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Kipor KG390 User Manual

Kipor KG390
32 pages
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KG390 Engine Service Manual
The Coast Distribution System,
Ver. 2, October 1, 2007
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Kipor KG390 Specifications

General IconGeneral
Type4-stroke, OHV, single cylinder
Displacement389
Bore x stroke88×64
Compression ratio8.5:1
Cooling systemForced air
Ignition systemTransistorized electric ignition
Ignition timing28°B.T.D.C
Spark plugF7RTC
CarburetorFloat type, Horizontal, butterfly valve type
Air cleanerDry Replaceable Element
GovernorElectronic control type (Inverter Module)
Lubrication systemSplash
Oil Capacity1.2 Qt (1.1 L)
Starting SystemElectric starter
Stopping SystemElectric ground
Fuelautomotive grade unleaded gasoline 87 Octane
Maximum horsepower7.7 @ 3600 RPM

Summary

Preface

Specifications

Service and Maintenance

Importance of Proper Servicing

Highlights the critical role of correct servicing for operator safety and generator reliability.

General Safety Precautions

Provides essential safety guidelines and personal protective equipment advice for maintenance.

Service Rules and Best Practices

Outlines rules for using genuine parts, special tools, and proper assembly procedures.

Electrical Precautions

Details precautions for handling connectors, wiring harnesses, and electrical testing.

Serial Number and Bar Code Location

Explains where to find the engine serial number and the purpose of the bar code.

Maintenance Standards

Fastening Torques

Cylinder Cover and Cylinder Head Assembly

Cylinder Head Removal Procedure

Step-by-step instructions for removing the cylinder head, including bolt tightening sequence.

Cylinder Head Disassembly and Reassembly

Details on disassembling and reassembling the cylinder head components, including spring basis.

Valve Spring Free Length Inspection

Procedure to measure the free length of valve springs and compare it to service limits.

Valve Base Width Inspection

How to measure the width of the valve base and check against service limits.

Cylinder Cover Inspection

Instructions for cleaning and checking the cylinder cover for cracks and distortion.

Valve Stem External Diameter Inspection

Measures the external diameter of the valve stem and compares it to the service limit.

Valve Bore Inner Diameter Inspection

Details on measuring the inner diameter of the valve bore against service limits.

Valve Bore to Conduit Pipe Clearance

Procedure to measure the clearance between the valve bore and the valve conduct pipe.

Valve Clearance Adjustment

Provides instructions and specifications for adjusting the engine's valve clearance.

Crankshaft, Piston, Connecting Rod, and Camshaft

Crankshaft Cover Service

Details on the crankshaft cover, including gasket and positioning pin.

Crankshaft, Camshaft, and Piston Service

Procedures for installing the piston, camshaft, and connecting rod, noting key marks and torque.

Timing Mark Alignment

Guidance on aligning the camshaft gear and timing gear using marks for proper installation.

Bearing Clearance Inspection

Method for checking bearing clearance by rotating the shaft and identifying noise or movement.

Piston Ring and Connecting Rod Installation

Instructions for installing piston rings and connecting rod, including manufacturer marks and orientation.

Piston Ring Assembly Guidelines

Rules for piston ring installation: marking orientation, avoiding mix-ups, and checking rotation.

Piston Inspection Procedures

Cylinder Inner Diameter Inspection

Measures the inner diameter of the cylinder and compares it to the service limit.

Piston Apron External Diameter

Details on measuring the piston apron's external diameter against service limits.

Piston-to-Cylinder Clearance

Measures the clearance between the piston and the cylinder bore, including side clearance.

Piston Ring Terminal Clearance

Measures the terminal clearance of the piston ring within the cylinder.

Piston Ring Height Inspection

Procedure to measure the height of piston rings and check against service limits.

Piston Pin External Diameter

Measures the external diameter of the piston pin and compares it to the service limit.

Piston Pin Bore Internal Diameter

Details on measuring the internal diameter of the piston pin bore against service limits.

Piston Pin to Bore Clearance

Measures the clearance between the piston pin and its bore.

Connecting Rod Inspection

Connecting Rod Small End Diameter

Measures the internal diameter of the connecting rod's small end.

Connecting Rod Big End Diameter

Measures the internal diameter of the connecting rod's big end.

Crankshaft Inspection

Crankshaft Main Journal Diameter

Measures the external diameter of the crankshaft's main journal.

Connecting Rod Big End to Journal Clearance

Measures the clearance between the connecting rod big end and the crank journal.

Crankshaft Oil Film Clearance

Procedure using plastic gauge to measure crankshaft oil film and connecting rod big end clearance.

Camshaft Inspection

Camshaft Height Inspection

Measures the height of the camshaft lobes for wear.

Camshaft External Diameter

Measures the external diameter of the camshaft journals.

Camshaft Bearing Inner Diameter

Measures the inner diameter of the camshaft bearing and compares it to the service limit.

Electric Starter System

Electric Starter Disassembly and Reassembly

Provides instructions for disassembling and reassembling the meshing gear assembly of the electric starter.

Electric Starter Inspection

Electromagnetic Switch Inspection

Checks continuity of the electromagnetic switch's pull and hold coils and contactors.

Starter Brush Length Inspection

Measures starter brush length and advises replacement if worn beyond the service limit.

Starter Mica Depth Inspection

Checks mica depth and provides guidance on finishing if below the limited value.

Commutator Sector Conductivity

Checks conductivity between commutator sector parts, recommending armature replacement if un-conductive.

Commutator Insulation to Shaft

Checks insulation between the commutator and shaft, advising armature replacement if continuity exists.

Meshing Gear and Clutch Inspection

Inspects meshing gear teeth for wear and checks clutch operation for free rotation.

Spline Gear Inspection

Checks the spline gear for free movement and wear on the rotor shaft.

Brush Holder Inspection

Checks brush movement in the holder, cleaning/replacing if resistance is noted, and checks insulation.

Excitation Coil Continuity Inspection

Checks continuity of the excitation coil between the brush lead wire and coil.

Excitation Coil Ground Inspection

Checks continuity between the brush and starter cover to detect coil failure.

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