DIAGNOSTIC

REPAIR
MANUAL

GP-i, GP-iO, iQ, and iX Series Inverter

MODELS:

iQ2000 C0010020

iX800 C0010030

iX1600 INV 2000 DMN

iX2000 INV 3000 DMN

GP2200i

GP3000i

iQ3500

GP3500iO

Important Note: Always use the unit specific Schematics and

Wiring Diagrams for troubleshooting.

P O R T A B L E G E N E R AT O R S
Safety Read This Manual Thoroughly
Throughout this publication and on tags and decals This diagnostic manual has been written and published
affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company
CAUTION blocks are used to alert personnel to special service personnel when servicing the products described
instructions about a particular operation that may be herein.
hazardous if performed incorrectly or carelessly. Observe It is assumed that these personnel are familiar with the
them carefully. Their definitions are as follows: servicing procedures for these products, or like or similar
products manufactured and marketed by Generac, and
DANGER that they have been trained in the recommended
servicing procedures for these products, including the
Indicates a hazardous situation which, if not avoided, use of common hand tools and any special Generac tools
will result in death or serious injury. or tools from other suppliers.
(000001) 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
WARNING and/or results of each method. We have not undertaken
any such wide evaluation. Therefore, anyone who uses a
Indicates a hazardous situation which, if not avoided, procedure or tool not recommended by Generac must
could result in death or serious injury. first satisfy themselves that neither his nor the products
safety will be endangered by the service procedure
(000002)
selected.
All information, illustrations and specifications in this
CAUTION manual are based on the latest product information
available at the time of publication.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury. When working on these products, remember that the
electrical system and engine ignition system are capable
(000003) of violent and damaging short circuits or severe electrical
shocks. If you intend to perform work where electrical
NOTE: Notes provide additional information important to terminals could be grounded or touched, the battery
a procedure or component. cables should be disconnected at the battery.
Any time the intake or exhaust openings of the engine
These safety alerts cannot eliminate the hazards they
are exposed during service, they should be covered to
indicate. Observing safety precautions and strict
prevent accidental entry of foreign material. Entry of such
compliance with the special instructions while performing
materials will result in extensive damage when the
the action or service are essential to preventing
engine Is started.
accidents.
During any maintenance procedure, replacement
fasteners must have the same measurements and
WARNING strength as the fasteners that were removed. Metric bolts
and nuts have numbers that indicate their strength.
CANCER AND REPRODUCTIVE HARM Customary bolts use radial lines to indicate strength
[Link]. while most customary nuts do not have strength
(000393a) markings. Mismatched or incorrect fasteners can cause
damage, malfunction and possible injury.

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.

ii Diagnostic Repair Manual

 Table of Contents
Safety ........................................................................ ii Section 3Disassembly
Replacement Parts ................................................... ii iX Disassembly .......................................................29
iQ Disassembly .......................................................32
Section 1General Information iQ2000 Torque specifications .................................44
Unit Identification ......................................................1 GP3000i Torque specifications ...............................44
iX Unit Identification ..................................................1 Standard Fastener Torque Specification ................44
iQ Unit Identification ..................................................2 GP3500io/IQ3500 Torque specifications ................45
GP-i Unit Identification ..............................................3 Standard Fastener Torque Specification ................45
GP-iO Unit Identification ...........................................4 79.8cc Inverter Engine Torque Specifications ........45
Internal Major Engine Components ..........................5 Exploded View – iX800 ...........................................46
Internal Major Electrical Components .......................7 Exploded View – iX1600 .........................................50
Operational Analysis .................................................8 Exploded View – iX2000 .........................................54
Exploded View – iQ2000 ........................................58
Section 2Troubleshooting and Diagnostic
Tests Section 4Electrical Data
Introduction .............................................................65
Troubleshooting Flow Charts ..................................11
Wiring Diagram, iQ2000 Drawing No. 0L4354-B ... 66
Diagnostic Tests .....................................................15
Wiring Diagram, iQ2000 Drawing No. 0L4354-B ... 67
Check Engine RPM ................................................15 Wiring Diagram, iX800 ........................................... 68
Test Sub Coil of Stator ............................................15 Wiring Diagram, iX1600 and iX2000 ...................... 69
Test Main Coil of Stator ..........................................16 Wiring Diagram and Electrical Schematic,
GP2200i, Craftsman 2200i C0010020/Premier
Test DC Circuit Breaker ..........................................17
2200i INV2200DMN
Test DC Rectifier .....................................................17 Drawing No. 10000001954-A ............................... 70
Test DC Coil on Stator ............................................18 Wiring Diagram and Electrical Schematic,
GP3000i, Craftsman 3000i C00010030/PRO-3000i
Test Recoil Function ...............................................18
INV3000DMN INV 60HZ 120 VAC
Test Engine Function ..............................................18 Drawing No. 10000017588-A ................................ 71
Check Spark ...........................................................19 Wiring Diagram and Electrical Schematic,
Check Spark Plug ...................................................19 GP3500iO 60HZ 120 VAC
Drawing No. 10000017616-A ................................ 72
Check Fuel Pump ...................................................19
Wiring Diagram and Electrical Schematic,
Check Carburetion ..................................................20 iQ3500 Drawing No. 10000033847-A .................... 73
Check Engine Compression ...................................20 Wiring Diagram and Electrical Schematic, iQ3500
Drawing No. 10000033847-A ................................ 74
Test Ignition Trigger Assembly ...............................21
Electrical Formulas .................................................75
Test Ignition Coil .....................................................22
Test Fuel Shutoff Switch .........................................23
Check Choke Assembly ..........................................23
Test Stepper Motor .................................................23
Results ....................................................................24
Test Oil Level Switch ..............................................24
Test Ignition Coil Winding .......................................24
Test FlexPower/MODE Switch ................................25
Check/Adjust Valves ...............................................26
Fuel Display Inaccurate ..........................................26
Test Inverter ............................................................26

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 Table of Contents

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Diagnostic Repair Manual iv

Section 1 General Information
Unit Identification 1. Carrying Handle: Lift the generator by this handle
only.
Unit identification is broken down into two basic
categories: 2. Spark Plug Cover: Allows access to the engine
spark plug.
• items that are visual from the outside
3. Fuel System Primer: Used to prime the fuel system
• items located on the electrical control panel
for starting.
Internal major components are grouped into two
4. Fuel Cap Pressure Valve: Allows air to enter the
categories:
fuel tank to equalize pressure.
• mechanical and engine related items 5. Fuel Tank Cap: Access to fuel tank for filling.
• electrical items 6. Control Panel: location of generator controls and
output receptacles.
iX Unit Identification 7. Air Intake Slats: Allows for cooling air to enter the
See Figure 1-1. housing.
8. Muffler: Lowers engine exhaust noise.
1 2
9. Choke: Cold engine starting aid
3
4
10. Left Side Service Cover: Allows access to air filter,
fuel filter and oil fill.
5
11. Vent Hoses: Allow venting of the carburetor.
12. Fuel Shutoff: Controls fuel supply to the carburetor.
13. Starter Rope: Pull rope for starting engine.

Control Panel
14. Low Oil Level LED (yellow): Lights up when oil
6 7 level is below safe operating level and the engine
shuts down.
15. Overload LED (red): Lights up if the generator
experiences a load greater than the rated output,
13 low voltage, overheats or the powered circuit
8 experiences a short. The output is stopped even
though the engine keeps running.
16. Ready LED (green): Indicates output from the
generator unless there is a low oil or overload
12
condition.
17. 12 VDC Plug (if equipped): Connection for re-
11
charging 12VDC automotive-style batteries while
10
9 generator is in operation.
iX1600
iX2000
iX800 18. FlexPower™ Switch: This switch slows the engine
14 16
speed when the load is reduced to save fuel and
engine wear.
15 15
19. 12 VDC Circuit Breaker (if equipped): Overload
16 14
protection for the 12 VDC charging system.
17 20. Ground (Earth) Connection Lug: Grounding point
for the generator; consult state and local electrical
codes before use (floating ground).
18
21. 120 VAC Receptacles: Two (2) receptacles for
connecting accessories.

19 20 21 008573

Figure 1-1.

Diagnostic Repair Manual 1

Section 1 General Information

iQ Unit Identification 1. Fuel Cap: Access to fuel tank for filling.

2. Carrying Handle: Lift the generator by this handle
See Figure 1-2.
only.
1 3. Muffler: Lowers engine exhaust noise.
2
4. Service Door: Allows access to air filter, fuel filter
and oil fill.
5. Recoil Handle: Pull to start engine.
3
6. PowerDial: Controls ON/OFF functions, choke and
fuel valve operation.
7. Air Intake: Allows for cooling air to enter the
housing.

Control Panel
4 8. Ready to Load LED (green): Indicates output from
generator (unless there is a low oil or overload
condition).
9. Overheat LED (red): Illuminates when unit
temperatures exceed normal operating conditions.
10. Low Oil LED (orange): Lights up when oil level is
below safe operating level and engine shuts down.
7
5 11. Overload LED (red): Lights up if generator
experiences load greater than rated output, low
voltage, overheats or the powered circuit
experiences a short. The output is stopped even
6 though the engine keeps running.
12. Fuel Gauge: Indicates fuel level in tank.
10 11 12
13. Run Time Display: Shows engine run time hours.
9 13 14. PowerBar: Indicates amount of power being used
from the generator.
8 15. Parallel Ready 120 Volts AC Duplex Outlet: Two
(2) 5-20R receptacles for connecting accessories
14
or iQ2000 parallel kit (sold separately)
18
16. Reset Button: Press for 1 second and release to
reset any faults and to restore output power.
17. Grounding Location: Grounding point for the
generator; consult state and local electrical codes
before use (floating ground).
17
16 15 008574 18. Turbo/Standard/Economy Switch: Determines
Figure 1-2. mode of operation.

