4X12 94 2 PIN, GUIDE, B
21 1 NUT, HEX SCREW, W/ FLANGE
59 1 SWITCH, FUEL ON/OFF 95 2 WASHER/ GASKET, HOOK
22 1 FAN BLADES
60 3 SCREW, CROSS PAN HEAD, M6X14 96 1 SCREW, PHILIPS
23 1 SEAT, STARTING JAW
61 1 SHELL, UPPER 97 1 BOLT, HEX WITH FLANGE
BOLT, HEX HEAD W/FLANGE
24 3 62 1 SWITCH, IGNITION, ON/OFF
M6X16 98 2 NUT, M4
25 1 JAW, STARTER 63 1 COVER, SWITCH 99 8 WASHER, LOCK, M4
26 1 COVER 64 2 SCREW, PHILIPS, ST4,2X9.5 100 8 WASHER, FLAT, M4
27 1 RUBBER SET, HIGH PRESSURE 65 1 VALVE, FUEL 101 1 OUTLET, 120 VAC 20 AMP
28 1 IGNITION COIL 66 1 HOSE, OIL DISCHARGE 102 1 DISPLAY, LED
29 2 SCREW, PHILIPS, ST4. 8X22 67 2 CLAMP, HOSE 103 1 DIODE, RECTIFIER
30 1 MOUNTING PIN, TOP HOSE, FUEL PUMP OIL INJEC- 104 1 PANEL, FRONT
68 1
TION A
31 1 HOOK 105 2 WASHER, STAR LOCK M6
69 1 O-RING
32 1 AIR CLEANER 106 2 SCREW M4X12
70 1 DIPSTICK
33 1 COVER, AIR FILTER 107 1 SWITCH, FLEXPOWER
71 2 STUDS
BOLT, HEX HEAD W/FLANGE, 108 1 BREAKER, DC CIRCUIT
34 6 72 1 FILTER, GAS
M5X16
109 1 HOLDER, DC COMPONENTS
35 1 GASKET, CARBURETOR, (OUT B) 73 1 HOSE, FUEL PUMP
110 1 RECEPTACLE, 12 VDC
36 1 SPACER 74 1 HOSE, FUEL PUMP AIR

37 1 GASKET, CARBURETOR, (OUT A)

Page 35
 iX800

Page 36
Section 6
Electrical Data

AC RECPTACLES
1 RED
2 RED
J3
FLEX POWER SWITCH
C1
ORANGE 6

MAIN COIL WINDING C4 BROWN 2

ORANGE 5 INVERTER
ORANGE 4
ASSEMBLY
ORANGE 3

STATUS
LIGHT
SUB COIL WINDING
GRAY 2
C1 J1 OVERLOAD
3 GREEN 10
WHITE 5 WHITE 9 LIGHT
GRAY 1 4 YELLOW 8
PURPLE 7
J2 1 2 3 4 1 GRAY 6 LOW OIL
RED
LED MODULE

6 5 LIGHT
2 YELLOW 4
GRAY 5 WHITE 3
IGNITION WINDING 4 YELLOW 2
1 BLUE 1
3
C5

RED
2

PINK
C2 1

ORANGE
YELLOW
LOW OIL FUEL
LEVEL SHUTOFF
SWITCH SWITCH
TRIGGER
ASSEMBLY

STEPPER
MOTOR IGNITION
COIL
SPARK
PLUG
 RED
DC CHARGE OUTLET

RED

WHITE BLACK
DC CIRCUIT BREAKER
WHITE
iX1600 and iX2000

DC
RECTIFER
AC RECPTACLES
DC COIL WINDING RED

RED

FLEX POWER SWITCH

C1
ORANGE 6

MAIN COIL WINDING C4 BROWN 2

ORANGE 5 INVERTER
ORANGE 4
ASSEMBLY
ORANGE 3

STATUS
LIGHT
SUB COIL WINDING
GRAY 2
C1 J1 OVERLOAD
3 GREEN 10
WHITE 5 WHITE 9 LIGHT
GRAY 1 4 YELLOW 8
PURPLE 7
1 GRAY 6 LOW OIL
RED
LED MODULE

6 5 LIGHT
2 PINK 4
GRAY 5 WHITE 3
IGNITION WINDING 4 YELLOW 2
1 BLUE 1
3
C5

RED
2

PINK
C2 1

BLUE

ORANGE
YELLOW
C3 1 2 3 4 5 LOW OIL FUEL
LEVEL SHUTOFF
SWITCH SWITCH
TRIGGER
ASSEMBLY

STEPPER IGNITION
MOTOR COIL
SPARK
PLUG

Page 37
Electrical Data
Section 6
Electrical Formulas

TO FIND KNOWN VALUES 1-PHASE

ExI
KILOWATTS (kW) Volts, Current, Power Factor
1000

ExI
KVA Volts, Current
1000

kW x 1000
AMPERES kW, Volts, Power Factor
E

WATTS Volts, Amps, Power Factor Volts x Amps

2 x 60 x Frequency
NO. OF ROTOR POLES Frequency, RPM
RPM

RPM x Poles
FREQUENCY RPM, No. of Rotor Poles
2 x 60

2 x 60 x Frequency
RPM Frequency, No. of Rotor Poles
Rotor Poles

HP x 0.746
kW (required for Motor) Motor Horsepower, Efficiency
Efficiency

E
RESISTANCE Volts, Amperes
I

VOLTS Ohm, Amperes IxR

E
AMPERES Ohms, Volts
R

E = VOLTS I = AMPERES R = RESISTANCE (OHMS) PF = POWER FACTOR

Page 38
NOTES
NOTES

Page 40
 Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
Part No. 0H5039 Printed in USA Rev. A 04/30/10 1-888-GENERAC (1-888-436-3722)
©2010 Generac Power Systems, Inc. All rights reserved.
Specifications are subject to change without notice
No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. generac.com