Generac iX 800 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.

Tools: Small Engine Tachometer

1. With the engine running connect the engine tachometer according to the manufacturer's instructions and record the engine RPM.
2. If the engine rpm was 3000 ±200 rpm it is running within rated specs.
3. If outside the range, go to Problem 7.

Tools: Commercial Solvent

1. Remove spark plug. Clean with a commercial solvent. DO NOT BLAST CLEAN SPARK PLUG.
2. Replace spark plug if badly fouled, if ceramic is cracked, or if badly worn or damaged.
3. Refer to specifications for proper replacement spark plugs and spark plug gaps.

⚠ Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately.

Tools: Suitable Container

1. Open up the side panel that exposes the carburetor and fuel pump.
2. Carefully remove the fuel line from the filter on the inlet side of the carburetor.
3. Using a suitable container to catch fuel, slowly pull on the recoil cord and turn the engine over. Fuel should flow from the fuel line.
4. If fuel does not flow, verify fuel is available to the pump. If available, inspect the fuel filter and pulse line.

Tools: Carburetor Cleaner, Compressed Air

1. Ensure fuel tank has fresh, clean gasoline and all shutoff valves are open.
2. Remove the fuel line at the carburetor and ensure adequate fuel entering the carburetor.
3. Remove the float bowl and check for foreign matter.
4. Remove the plastic float to access the needle. Remove and clean the needle.
5. Use carburetor cleaner to clean the carburetor before reassembly.
6. Blow dry with compressed air and reassemble.

Tools: Compression Gauge

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

Tools: VOM

1. Remove the electrical panel so that the LED module is exposed and disconnect the J1 connector.
2. Set VOM to measure resistance.
3. Locate Pin 3 on the J1 connector. Connect one meter test lead to Pin 3 and the other to engine ground. Measure and record the resistance.