2 Diagnostic Repair Manual

 Section 1 General Information

GP-i Unit Identification

See Figure 1-3.
1. Fuel Cap: Access to fuel tank for filling.
2
1 2. Carrying Handle: Lift the generator by this handle
only.
3. Recoil Handle: Pull to start engine.
4. Control Panel
5. Spark Plug
6. Muffler
4
3 7. Oil Fill/Drain
8. Carburetor
9. Air Cleaner

5
Control Panel
8 10. Low Oil Warning
11. Overload Warning
6
12. AC Power Light
13. Economy Mode Switch
9
14. 120V, 20A Receptacle
7 15. Off/Run/Choke Switch
16. Parallel Operation Cable Connection
10 11 12 13 14 15 17. 1A/2.1A, 5 VDC USB Outlet
18. AC Breaker
16 19. Grounding Location
20. 120V, 30A Receptacle (NEMA L5-30R)
20
17

19
18
008592

Figure 1-3.

Diagnostic Repair Manual 3

Section 1 General Information

GP-iO Unit Identification

See Figure 1-3.
1. Fuel Gauge
3
2 4 2. Fuel Tank Cap
1
3. Fuel Tank
4. Frame
5. Control Panel
6. Inverter Module
7. Spark Plug
8. Carburetor
9. Air Cleaner
5
6
7
10. Oil Drain
8
11. Oil Fill
12. Muffler
12
9 Control Panel
11 13. AC Breaker
14. Engine Smart Control (ESC)
15. Low Oil Warning
16. Overload Warning
17. AC Power Light
10
18. Hour Meter
14 15 16 17 18 19
13 19. 1A/2.1A, 5 VDC USB Outlet
20. Parallel Outlets
21. 120V, 30A Receptacle (NEMA L5-30R)
22. Grounding Location
23. 120V, 20A Receptacle
25 24 23 24. Off/On/Choke Switch
25. Recoil Starter
22 21 20 008593

Figure 1-4.

4 Diagnostic Repair Manual

 Section 1 General Information

Internal Major Engine Components

Engine
A 4 stroke engine attached to the rotor creates the
mechanical energy necessary to maintain current flow at
the receptacles.

Ignition Coil
The ignition coil provides spark for the engine. Spark
timing is determined by LED module and the Trigger
Assembly (Hall Effect Sensor).

008601

Figure 1-7. Right Side of Unit

Trigger Assembly (Hall Effect Sensor)

The trigger assembly is located directly underneath the
stator on the iX series and under the Alternator cover on
the iQ2000. The stator sends timing pulses to the trigger
assembly, depending on the position of the engine, to
determine the correct timing for spark. This voltage is
delivered to the LED module.

008599

Figure 1-5. iX Ignition Coil

008602
008600
Figure 1-8. iX Trigger Assembly
Figure 1-6. iQ Ignition Coil

Diagnostic Repair Manual 5

Section 1 General Information

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 internal contact is closed it completes
a path to ground to the LED module that will inhibit spark
and shutdown the engine.

SWITCH OPEN

SWITCH CLOSED

008605

Figure 1-11. Low Oil Level Switch

Carburetor
The carburetor provides a sufficient air/fuel mixture to the
008603 engine to maintain the required speed. A stepper motor
Figure 1-9. iQ Trigger Assembly incorporated in the carburetor allows the engine to run at
variable speeds. The speed of the engine is maintained
Ignition Shutoff Switch by the inverter which will increase or decrease speed to
maintain the output current necessary for loads.
The ignition shutoff switch is mechanically connected to
the fuel shutoff valve. The internal contacts of the ignition
shutoff switch are open when the fuel shutoff valve is in
its ON position. 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 the engine.

008606

Figure 1-12. Carburetor Side View, iQ2000

Fuel Pump
The mechanical fuel pump is located on the exterior of
the housing around the engineon the iX, and on the
008604 support bracket for the iQ2000 which is accessible by
Figure 1-10. Ignition Shutoff Switch removing the side panels. Changes in pressure from the
crankcase actuates a diaphragm inside the pump which
then supplies fuel to the carburetor.

6 Diagnostic Repair Manual

 Section 1 General Information

to take and generates the required signals to the Motor.

The inverter signals the Motor to actuate in response to
changes in AC output voltage. Thus, in response to
decreasing AC output voltages, the Motor will increase
the throttle setting and engine speed will increase.
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

008607 Inverter Module
Figure 1-13. iX Fuel Pump, Stepper Motor and The inverter module receives voltage from two windings
Carburetor 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.

008608

Figure 1-14. iQ Fuel Pump

008609
Stepper Motor Figure 1-15. iX Inverter
The Stepper Motor consists of a motor along with a gear
and cam arrangement which allows motor movement to Fuel Sender (iQ2000 only)
change the engine carburetor throttle setting. The Motor
The fuel sending unit located in the fuel tank is an
is controlled by output signals from the inverter assembly,
electronic fuel level sensor that reports fuel level
which calculates the number of steps the stepper needs
Diagnostic Repair Manual 7
Section 1 General Information

percentage information back to the display (LED)

module. Power from the LED module provides the
required voltage and ground to the fuel sending unit to
which the fuel sending unit communicates the fuel level
information over these wires to the LED module.

008612

Figure 1-18. iQ LED Module

Permanent Magnet Rotor

Sixteen (16) permanent magnets have been affixed to
the Rotor on the iX and twelve (12) on the iQ. The Rotor
and Hub are balanced at the factory as an assembly and
008610
must be replaced as an assembly.
Figure 1-16. iQ Inverter
Stator
LED Module The stator has 4 separate windings that provide AC
The LED module receives inputs from the inverter voltage to several different components. The DC Coil
assembly to monitor an Overload condition. It also provides AC voltage to the bridge rectifier where 12 VDC
illuminates the Green Ready light when unit is producing is provided for charging on the iX. The same winding on
voltage and ready to accept load. An AC voltage is the iQ is for the LED display. The Main Coil provides
delivered to the module from the stator for firing of the voltage to the inverter which provides the 120 VAC to the
ignition coil. The module determines when to deliver receptacles. The Sub Coil provides operating voltage to
spark to the ignition coil by receiving timing pulses from the Inverter for operation. Finally, the Ignition winding
the trigger assembly and fires the coil using the voltage provides AC voltage to the LED module which triggers
from the stator winding. the ignition coil to fire at the correct position.

Operational Analysis
General
Figures 33 (iX) and 29 (iQ) are block diagrams of the
inverter generators. The diagrams are only for the
purpose of illustrating generator operation. Refer to
actual wiring diagram for wiring interconnections.

Operational Description
1. The iX and iQ inverter units are computer con-
trolled generators that use an inverter to create a
superior sine wave and maintain a steady fre-
quency of 60 hz. the permanent magnet rotor is
008611
directly coupled to the engine and rotates at the
Figure 1-17. iX LED Module same speed as the engine.
2. As the rotor turns, its magnetic field cuts across
stator windings, to induce a voltage into those
windings as follows:
a. The main coil winding provides the AC voltage
necessary for the inverter to supply rated
output voltage to the receptacles.

8 Diagnostic Repair Manual

 Section 1 General Information

b. The sub coil winding provides the AC voltage e. The ignition winding provides the voltage
needed to operate the Inverter. needed for the LED module to fire the ignition
c. The DC coil winding provides the AC voltage coil.
necessary to provide the DC charging outlet 3. While unit is running, it continues to monitor current
with 12 VDC (iX only). on receptacles and make needed adjustments to
d. The LED winding powers the fuel LED's, run engine speed by changing output signals to the
time clock, status LED's and supplies power to STEPPER MOTOR to either increase or decrease
the LED module for the PowerBar display engine speed based on load demand.
(iQ2000 only).

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 008613

Figure 1-19. iX Inverter Operating Diagram

TRIGGER LED
ASSEMBLY MODULE

IGNITION
COIL
MAGNETIC
FIELD

IGNITION WINDING

DC WINDINGS

ENGINE ROTOR STATOR

MAIN WINDING
INVERTOR
MODULE
SUB COIL WINDING

MAGNETIC
FIELD OUTLETS
STEPPER
MOTOR 008614

Figure 1-20. iQ, GP-i, GP-iO Inverter Operating Diagram

Diagnostic Repair Manual 9

Section 1 General Information

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10 Diagnostic Repair Manual

Section 2 Troubleshooting and Diagnostic Tests
Troubleshooting Flow Charts
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 TO
INVERTER
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
YES (iQ2000) NO
CONNECTED? STATOR STATOR

DISCONNECT LOAD, YES (iX) REPLACE

PERFORM RESET GOOD
INVERTER
PROCEDURE AND VERIFY BAD BAD
MODULE
LOAD DOES NOT EXCEED
UNIT’S CAPABILITY AND DISCONNECT THE LOAD, REPLACE
RED LIGHT GOES OUT. THEN RESTART THE INVERTER
CHECK HARNESS FOR
TEST AC OUTPUT. ENGINE AND CHECK THE MODULE
GOOD CONNECTIONS
AC OUTPUT AGAIN

GOOD BAD

REPLACE REPAIR OR
STATOR REPLACE WIRE

Problem 2 – No DC Output (iX Units Only)

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

Diagnostic Repair Manual 11

Section 2 Troubleshooting and Diagnostic Tests

Problem 3 – Overload Light Is On

IS THE LOAD iX Units - DISCONNECT LOAD, RESTART

YES ENGINE AND CHECK AC OUTPUT AGAIN.
CONNECTED?

iQ2000 - DISCONNECT LOAD, PRESS AND

NO HOLD RESET BUTTON, THEN RELEASE. IF
OVERLOAD LIGHT GOES OUT, LOAD IS TO
MUCH FOR THE UNIT.
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/Mode Feature is Not Responding

TEST 21 – TEST REPLACE

FLEX GOOD INVERTER
POWER/MODE MODULE
SWITCH

BAD

REPLACE
SWITCH

12 Diagnostic Repair Manual

 Section 2 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

Diagnostic Repair Manual 13

Section 2 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 GOOD 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

Problem 9 – LED Display INOP

TEST 6 –
BAD
DC WIRING

GOOD REPLACE STATOR

WINDING
ASSEMBLY
REPLACE LED
MODULE

14 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

Diagnostic Tests

Check Engine RPM

Tools Required
Small Engine Tachometer or Inductive Tachometer

iX Procedure
1. With engine running, connect engine tachometer
according to manufactures instructions and record
the engine RPM.

