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.

⚠ 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.

⚠ Change the oil only when the fuel tank is low or nearly empty; tipping with a full tank may cause fuel leakage

1. Run generator briefly to warm oil
2. Change oil only when fuel tank is low or nearly empty
3. Place generator over drain pan and remove drain plug; tip on side to drain
4. Tip generator upright once drained; refill with proper grade; replace drain plug

⚠ Wipe up any fuel spills immediately; do not smoke or replace fuel filter near sparks or open flame

1. Make sure Fuel Shutoff is in OFF position
2. Remove pinch clamps securing fuel filter; pull hoses free
3. Replace used filter with a new one; push fuel hoses onto barbed filter fittings until seated
4. Replace clamps, making sure they are seated on the fittings

Tools: socket wrench

1. Remove spark plug cover on top right side of generator below handle
2. Pull spark plug lead from spark plug; use socket wrench to remove spark plug
3. Install new spark plug into cylinder head; tighten to 15 ft/lb
4. Replace spark plug lead, making sure fully seated
5. Replace spark plug cover

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.

⚠ Do not store gasoline from one season to another

1. Remove all gasoline from fuel tank
2. Run engine until it stops from lack of fuel or drain carburetor bowl via valve
3. While engine is still warm, drain oil from crankcase and refill with recommended grade
4. Remove spark plugs and pour about 1/2 ounce (15 ml) of engine oil into cylinders; cover spark plug hole with rag; pull starting rope several times
5. Install and tighten spark plug
6. Clean generator outer surfaces; check cooling air slots are open and unobstructed
7. Store unit in a clean, dry place