Generac iX 1600 Generator Set

Tools: socket, feelers/gauges

1. Verify the piston is at top dead center (TDC) of its compression stroke (both valves closed).
2. Remove four (4) screws from rocker cover.
3. Remove rocker cover and rocker cover gasket.
4. Loosen rocker arm jam nut. Turn adjustment screw in to decrease clearance or out to increase clearance.
5. Hold socket steady and tighten lock nut to specification; check clearance and make minor adjustments.
6. After tightening jam nut, recheck valve clearance to make sure it did not change.
7. Install rocker cover, gasket and four screws; tighten to specifications.

Tools: non-metallic feeler gauge

1. Install or replace trigger pickup; ensure routing of wires is correct and not pinched.
2. With rotor in place, set gap to 0.20-0.30mm using the oval holes in the pickup bracket.
3. Align trigger point on rotor outside surface in-line with sensor and check/adjust gap with a non-metallic feeler gauge.
4. Tighten mounting screws to specification and check gap; adjust if necessary.

Tools: compression gauge

1. Remove spark plug.
2. Insert an automotive type compression gauge into spark plug hole.
3. Crank engine until there is no further increase in pressure; record highest reading.

Tools: Small engine tachometer or inductive tachometer

1. With engine running, connect engine tachometer per manufacturer instructions and record the engine RPM.
2. If engine rpm is within rated specs refer to flow chart; if outside range go to Problem 7 flowchart.

⚠ Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away.

Tools: suitable fuel container

1. Open side panel to expose carburetor (A) and fuel pump (B).
2. Carefully remove fuel line from filter on inlet side of carburetor.
3. Using a suitable container, slowly pull on recoil cord and turn engine over; fuel should flow from fuel line.
4. If fuel does not flow, verify fuel is available to pump; inspect fuel filter and pulse line.
5. If fuel does not flow, replace fuel pump.

Tools: spark tester

1. Disconnect spark plug lead from spark plug.
2. Attach high tension lead to spark tester terminal.
3. Ground spark tester clamp by attaching to cylinder head.
4. Attempt to pull start engine; if spark jumps tester gap, ignition system is working properly.

⚠ Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away.

Tools: DMM

1. Stop engine and drain fuel from tank.
2. Remove electrical box assembly, back window, and upper enclosure half.
3. Take out C4 connector (do not remove harness of control panel).
4. Set DMM to measure resistance.
5. On female side of C4, connect one lead to Pin 1 and the other to Pin 4; measure and record resistance.
6. If within specified values refer to flow chart; if outside tolerance replace stator.

⚠ Hot oil may cause burns

⚠ Avoid prolonged skin exposure to used oil

Tools: Drain pan

1. Run generator briefly to warm engine oil.
2. Place generator over drain pan.
3. Remove drain plug and tip generator on its side to drain used oil.
4. Replace drain plug.
5. Fill with proper grade oil and replace fill cap.

1. With enclosure and air duct removed, access fuel filter and fuel pump.
2. Assemble connection lines to proper location.
3. Perform 'Test with Enclosure OFF' to verify operation and no leaks.

1. Remove air filter cover and filter for access to filter housing mounting bolts.
2. Remove the two nuts for inlet duct to carburetor and the vent tube; remove air cleaner housing as an assembly.
3. Disconnect choke cable and stepper motor connector from Inverter.
4. Disconnect black vent tube from carburetor.
5. Disconnect fuel line at carburetor fuel inlet.
6. Remove fuel tank support bracket mounting bolts on right side; only loosen left side.
7. Move fuel tank support bracket enough to slide carburetor assembly off the studs.
8. Assemble in reverse order, use new gaskets.

Tools: Phillips screwdriver, flat head screwdriver

1. Remove one (1) flat head screw holding the service access panel.
2. Remove retaining clip underneath fuel fill cap cover.
3. Remove four (4) Phillips screws holding control panel to the housing.
4. Disconnect connectors and ground wires; remove control panel.
5. Remove one (1) Phillips screw to remove fuel shutoff knob.
6. Remove one (1) Phillips screw from recoil access area.
7. Remove three (3) Phillips screws on handle (two on iX 800).
8. Remove two (2) Phillips bolts on underside of plastic housing.
9. With spark plug access facing up, remove this half of enclosure.
10. Disconnect fuel tank by removing hose clamp and hose from fuel shutoff valve.
11. Remove one (1) Phillips screw from fuel shutoff valve to isolate it from enclosure.
12. On iX1400, iX1600 and iX2000 disconnect connectors and remove inverter.
13. Feed recoil cord through lower enclosure piece.
14. Lift engine assembly out and set aside.

Tools: Phillips screwdriver, 8 mm wrench

1. Remove one (1) Phillips screw from fuel pump housing.
2. Remove two (2) 8 mm nuts from carburetor plastic intake assembly; remove fuel pump and carburetor as one assembly.
3. Isolate fuel hose from fuel shutoff valve (keep the two spacers with the housing).
4. Remove ten (10) Phillips screws around top and bottom seams of housing.
5. Isolate wiring harness from housing and remove low oil plug; pull wire through for removal.
6. Separate housings to expose engine.