Results 008616

1. If engine rpm is 3000 ±200 rpm it is running within Figure 1-21. C4 Connector Pin Locations, Male Side
rated specs. Refer to flow chart.
2. If engine rpm is outside range of 3000 ±200 rpm,
go to Problem 7 flowchart.

iQ2000 Procedure
1. With no load on unit, verify rpm based on each of
the mode selections:

Turbo Mode 4500 ± 200 RPM

Standard Mode 3600 ± 200 RPM

008617
ECO Mode 3000 ± 200 RPM Figure 1-22. Sub Coil Connector

2. If engine rpm is running within rated specs, refer to

flow chart. 1 – YELLOW
1 2
2 – YELLOW
3. If engine rpm is outside range of rated specs, go to 008618
Problem 7 flowchart. Figure 1-23. F2 Sub Coil Connector

Test Sub Coil of Stator

1 – GRAY
Procedure 2 – EMPTY 1 2 3
3 – ORANGE
1. Stop engine. 4 – GRAY
5 – ORANGE 4 5 6
6 – ORANGE
DANGER 008619

Figure 1-24. C4 Connector Pin Locations, Male Side

Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark Results
away. Failure to do so will result in death
or serious injury. 1. Resistance measured between Pin 1 and Pin 4
(000105)
should be as follows:
2. Drain fuel from tank.
3. Remove electrical box assembly, back window, iX 800 0.5 Ohms
and upper enclosure half. iX 1600 0.7 Ohms
4. Take out C4 connector.
iX 2000 0.3 Ohms
NOTE: Do not remove harness of control panel.
5. Set DMM to measure resistance. 2. If resistance measured is between specified
6. Disconnect C4 connector. On female side of values, refer to flow chart.
connector, connect one meter test lead to Pin 1 3. If resistance reading is outside tolerance, replace
and the other meter test lead to Pin 4. Measure stator.
and record resistance.

Diagnostic Repair Manual 15

Section 2 Troubleshooting and Diagnostic Tests

iQ2000 Control Winding Procedure

1. Remove electrical panel so components are
exposed. 1 2
2. Disconnect F2 connector from inverter (2 wire Sender
connector). B Connector
3. Set DMM to measure resistance. 1 – ORANGE 1 – RED
2 – BLACK 2 – BLACK 008622
4. On female side of connector, connect one meter
test lead back probe to Pin 1 and the other meter Figure 1-27. Fuel Sender Connector
test lead back probed to Pin 4. Measure and record
resistance.
5. With one lead still back probed into Pin 1 connect 1 – EMPTY 1 2
the other lead to ground. Measure and record 2 – EMPTY
resistance. 3 – BROWN
3 4
4 – GREY
008623
Figure 1-28. C Comms (Connected to LED Board)

1 2 3 4

7 8 9 10

1 – DK BLUE 5 – GREY
2 – EMPTY 6 – YELLOW
3 – BLACK 7 – BROWN
008620 4 – EMPTY 8 – RED 008624
Figure 1-25. Stator Connector Figure 1-29. F (Connected to Inverter)

Results
1. Resistance measured between Pin 1 and Pin 2 and 1 – RED 2
compare to chart. 2 – RED 1
3 – RED
2. Connection to ground should read INFINITY 3
3. If not within specifications replace stator assembly. 008625
Figure 1-30. F1 Stator Connection

1 2 3 4 5 6 Test Main Coil of Stator

7 8 9 10 11 12 iX Procedure
Board Jumper Power Head
1. Stop engine.
Harness Connector Connector
A G DANGER
1 – YELLOW 1 – LT BLUE
2 – GREY 2 – DK BLUE
Explosion and Fire. Fuel and vapors are
3 – BLACK 3 – BLACK
extremely flammable and explosive. Add fuel
4 – BROWN 4 – BLACK in a well ventilated area. Keep fire and spark
5 – PURPLE 5 – BLACK away. Failure to do so will result in death
6 – DK BLUE 6 – BLACK or serious injury. (000105)
7 – ORANGE 7 – GREEN
8 – PINK 8 – YELLOW/GREEN
2. Drain fuel from tank.
9 – WHITE 9 – WHITE 3. Remove electrical box assembly, back window,
10 – RED/BLACK 10 – DK GREEN
11 – RED 11 – DK GREEN
and upper enclosure half.
12 – BLUE/WHITE 12 – BLACK
008621 4. Take out 6 pin connector
Figure 1-26. iQ Connector ID NOTE: Do not remove harness of control panel.
5. Set DMM to measure resistance.

16 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

6. Disconnect C4 connector. On female side of

Table 1-2. iQ3500/GP3500io Resistance Values
connector, connect one meter test lead to Pin 3
and the other meter test lead to Pin 5. Measure Main Winding Brown 0.75-0.85 Ohms
and record resistance.
Secondary Winding Orange 0.50-0.55 Ohms
7. Repeat Step 6 between these test points:
• Pin 3 and Pin 6 DC Winding Blue 0.19-0.21 Ohms
• Pin 6 and Pin 5
Table 1-3. GP3000i Resistance Values
Results
1. Resistance measured between tests points should Main Winding Brown 0.97 Ohms ±15%
be as follows: Secondary Winding Orange 0.42 Ohms ±15%
iX 800 1.9 Ohms DC Winding Blue 0.86 Ohms ±15%
iX 1600 1.9 Ohms

iX 2000 1.6 Ohms ± 0.4 Ohms Test DC Circuit Breaker

Procedure
2. If resistance measured is within specified values, 1. Remove electrical panel to expose the DC circuit
refer to flow chart. breaker and remove both wires from breaker. Ver-
3. If resistance reading is outside tolerance, replace ify the breaker is reset from front of panel and is
stator. not tripped.
2. Set DMM to measure resistance.
iQ2000 procedure
3. Connect one meter test lead to each side of
1. Set DMM to measure resistance. breaker. Measure resistance. CONTINUITY should
2. Disconnect F1 connector from Inverter (3-wire be measured.
connector).
3. On female side of connector, connect one meter
test lead back probe to Pin 1 and the other meter
test lead to Pin 2. Measure and record resistance.
4. Measure and record resistance between 2 and 3
and 1 to 3.
5. Compare readings to Table 1-1.
6. Check each connection to ground. They should
read INFINITY.

Results
1. Resistance measured between tests points and
compare to chart.
008628
2. Resistance to ground from each test point. They
Figure 1-31. DC Breaker and DC Bridge Rectifier
should read INFINITY.
3. If not within specifications replace stator assembly. Results
Table 1-1. iQ Resistance Values 1. If CONTINUITY is measured across circuit breaker,
refer to flow chart.
Main Winding Red 1-2 1.97-2.18 Ohms 2. If circuit breaker reads open, replace DC circuit
breaker and test.
Main Winding Red 1-3 1.97-2.18 Ohms

Main Winding Red 2-3 1.97-2.18 Ohms Test DC Rectifier

Control Winding: Yellow-Yellow 0.16-0.18 Ohms Procedure
Ignition: Blue-Yellow/Green 0.63-0.71 Ohms 1. With electrical panel still exposed, remove wires on
DC rectifier and mark location of each wire on
DC Winding: Green-Green 0.13-0.15 Ohms rectifier.
2. Set DMM to Diode test feature (marked on most
meters by diode symbol).
Diagnostic Repair Manual 17
Section 2 Troubleshooting and Diagnostic Tests

3. Connect meter test leads according to chart and 2. If resistance measured is within specified values,
record results. refer to flow chart.
3. If resistance reading is outside tolerance, replace
Results stator.
1. If meter indicated correct readings at all test points,
refer back to chart. iQ2000 Procedure
2. If meter indicated any reading other than specified, 1. Locate the G connector and disconnect.
replace rectifier. 2. Set DMM to measure resistance.
1 2 3. Connect one meter lead back probed into Pin 10
and connect the other meter lead back probed into
Pin 11. Measure and record resistance.
3
4. With one lead still back probed into Pin 10 connect
4
the other lead to ground. Measure and record
008629
resistance.
(+) Test Lead
(-) Test Lead
1 2 3 4
Results
1 CONTINUITY CONTINUITY CONTINUITY 1. The resistance measured between Pin 10 and Pin
2 INFINITY INFINITY CONTINUITY 11 should be within specs of the chart.
3 INFINITY INFINITY CONTINUITY 2. Connection to ground should read INFINITY.
4 INFINITY INFINITY INFINITY
3. If not within specifications replace stator assembly.
Figure 1-32. DC Rectifier iX
Test Recoil Function
Red Blue
Procedure
Attempt to pull start engine and observe the following:
Blue Black
• Does cord pull easily and smoothly?
009030 • Does cord return with no assistance?
(+) Test Lead • Does engine turn over as cord is pulled?
Blue Blue Red Black
(-) Test Lead
Blue INFINITY INFINITY CONTINUITY
Results
Blue INFINITY INFINITY CONTINUITY If recoil did not perform correctly, these problems could
Red CONTINUITY CONTINUITY CONTINUITY exist:
Black INFINITY INFINITY INFINITY • Engine could be seized.
Figure 1-33. DC Rectifier GP3000i • Recoil could have become detached from flywheel.
• Recoil mechanism could be broken and not
Test DC Coil on Stator retracting properly.

iX Procedure
Test Engine Function
1. Locate two white wires coming from stator. One will
be located on the DC circuit breaker, and the other Procedure
will be located on the rectifier. 1. Remove recoil and front cover assembly.
2. Set DMM to measure resistance. 2. Remove spark plug from unit.
3. Connect one meter lead to each wire. Measure and 3. Attempt to turn engine over by hand.
record resistance.
Results
Results
1. If engine can not turn over freely with spark plug
1. The resistance measured between all tests points removed, engine has an internal failure and has
should be as follows: seized.
iX 1600 0.2 Ohms 2. Refer to flow chart.

iX 2000 0.3 Ohms

18 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

Check Spark
Procedure
A commercially available spark tester may be used to
test engine ignition system.
1. Disconnect spark plug lead from spark plug.
2. Attach high tension lead to spark tester terminal.
3. See Figure 1-34. Ground spark tester clamp by
attaching to cylinder head.

002418
Figure 1-36. Spark Plug Conditions
008630
Figure 1-34. Ground Spark Tester
Series Spark Plug Gap
4. Attempt to pull start engine. If spark jumps tester
gap, ignition system is working properly. iQ/GP3500io/IQ3500 0.024 - 0.028 in (0.6 - 0.7 mm)

NOTE: The fuel shutoff switch should be in the open iX (all) 0.03 in (0.76 mm)
position. GP3000i 0.028-0.031in (0.7-0.8mm)
NOTE: It may take several start attempts before a good
spark is observed in the tester. 2. Refer to flow chart.

Results Check Fuel Pump

1. Refer back to flow chart
Procedure
1. See Figure 1-34. Open up side panel to expose
Check Spark Plug carburetor (A) and fuel pump (B).
Procedure 2. Carefully remove fuel line from filter on inlet side of
Remove spark plug. Clean with a commercial solvent. carburetor
DO NOT BLAST CLEAN SPARK PLUG. Replace spark
plug if badly fouled, if ceramic is cracked, or if badly worn DANGER
or damaged. Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
Results in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
1. Clean and regap, or replace sparks plug as neces- or serious injury. (000105)
sary.
3. Using a suitable container to catch fuel, slowly pull
on recoil cord and turn engine over. Fuel should
flow from fuel line. If fuel does not flow, verify fuel is
available to pump. If fuel is available to pump
inspect fuel filter and pulse line.

Results
1. If fuel does not flow, replace fuel pump.
000211
2. If fuel flow has been verified proceed to Test 12.
Figure 1-35. Setting Spark Plug Gap
Diagnostic Repair Manual 19
Section 2 Troubleshooting and Diagnostic Tests

If spark plug is dry, check for:

• Leaking carburetor mounting gaskets.
• Intake valve stuck closed.
• Inoperative fuel pump.
• Plugged fuel filter(s).
• Varnished carburetor
A
• Check the choke is working properly.
1. Remove fuel line at carburetor and ensure there is
B
an adequate amount of fuel entering the carbure-
tor.
2. Remove float bowl and check for any foreign
matter in bottom of bowl.
3. Remove plastic float to gain access to needle.
4. Remove needle for cleaning.
5. Use a suitable carburetor cleaner to clean
carburetor before assembly.
008632
6. After cleaning the carburetor, blow dry with
compressed air and assemble.
Figure 1-37. Check Fuel Pump (iX)
NOTE: The shelf life of gasoline is about 30 days. Proper
procedures need to be taken so the fuel doesn’t varnish
over time. A fuel stabilizer should always be used to
A ensure the fuel stays fresh.

Results
1. If carburetor is varnished, clean or replace. Refer
to flow chart.

Check Engine Compression

B
Discussion
Most engine problems may be classified as one, or a
combination of the following:

008633
• Will not start.
Figure 1-38. Check Fuel Pump (iQ) • Starts hard.
• Lack of power.
Check Carburetion • Runs rough.
Before checking carburetor, be sure fuel tank has an • Vibration.
ample supply of fresh, clean gasoline. Check all shutoff
valves are open and fuel flows freely through fuel line. • Overheating.
Make sure choke operates properly. If engine will not • High oil consumption.
start, remove and inspect spark plug.
If spark plug is wet, check for: Check Compression
• Over choking. To check engine compression, remove spark plug. Insert
an automotive type compression gauge into spark plug
• Excessively rich fuel mixture. hole. Crank engine until there is no further increase in
• Water in fuel. pressure. The highest reading obtained is the engine
• Intake valve stuck open. compression pressure.

• Needle/float stuck open.

Minimum allowable compression 60 psi
pressure cold engine

20 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

If compression is poor, look for any of these causes:

• Loose cylinder head bolts.
• Failed cylinder head gasket.
• Burned valves or valve seats.
• Insufficient valve clearance.
• Warped cylinder head.
• Warped valve stem.
• Worn or broken piston ring(s).
• Worn or damaged cylinder bore.
• Broken connecting rod.
• Worn valve seats or valves.
• Worn valve guides.
NOTE: Due to the decompression system on the
iQ2000, performing a compression test will not be valid. 008635
You will typically get about 5 PSI. Verify valve Figure 1-40. iQ Trigger
adjustment, fuel system and ignition system and start unit
again. If it is determined there is an internal issue with the Table 1-4. Table 1. J1 Connector Pin Chart
engine, contact technical service.
Location Function Wire Color

Test Ignition Trigger Assembly Pin 1 Ignition Coil Blue

Pin 2 Low Oil Switch Yellow
iX Procedure
1. See Figure 1-39. Remove electrical panel so the Pin 3 Trigger Assembly White
LED module is exposed and disconnect J1 con- Pin 4 Ground Pink
nector.
Pin 5 Ignition Winding Red
2. Set DMM to measure resistance.
Pin 6 Fuel Shutoff Switch Gray
3. Locate Pin 3 on J1 connector. Connect one meter
test lead to Pin 3 and the other meter test lead to Pin 7 Inverter Purple
engine ground. Measure and record resistance. Pin 8 Inverter Yellow
Pin 9 Inverter White
Pin 10 Inverter Green

Results
1. If meter reading is within ± 5 ohms of correct resis-
tance, refer to flow chart.
iX 800 30 Ohms
iX 1600 30 Ohms
iX 2000 129 Ohms

2. If meter did not indicate correct resistance, replace

trigger assembly.

iQ 2000 Procedure
1. Remove electrical panel.
008634
2. Locate the G connector and disconnect.
Figure 1-39. J1 Connector on LED Module
3. Set DMM to measure resistance.
4. Locate Pin 12 on G connector. Connect one meter
test lead to Pin 12 and the other meter test lead to
engine ground. Measure and record resistance.

Diagnostic Repair Manual 21

Section 2 Troubleshooting and Diagnostic Tests

Results Results
1. If meter reading is within ± 5 ohms of correct resis- 1. Refer to chart. If correct values were measured in
tance, 128 Ohms is spec go to step 3. Steps 4 and 5, refer to flow chart.
2. If meter did not indicate correct resistance, replace 2. If incorrect values were measured in Steps 4 and 5,
trigger assembly. inspect ignition coil connector for bad connection. If
3. If within specs set your meter to measure AC connection is verified good, replace ignition coil.
voltage with the meter set to Min/Max recording, 3. If incorrect value was measured in Step 5, inspect
the fuel system shut off pull the recoil several times ground connection on Pin 2 of C2 connector going
and record the AC voltage output on the Min/Max to ignition coil.
recordings typically 1.2 to 1.4 volts if low check
pickup trigger gap, readjust and retest.
4. If all measurements are good go back to the flow
chart.

Test Ignition Coil

iX Procedure
1. Open electrical panel to expose control panel wir-
ing.
2. Disconnect J1 connector and ignition coil boot from
spark plug.
3. Set DMM to measure resistance.
4. Connect one meter test lead to ground and the
other test lead to Pin 1 on the J1 connector.
Measure and record resistance.

008637
Figure 1-42. Measured Values (iX Shown)

iQ2000 Procedure
1. Open electrical panel to expose control panel wir-
ing.
008636 2. Disconnect G connector and ignition coil spark
Figure 1-41. Test Ignition Coil plug boot from spark plug.
3. Set DMM to measure resistance.
5. Connect one meter test lead to spark plug wire and
4. Connect one meter test lead to ground and the
the other test lead to engine ground. Measure and
other test lead back probed into Pin 1 on the G
record resistance.
connector Measure and record resistance. Meter
Test Point iX GPi readings should be INFINITY.
5. Connect one meter test lead to ground and the
Pin 1 to Ground 1.7 Ohms ± 0.5 other test lead back probed into Pin 7. Measure
Ohms and record resistance. Meter readings should be
Spark Plug to 12.5K Ohms ± INFINITY.
Ground 2K Ohms 6. With one meter lead still on ground measure
resistance on the shield (metal cover) at the spark
Primary coil 0.8-1.0 Ohms plug boot. CONTNIUITY (low resistance) should be
Secondary coil 5.9-7.1 Ohms measured.

22 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

7. With the meter lead still to ground measure the Procedure

resistance of the spark plug lead inside the spark 1. Open up electrical panel to expose control panel
plug boot should read INFINITY. wiring.
8. Connect one meter test lead back probe to Pin 1 2. Set fuel shutoff valve to STOP position.
and connect the other lead and back probe to Pin 7 3. Disconnect the G connector from LED module.
of the G connector Measure and record resistance.
4. Set DMM to measure resistance.
Typical reading 1.2 Ohms +/- 0.2 ohms.
5. Connect one meter test lead to Pin 9 and the other
9. With one meter lead still connected to Pin 1 take
test lead to ground. Measure and record the
the other lead and connect to spark plug lead
resistance.
inside spark plug boot typically a reading of 17.7k
plus or minus 1000 Ohms is typical. 6. Then set the fuel shutoff valve to RUN and then
CHOKE position.
10. If these readings are not correct replace ignition
7. Repeat Step 5 for RUN and CHOKE position and
coil assembly.
record your results. Fuel Shutoff Valve Position
11. If the readings are correct refer back to the flow Fuel Shutoff Switch Reading RUN and CHOKE
chart. position (INFINITY) to ground STOP
(CONTINUITY) to ground.
Test Fuel Shutoff Switch Results
iX Procedure 1. If INFINITY was measured when shutoff valve was
1. Open up electrical panel to expose control panel RUN and CHOKE position, and CONTINUITY was
wiring. indicated when valve was in the STOP position,
refer back to the flow chart.
2. Set fuel shutoff valve to CLOSED.
2. If CONTINUITY to ground was not measured when
3. Disconnect J1 connector from LED module. valve was in the STOP position, verify electrical
4. Set DMM to measure resistance. connections between G connector and switch.
5. Connect one meter test lead to J1 Pin 6 and the Re-test at the 2 wire connector of the fuel shut off switch
other test lead to ground. Measure and record the pig tail and check for continuity when in the STOP
resistance. position. If no continuity replace the fuel shutoff switch
6. Set fuel shutoff valve to OPEN. and re-test.
7. Repeat Step 5. If CONTINUITY - check black wire from fuel shut off switch
to the LED module. If wire is good check the ground
Fuel Shutoff Valve Fuel Shutoff Switch connections to the LED module. If these connections are
Position Reading good replace the LED module and retest operation.

CLOSED OPEN (INFINITY)

Check Choke Assembly
OPEN CLOSED (CONTINUITY)
Procedure
1. If generator surges, it may be a carburetion prob-
Results
lem. A lean condition can cause erratic RPM.
1. If INFINITY was measured when shutoff valve was Slowly slide choke to see if surging stops. If it
CLOSED, and CONTINUITY was indicated when stops, check carburetion.
valve was OPEN, refer to flow chart.
2. Verify the choke and mechanical connection to
2. If CONTINUITY to ground was not measured when carburetor are functioning properly.
valve was in the OPEN position, verify mechanical
connection between valve and switch. If Results
mechanical connection is good, replace switch. 1. If choke is functioning correctly, refer to flow chart.
3. If meter read CONTINUITY when shutoff valve was 2. If choke is not functioning correctly, replace choke
in either the open or closed position, verify assembly.
mechanical connection between valve and switch.
If mechanical connection is good, replace shutoff Test Stepper Motor
switch.
NOTE: A fuel shutoff switch that does not read INFINITY Procedure
when the fuel shutoff valve is in the closed position will 1. Disconnect Stepper Motor connector from Inverter
cause a no spark condition. module.
2. Set DMM to measure resistance.

Diagnostic Repair Manual 23

Section 2 Troubleshooting and Diagnostic Tests

NOTE: Connector view is from the harness side on the d. Pin 4 to Pin 5 – approximately 195 ohms
iQ2000. When testing these connections the backside of should be measured.
this connector is epoxied so use extreme caution when
front probing these connections to prevent damaging
terminals.
1 2 3 4 5
1 – RED 4 – YELLOW
1 2 2 – ORANGE 5 – BLUE
1 – PINK 3 – WHITE
2 – YELLOW 008640
3 – BLUE 3 4 Figure 1-45. C3 Connector Female Side, iX1600,
4 – ORANGE
008638 iX2000
Figure 1-43. C3 Connector Female Side, iX800
Results
1. If values in steps 3a through 3d are good, refer to
1 – YELLOW 4 3 flow chart.
2 – PINK 2. If any values in steps 3a through 3d tested bad,
3 – ORANGE
4 – BLUE
2 1 replace stepper motor.
008639
Figure 1-44. F3 Connector Female Side, iQ2000 Test Oil Level Switch
3. Connect DMM test leads across these test points: Procedure
a. Pin 1 and Pin 4 – approximately 50 ohms 1. Verify engine is filled with appropriate amount of
should be measured. oil.
b. Pin 1 and Pin 3 – INFINITY should be 2. Locate low oil shutdown wire on engine and isolate
measured. from the rest of the harness.
c. Pin 1 and Pin 2 – INFINITY should be 3. Set DMM to measure resistance.
measured. 4. Connect one meter lead to wire that running
d. Pin 2 and Pin 3 – approximately 50 ohms through plastic engine housing to oil level switch.
should be measured. Connect the other test lead to engine frame
e. Pin 2 and Pin 4 – INFINITY should be ground. Measure and record resistance.
measured.
f. Pin 3 and Pin 4 – INFINITY should be Results
measured. 1. If oil level was good and meter indicated an open
g. Test all pins to clean ground INFINITY should circuit, check for a short to ground on wire between
be measured. low oil level switch and LED module.
2. If oil level was good and meter indicated a closed
Results circuit to ground, replace engine.
1. If values in steps 3a through 3f are good, refer to
flow chart.
Test Ignition Coil Winding
2. If any values in steps 3a through 3f tested bad,
replace stepper motor. iX Procedure
1. Remove electrical panel so components are
Procedure
exposed.
1. Disconnect C3 connector (Stepper motor) from
2. Disconnect J1 Connector.
Inverter module.
2. Set DMM to measure resistance. 3. Set DMM to measure resistance.
3. Connect a DMM test leads across these test 4. Connect one meter lead to Pin 5 of the J1
points: connector and the other meter test lead to ground.
Measure and record resistance. Refer to Table 1.
a. Pin 1 to Pin 5 – approximately 195 ohms
should be measured.
Results
b. Pin 2 to Pin 5 – approximately 195 ohms
1. Refer to chart. If meter reading is within ± 0.2
should be measured.
ohms, refer to flow chart.
c. Pin 3 to Pin 5 – approximately 195 ohms
should be measured.

24 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

7. If readings are within specifications refer to back to

flow chart. If not replace stator assembly.

Test FlexPower/MODE Switch

Procedure (iX switch)
1. Disconnect orange and brown wires from Flex-
Power switch (FPS).
2. Set DMM to measure resistance.
3. Set FPS to “ECO” position.
4. Connect one meter test lead to Pin 1 and the other
meter test lead to Pin 2. Measure resistance and
record results.
5. Set FPS to “HIGH” position.
008634 6. Repeat Step 4. Measure resistance and record
Figure 1-46. J1 Connector on LED Module results.

iX 800 0.8 Ohms

iX 1600 0.5 Ohms

iX 2000 0.7 Ohms

1 – ORANGE 1 – YELLOW
2 – BROWN 2 – BLACK
A Side Position G Side Position 3 – EMPTY 3 – RED
(iX units ONLY) (iQ units ONLY)
1 - Yellow 1 - Blue
3 2 1
2 - Grey 2 - Blue
3 - Black 3 - Black 008641
4 - Brown 4 - Black Figure 1-47. FlexPower Switch Test Points
5 - Violet 5 - Black
6 - Blue 6 - Black Test Points ECO HIGH
7 - Orange 7 - Green Pin 1 to Pin 2 INFINITY CONTINUITY
8 - Pink 8 - Green/Yellow
Results (iX Switch)
9 - White 9 - White
1. If INFINITY was measured in Step 4 and CONTI-
10 - Black/Red 10 - Green NUITY in Step 5, replace inverter module.
11 - Red 11 - Green 2. If either CONTINUITY was measured in Step 4 or
12 - Blue/White 12 - Black INFINITY in Step 5, replace FPS switch.

Procedure (iQ switch)

iQ2000 Procedure
1. Disconnect wires from switch.
1. Remove electrical panel to expose components.
2. Set DMM to measure resistance.
2. Disconnect G connector.
3. Connect one meter test lead to Pin 2 and the other
3. Set DMM to measure resistance.
meter lead to 1 or 3 based on switch position.
4. Connect one meter lead back probed into Pin 2 of
4. Set switch to each position and measure
the G connector and the other meter test lead back
resistance.
probe into Pin 8.
5. Record results compared to chart below.
5. Measure and record resistance. Compare your
meter reading to the chart and is within ± 0.2 ohms, TURBO 2 and 3 continuity ONLY
6. With one lead still back probed into Pin 2 connect STANDARD NO continuity on any terminal
the other lead to ground. Measure and record
ECO 1 and 2 continuity ONLY
resistance.

Diagnostic Repair Manual 25

Section 2 Troubleshooting and Diagnostic Tests

6. If values are correct check the wires to the inverter jam nut, check valve clearance to make sure it did
board. If the wires and connections are good not change.
replace the inverter.

Procedure (GP3000i Economy Switch)

1. Disconnect wires from switch.
2. Set DMM to measure resistance.
3. Set switch to “ON” position.
4. Connect one meter test lead to Pin 1 and the other
meter test lead to Pin 2. Measure resistance and
record results.
5. Set switch to “OFF” position.
6. Repeat Step 4. Measure resistance and record
results.

Test Points ON OFF 008642

Pin 1 to Pin 2 CONTINUITY INFINITY Figure 1-48. Valve Adjustment

5. Install rocker cover and inspect/replace rocker

Results (GP3000i Switch)
cover gasket and four (4) screws. Tighten screws
1. If CONTINUITY was measured in Step 4 and to appropriate specifications.
INFINITY in Step 5, replace inverter module.
2. If either INFINITY was measured in Step 4 or Fuel Display Inaccurate
CONTINUITY in Step 5, replace switch.
iQ2000
Check/Adjust Valves Fuel level is displayed by the LED module based on the
information sent via the Fuel sending unit.
Discussion
If the LED display is not accurately displaying fuel level,
Improperly adjusted valves can cause various engine
the problem may be the LED module, wiring, or fuel
related problems including, but not limited to, hard
sending unit.
starting, rough running and lack of power. The valve
adjustment procedure for all units the same process. 1. Remove the screws holding the front cover in place
leaving all connectors connected. Locate the 2 wire
Procedure: Intake and Exhaust connector to the Fuel sending unit and back probe
the connector on the LED Module side.
Verify the piston is at top dead center (TDC) of its
compression stroke (both valves closed). 2. Set VOM to measure DC volts.
Check and adjust the valve to rocker arm clearance as 3. Start and run the unit in ECO mode and record
follows: your reading.
1. Remove four (4) screws from rocker cover.
Based on the reading perform the following:
2. Remove rocker cover and rocker cover gasket.
1. Reading of 13 VDC or higher replace the Fuel Tank
3. See Figure 1-48. Loosen rocker arm jam nut. Use assembly.
a proper size socket to turn adjustment screw in to
2. Reading below 13 VDC disconnect 2 wire
decrease clearance or out to increase clearance.
connector and recheck.
Hold socket steady to tighten lock nut to
specification. Check clearance. Make minor 3. With 2 wire connector disconnected and a reading
adjustments until proper clearance is achieved. of 13 VDC replace fuel tank assembly.
4. With 2 wire connector disconnected and a reading
GP3000i/ 0.004-0.006 in (0.10-0.15 mm)
of below 13 VDC replace the LED module
GP3500io/IQ3500
assembly.
iQ and iX 0.004 ± 0.001 in (0.10 ± 0.02
mm)
Test Inverter
Check inverter leads, electric parts, connectors, and
4. When valve clearance is correct, tighten the jam
connecting wires for bulging blisters or visible color
nut to proper specifications. After tightening the
change or damage.

26 Diagnostic Repair Manual

 Section 2 Troubleshooting and Diagnostic Tests

Short Circuit Input (Low-voltage) Short Circuit Output

Neither the red nor the green light are illuminated. No Green light not illuminated, red light remains on all the
output is produced. time. Use the Ohm scale to measure output terminals. If
Use the Ohm scale to measure low-voltage connectors. If measured resistance value is zero or INFINITY, replace
measured resistance value is zero or INFINITY, replace the inverter.
the inverter.

009029
009026
Figure 1-52.
Figure 1-49.

009027

Figure 1-50.

Short Circuit Input (3-phase)

Green light remains on all the time, red light flashes
(during loading). Use the Ohm scale to measure 3-phase
connectors (measure resistance between each pair). If
measured resistance value is zero or INFINITY, replace
the inverter.

009028
Figure 1-51.

Diagnostic Repair Manual 27

Section 2 Troubleshooting and Diagnostic Tests

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28 Diagnostic Repair Manual

Section 3 Disassembly
Discussion
During the process of tearing a unit apart, it's critical to
make notes as to the location of parts inside. There is no
room for error when putting unit back together. When
assembling unit, it's good to be proactive and always
thinking about the next step to eliminate back tracking. It
is also a good idea to continually check what parts are
left for assembly to ensure that no parts are forgotten
during the process.

iX Disassembly
Muffler Removal
1. Drain all fuel and oil from unit.
2. Remove four (4) Phillips screws located on black Figure 1-54. Servicable Items
exhaust cover.
3. Remove rubber muffler gasket (note orientation of 2. Remove retaining clip underneath fuel fill cap
seal before removing). cover.

Enclosure Removal
1. Remove one (1) flat head screw holding the ser-
vice access panel.

Figure 1-55. Remove Retaining Clip

3. Remove four (4) Phillips screws holding control

panel to the housing.

Figure 1-53. Remove Screw

Service and replace these items:

• Fuel pump
• Stepper motor
• Carburetor
• Air filter

Diagnostic Repair Manual 29

Section 3 Disassembly

13. On the iX1400, iX1600 and iX2000 disconnect

connectors and remove inverter. On the iX800 the
inverter is connected to the fuel shutoff switch and
can not be removed.
14. Feed recoil cord through lower enclosure piece.
15. Lift engine assembly out and set aside.

Time to reach this point: 15 minutes

Service and replace these items:

• Inverter assembly
• Fuel shutoff valve
• Fuel shutoff switch
• Lower and upper enclosures
Figure 1-56. Remove Control Panel
• ignition coil
4. Disconnect connectors and ground wires. Remove • Recoil assembly
control panel.
Engine Housing Removal
5. Remove one (1) Phillips screw to remove fuel
shutoff knob. 1. Remove one (1) Phillips screw from fuel pump
housing.
6. Remove one (1) Phillips screw from recoil access
area. 2. Remove two (2) 8 mm nuts from carburetor plastic
intake assembly and remove fuel pump and
7. Remove three (3) Phillips screws located on
carburetor as one assembly. Isolate fuel hose from
handle. (two on iX 800).
fuel shutoff valve.
8. Carefully orient assembly so the side with access
Note: Keep the two spacers with the housing when
cover is facing down (Figure 38).
removed.
9. Remove two (2) Phillips bolts on underside of
3. Remove ten (10) Phillips screws around top and
plastic housing.
bottom seams of housing. There are two different
10. The side with spark plug access should now be sizes of screws. Make note of which one is which
facing up. Remove this half of enclosure. for assembly.
4. Isolate wiring harness from housing and remove
low oil plug. Pull wire through for removal.
5. Separate housings to expose engine.

Figure 1-57. Remove Enclosure

11. Disconnect fuel tank by removing the hose clamp

and hose from fuel shutoff valve.
12. Remove one (1) Phillips screw from fuel shutoff
valve so it is isolated from enclosure.
NOTE: Make note of the orientation of fuel shutoff valve Figure 1-58. Housing Removed
for assembly.
Time to reach this point: 25 minutes

30 Diagnostic Repair Manual

 Section 3 Disassembly

The following items can now be serviced:

• Engine
• Rotor
• Stator
• Low oil switch
• Fan
• Trigger assembly

The following items can now be replaced:

• Low oil switch
• Trigger assembly

Rotor/Stator Removal
1. Remove 8mm bolt in center of recoil jaw.

Figure 1-60. Remove 15mm Nut

5. With nut removed, install steering puller with the

center bolt tight against the center shaft and
remove rotor assembly.

Figure 1-59. Recoil Jaw

2. Remove two 8mm bolts from recoil jaw seat.

3. Remove fan.
4. Remove 15mm nut in center of rotor by inserting
the socket wrench first, then install a steering
wheel puller over the socket wrench (Figure 41).
Use an adjustable wrench to counter the torque
from the socket to break nut free.
Figure 1-61. Remove iX Rotor Assembly

Diagnostic Repair Manual 31

Section 3 Disassembly

8. Fuel Shutoff Switch

NOTE: Test fuel switch for correct orientation before
putting halves together.
9. Fuel Tank
10. Inverter
11. Upper Enclosure
12. Retaining Clip below fuel cap
13. Receptacle panel

iQ Disassembly
Enclosure removal and assembly.
1. Remove the four (4) screws on the front and back
panels of unit.
When removing the front panel, carefully tilt cover away
from unit to note the routing of the harnesses. They run
along the outside of the inverter air duct on both sides.
Disconnect electrical connectors, fuel level sensor, outlet
connections, and panel connector. Set panel aside.

Figure 1-62. Remove iQ Rotor Assembly

6. Remove two (2) 8mm bolts holding stator to engine

casting.
7. Remove stator.

Time to reach this point: 45 minutes

The following items can now be replaced:

• Engine
• Stator Figure 1-63. Front Cover
• Rotor

Assembly Notes
The above procedure should be reversed to assemble
unit.
Order of assembly:
1. Engine
2. Stator
3. Rotor
4. Engine housing
5. Fuel pump
6. Carburetor
7. Place engine housing in lower enclosure
NOTE: Locate all harnesses and fuel lines to ensure
they will not be obstructed during assembly process. The
stepper motor harness must be able to reach inverter. Figure 1-64. Back Cover

32 Diagnostic Repair Manual

 Section 3 Disassembly

2. Remove the screw on, and behind, the PowerDial.

Remove screws from guide plate for recoil handle.

Figure 1-67. Fuel Tank Isolator Grommets

Figure 1-65. Remove Screw from PowerDial

Figure 1-68. Fuel Tank Isolator Tab

Figure 1-66. Remove Screw from PowerDial and Fuel Tank Isolator Grommets
Recoil Handle
1. Assemble halves and be sure of proper alignment
3. Remove service access panel and all allen head of side panels and fuel tank support tabs.
screws which hold the side panels and base frame
together. Be aware of the two rubber isolators
supporting the fuel tank as you separate the side
panels.

Testing with Enclosure OFF

With enclosure panels off, front panel harnesses
connected, and PowerDial attached, carefully pull start
unit to verify operation to check for leaks etc. With testing
complete, install sides of enclosure and test unit for full
operation.

Assembly Of Enclosure
When installing enclosure panels, make sure the support Figure 1-69. Fuel Tank Support Grommet Alignment
grommets on both sides of the fuel tank are in place.

Diagnostic Repair Manual 33

Section 3 Disassembly

• Recoil
• Rotor
• Stator
• Ignition magneto
• Trigger unit
• Powerhead assembly

Fuel Tank Assembly (After Enclosure Removal)

1. Carefully lift fuel tank from mount and disconnect
fuel line. Set tank aside.
2. Install in reverse order.
NOTE: Note routing and seating of fuel tank. Choke
cable cannot be between tank and support bracket.

Figure 1-70. Fuel Neck Grommet

Be sure the rubber seal around fuel tank filler neck is

aligned with enclosure sides.
NOTE: Graphic shows grommet removed for better view Figure 1-71. Fuel Pin to Grommets
of tab.
2. Install back panel.
3. Connect all connectors on front panel.
NOTE: Note routing of harnesses as in disassembly and
fasten panel into place.
4. Check/fill to proper oil and fuel level. Test unit for
operation.

Disassembly Of Unit After Enclosure Removal

The following items are now accessible for servicing:
• Fuel tank
• Fuel sending unit
• Inverter Figure 1-72. Routing of Choke Cable

• Fuel pump Inverter Removal And Install (Enclosure

• Fuel filter Removed)
• Fuel lines NOTE: Access and testing of the Inverter can also be
• Stepper motor/carburetor done with just the front cover off.
• Air filter housing 1. Remove two mounting nuts from air inlet duct.
• Muffler Remove duct, slide inverter off studs, and discon-
nect harness connectors.
• Rotary control

34 Diagnostic Repair Manual

 Section 3 Disassembly

With the inverter removed, the fuel filter, rotary control,

fuel pump, and recoil can be serviced.
2. Install in reverse order and be sure connectors are
plugged in securely.

Figure 1-76. Inverter Removed

Access to Carburetor (with the enclosure off,

fuel tank out, and inverter out)
Figure 1-73. Inverter Inlet Duct 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.

Figure 1-74. Inverter

Figure 1-77. Air Filter Housing

Figure 1-75. Connection Side of Inverter

Diagnostic Repair Manual 35

Section 3 Disassembly

Figure 1-78. Carburetor Inlet Duct

3. Disconnect choke cable and stepper motor

connector from Inverter.
4. Disconnect black vent tube from carburetor.

Figure 1-80. Right Side Support Bracket

Figure 1-79. Disconnect Fuel Inlet Line

5. Disconnect fuel line at carburetor fuel inlet.

6. Remove fuel tank support bracket mounting bolts
on right [Link] loosen left side.

Figure 1-81. Left Side Support Bracket

36 Diagnostic Repair Manual

 Section 3 Disassembly

7. Move fuel tank support bracket enough to slide

carburetor assembly off the studs.
8. Assemble in reverse order, use new gaskets.

Access to Trigger Pickup, Alternator Fan, Rotor,

Stator Assembly (enclosure assembly removed)
1. Remove fasteners attaching muffler housing to
back support and remove. Be aware of seal grom-
met on bottom right.

Figure 1-84. Muffler to Cylinder Head

Figure 1-82. Muffler Cover

Figure 1-85. Lower Support Bracket

3. Remove fasteners from alternator cover. Make

note of wires attached and routing for assembly.
Remove cap screws on sides of alternator cover to
support mounts. Remove alternator cover.

Figure 1-83. Grommet On Cover

2. Remove two nuts attaching the muffler to cylinder

head, and one cap screw on bottom right. Remove
muffler and set aside.

Diagnostic Repair Manual 37

Section 3 Disassembly

Figure 1-88. Alternator Cover

Figure 1-86. Alternator Cover

Figure 1-89. Trigger Pickup and Seal

Trigger pickup
With alternator cover removed, replacement and
adjustment of trigger pickup is possible. Two fasteners
hold the pickup in place.
1. Make sure routing of wires is correct and not
pinched when installing or replacing the pickup.
The holes in pickup bracket are oval for adjustment
purposes. With rotor in place, set gap to 0.20-
0.30mm.
Figure 1-87. Isolator Mounting Bolt 2. Align trigger point on rotor outside surface in-line
with sensor and check/adjust gap using a non-
Lift engine assembly slightly to slide alternator cover off metallic feeler gauge.
unit. Be aware of seal grommet located by the trigger
3. Tighten mounting screws to specification and
pickup and be sure to reinstall when reassembling.
check gap. Adjust if necessary.
Removing the cover allows access to the trigger pickup,
rotor, and stator components.

38 Diagnostic Repair Manual

 Section 3 Disassembly

Figure 1-90. Rotor View Figure 1-92. Adjustment Mounting Screws

Fan, Rotor, Stator Assembly (with alternator

cover removed)
The two screws on the fan have thread locking
compound.
1. Use a socket and ratchet to hold main shaft in
place while breaking loose two fan cap screws with
another ratchet and socket.

Figure 1-93. Alternator Fan

Figure 1-91. Trigger Pickup Gap

Diagnostic Repair Manual 39

Section 3 Disassembly

Figure 1-94. Rotor View

2. Remove the rotor nut using the setup shown to

break the rotor nut loose. Do not remove this nut
using an impact which can cause issues with the
magnets. The nut has thread locking compound
and will be challenging to remove.

Figure 1-96. Remove Rotor with Puller

Figure 1-97. Use Puller as Handle

5. Remove two screws (with thread locking

Figure 1-95. Breaking Nut Loose
compound) from stator winding.
3. Use a suitable puller to separate the rotor. Use the 6. Slide stator off center hub.
puller as a handle to help pull the rotor off the unit. 7. Install in reverse order and to proper torque.
NOTE: The magnets are strong and will make it difficult
to remove rotor completely from the taper. DO NOT get
fingers pinched between the edge of the rotor and back
housing.
4. Reverse sequence for assembly.

40 Diagnostic Repair Manual

 Section 3 Disassembly

9. Attach puller to use as a handle to for proper

assembly and alignment of the rotor to shaft.
10. Apply thread locking compound to crankshaft
threads. Install nut and torque rotor nut to
specifications.
11. Check trigger pickup gap for proper gap.
12. Assemble unit in reverse order and place thread
locking compound on the rotor fan cap screws.
13. When torquing the rotor nut to specifications, use
the puller to hold the rotor as when used to break
the rotor nut loose.

Fuel Filter and/or Pump Removal

With enclosure and air duct removed, access fuel filter
Figure 1-98. Remove Stator Assembly and fuel pump.
NOTE: Fuel filter can be serviced with the enclosure still
on via removing the front panel and Inverter.
Assemble connection lines to proper location. Perform
“Test with Enclosure OFF” to verify operation and no
leaks.

Figure 1-99. Remove Stator Assembly

Figure 1-101. Fuel Pump

Figure 1-100. Remove Stator Assembly

8. Install rotor and be sure of proper alignment of the

key-way.
NOTE: Note: The magnets are strong. DO NOT get
fingers pinched between the edge of the rotor and back
housing.

Diagnostic Repair Manual 41

Section 3 Disassembly

Figure 1-104. Choke Cable Mount

Figure 1-102. Inverter

Rotary control assembly (fuel shutoff, Ignition stop

switch, Choke control)
1. To service the rotary control, remove mounting
screws holding the control to the support bracket.
2. Disconnect the 2-wire connector, choke cable from
carburetor mount, and lever. Note routing of choke
cable when removing for proper assembly.
3. Disconnect fuel line.
4. Assemble in reverse order.
5. When connecting the choke cable to the
carburetor, place choke in choked position (to left).
6. Turn rotary knob to choke position.
7. Route cable through cable clamp. Figure 1-105. Powerdial Control and Fuel Filter
8. Seat cable end in mount. Hold choke lever to the
left and pull cable taut through clamp and tighten.
9. Test choke to be sure of proper opening and
closing. Adjust if necessary.

Figure 1-106. Fuel Tank Support Grommet Alignment

Powerhead
1. With fuel tank removed, harnesses, choke cable,
Figure 1-103. Powerdial Control Mount Screws fuel line and vent lines at carburetor disconnected,
disconnect the green ground wire from Alternator
cover bolt.
2. Remove four support mount cap screws (2 per
side) and lift powerhead assembly from base.
3. Assemble in reverse order.

42 Diagnostic Repair Manual

 Section 3 Disassembly

Figure 1-107. Isolator Mount Screws Figure 1-110. Shield Ground

Figure 1-108. Base of Unit

Ignition Coil
1. With enclosure removed, remove blower duct from
muffler housing.
2. Remove two cap screws holding coil in place. Be
aware of spark plug wire routing.
3. Install in reverse order and be sure the blower duct
is properly seated in the muffler housing.

Figure 1-109. Magneto

Diagnostic Repair Manual 43

Section 3 Disassembly

iQ2000 Torque specifications

Item Bolt Dimension Torque
Feet to Base Screw HHFCS M6-1.0 X 10 G8.8 5 ft-lb 6.7 Nm
Iso Mount to Base Nut Hex FL Whiz M6-1.0 BLK 5 ft-lb 6.7 Nm
Iso Mount to Power Head Screw HHFC M6-1X12 8.8 W/Patch 5 ft-lb 6.7 Nm
Bracket to Base SCREW HHFCS M6-1.0 X 10 G8.8 5 ft-lb 6.7 Nm
Power Dial to Bracket Screw BFHSC M5-0.8 X 16 BLK ZP 20 in-lb 2.2 Nm
Pump to Bracket Screw HHFCS M6-1.0 X 20 G8.8 5 ft-lb 6.7 Nm
Ground Lugs to Base Extrdtite M5 X 10 LG 6.5 ft-lb 8.8 Nm
Fuel Fitting to Base Screw SHC M4-0.7 X 10 G10.9 2.5 ft-lb 3.3 Nm
Inverter Module to Bracket Nut Hex FL Whiz M6-1.0 BLK 3 ft-lb 4 Nm
Enclosure M5's Screw BFHSC M5-0.8 X 12 BLK ZP 2.5 ft-lb 3.3 Nm
Enclosure M6's Screw SHC M6-1.0 X 10 G10.9 2.5 ft-lb 3.3 Nm
Carb Drain Screw SHC M4-1.0 X 10 G10.9 1.0 ft-lb 1.3 Nm
On-Off Selector to Power Dial Screw BFHSC M3-0.5 X 16 BLK ZP 6 in-lb 0.67 Nm

GP3000i Torque specifications

Item Bolt Dimension Torque
Connecting rod Bolt M6 X 1 8.8-10.3 ft-lb 12-14 Nm
Cylinder head Bolt M8 X 1.25 23.6-25.8 ft-lb 32-35 Nm
Flywheel mounting Nut M14 X 1.5 59-66.3 ft-lb 80-90 Nm
Crankcase cover Bolt M8 X 1.25 19.9-22.1 ft-lb 27-30 Nm
Air cleaner mounting Nut M6 X 1 5.9- 8.8 ft-lb 8-12 Nm
Valve Nut M5 X 0.5 3.6-5.9 ft-lb 5-8 Nm
Muffler mounting Nut M8 X 1.25 14.7-20.6ft-lb 20-28 Nm
Muffler mounting Bolt M8 X 1.25 14.7-20.6 ft-lb 20-28 Nm
Breather chamber Cap bolt M5 X 0.75 3.6-5.9 ft-lb 5-8 Nm
Starter motor fastening Bolt M6 X 1.25 5.9- 8.8 ft-lb 8-12 Nm
Spark plug 18.4-22.1 ft-lb 25-30 Nm

Standard Fastener Torque Specification

Component Torque
5mm bolt, nut 2.9-5.1 ft-lb 4-7 Nm
6mm bolt, nut 5.9- 8.8 ft-lb 8–12 Nm
8mm bolt, nut 14.7-20.6 ft-lb 20–28 Nm
10mm bolt, nut 25.8-29.5 ft-lb 35-40 Nm
12mm bolt, nut 36.8-44.2 ft-lb 50–60 Nm

44 Diagnostic Repair Manual

 Section 3 Disassembly

GP3500io/IQ3500 Torque specifications

Item Bolt Dimension Torque
Connecting rod bolt M7×1 8.8-10.3 ft-lb 12-14 Nm
Cylinder head bolt M8×1.25 23.6-25.8 ft-lb 32-35 Nm
Flywheel mounting bolt M8×1.5 22.1-26.5 ft-lb 30-36 Nm
Crankcase cover bolt M8×1.25 19.1-23.6 ft-lb 26-32 Nm
Oil drain bolt (in crankcase) M10×1.25 14.7-18.4 ft-lb 20-25 Nm
Air cleaner mounting nut M6×1 5.9- 8.8 ft-lb 8-12 Nm
Pivot adjusting nut M9 2.9-5.9 ft-lb 4-8 Nm
Muffler mounting nut M8×1.25 19.9-22.1 ft-lb 27-30 Nm
Governor arm nut M6×1.0 6.6-9.5 ft-lb 9-13 Nm
Starter motor fastening bolt M6×1.25 5.9- 8.8 ft-lb 8-12 Nm
Spark plug 19.9-22.1 ft-lb 27-30 Nm

Standard Fastener Torque Specification

Component Torque
5mm bolt, nut 2.9-5.1 ft-lb 4-7 Nm
6mm bolt, nut 5.9- 8.8 ft-lb 8–12 Nm
8mm bolt, nut 14.7-20.6 ft-lb 20–28 Nm
10mm bolt, nut 25.8-29.5 ft-lb 35-40 Nm
12mm bolt, nut 36.8-44.2 ft-lb 50–60 Nm

79.8cc Inverter Engine Torque Specifications

Component Torque
Connecting Rod 2-2.2 ft-lb 9–10 Nm
Crankcase Cover 2-2.5 ft-lb 9–11 Nm
Spark Plug 4-4.9 ft-lb 18–22 Nm
Cylinder 2.7-3.1 ft-lb 12–14 Nm
Valve Lock Nut 1.1-1.8 ft-lb 5–8 Nm
Valve Cover 2.2-2.7 ft-lb 10–12 Nm
Cooling Fan 1.1-1.3 ft-lb 5–6 Nm
Crankshaft Nut 7.9-10.1 ft-lb 35–45 Nm
Fan Cover 1.3-1.8 ft-lb 6–8 Nm
Recoil 0.9-1.1 ft-lb 4–5 Nm
Ignition Coil 2.2-2.7 ft-lb 10–12 Nm
Stator 2-2.5 ft-lb 9–11 Nm
Alternator Cover 1.8-2.2 ft-lb 8–10 Nm
Muffler Cover - back 1.8-2.7 ft-lb 8–12 Nm
Muffler 2.2-2.7 ft-lb 10–12 Nm

Diagnostic Repair Manual 45

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX800

46 Diagnostic Repair Manual

 Section 3 Disassembly

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 1 Engine Assy. 38 2 Washer

2 1 Supercharged Cap Assy, Fuel Tank 39 2 Damping Ring, Pothook

3 1 Fuel Filler Inlet Rubber Ring 40 2 Stud Bolt

4 8 Clamp, Fuel Hose 41 1 Gasket, Pothook

5 1 Cup, Fuel Filter 42 1 Pothook

6 1 Tank, Fuel 43 2 Pin, Hollow Fixed Position

7 4 Shock Absorber Block 44 1 Block, Carburetor Cushion

8 2 Screw, Cross Recessed Pan Head, M6x120 45 2 Seal Gasket, Carburetor (In)

9 1 Cover, Upper Shell 46 1 Carburetor Regulating Assy.

10 1 Shell, Upper 47 1 Seal Gasket, Carburetor (In)

11 2 Screw, Cross Recessed Pan Head, M6x14 48 1 Filter Adapter Box (Breather)

12 8 Lock Slice/screw Clip 49 1 Tube, Breather

13 2 Alignment Pin 50 2 Circlip, Adapter

14 4 Feet, Vibration Mounts 51 1 Sleeve, Filter Adapter

15 4 Bolt, Hex, Flange Face (M6x12) 52 2 Alignment Pin, Adapter Box

16 1 Lower Casing, Engine 53 3 Nut, Hex Flange Face

17 2 Bolt, Hex, Flange Face (M5x16) 54 1 Starter Assy.

18 4 Washer 55 3 Safeguard Tube

19 4 Sleeve, Damping/vibration Mounts 56 3 Rec. Pan Head Screw/washer Assy.(M5x12)

20 1 Key, Woodruff--3x5x13 57 1 Handle Panel

21 1 Stator Assy. 58 1 Recessed Head Bolt & Washer Assy.

22 2 Bolt, Hex, Flange Face (M5x25) 59 1ea Handle, Recoil Assy

23 1 Flywheel Rotor Assy. 59a 1ea Starter Handle Hood

24 1 Nut, Hex Flange Face(M10x1.25-8) 60 1 Cord, Recoil Assy

25 1 Fan 61 1 Inverter

26 1 Seat, Starting Jaw 66 1 Frame, Front Panel

27 2 Bolt, Hex , Flange Face(M6x14) 67 1 Panel, Ic

28 1 Jaw, Starting 68 1 Adapter Sleeve, Respirator

29 1 Washer (6) 69 1 Igniter (With Indicator)

30 1 Bolt, Hex, Flange Face(M6x18) 70 1 Backoil Assy. Respirator

31 1 Cowling & Inlet Cover Assy. 71 4 Screw, Cross Recessed Pan Head (M5x12)

32 2 Screw, Cross Recessed Pan Head Tapping 72 7 Washer, Flat(5)

33 1 Coil, Ignition 73 1 Switch, Flexpower

34 1 Sleeve, Rubber (High Voltage) 74 1 Ic Screen

35 2 Sponge, Air Filter 75 2 Nut, I Type Hex.(M4)

36 1 Cover, Air Filter 76 8 Washer, Flat, M4

37 1 Alignment Pin 77 8 Washer, Lock, M4

Diagnostic Repair Manual 47

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX800 (Continued)

48 Diagnostic Repair Manual

 Section 3 Disassembly

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

77 8 Washer, Lock, M4 98 1 Seal, Lower Shell Cover

78 6 Screw, Crossed Recessed Pan Head 99 1 Screw(M6x14)

79 1 Outlet Assy 120v 100 6 Screw, Tap/crs/rec/(St4.2x16)

80 3 Screw, M4x12 101 1 Washer, Flat

81 1 Casing, Engine Upper 102 1 Shim, Muffler

82 4 Screw, Tapping, Cross, Recsd, P/ 103 1 Muffler Assy.

head(St4.2x13)
104 2 Bolt, Hex, Flange Face(M6x50)
83 1 Pump Assy. Fuel
105 3 Washer, Flat
84 1 Gaspipe, Fuel Pump
106 1 Bolt, Hex (M5x70)
85 1 Outlet Pipe, Fuel Pump
107 1 Gasket, Rubber, Back Window
86 1 Screw, Philips, St4.8x19
108 1 Window, Back
87 1 Shell, Lower
109 4 Screw, Ph Recessed M5x20
88 1 Switch, Ignition On/off
110 1 Seal Cover, Oil Sensor
89 1 Cover, Switch
111 3 Gasket, Shaft
90 2 Screw, Tap/crs/recsd(St4.8x19)
112 1 O-ring
91 1 Switch/valve. Fuel
113 1 Dipstick/cover, Oil
92 1 Pipe, Outlet
114 2 Nut, Hexagonal
93 1 Pipe, Inlet, Fuel Pump
115 1 Spring Washer, Standard Type
94 1 Screw, Tap,crs,recd(St6.3x16)
116 1 Panel Assy., Control
95 1 Knob, On/off Fuel Switch

96 1 Connection-peg, Grounded

97 1 Cover, Lower Shell

Diagnostic Repair Manual 49

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX1600

50 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description Item Qty. Description

1 1 Engine 38 1 Gasket, Carburetor (B) Out

2 1 Cap Assy., Fuel Tank 39 1 Block, Carburetor Spacer (Cushion)

3 1 Cover, Fuel Filler Port 40 1 Carburetor, Seal Gasket A (Out)
4 1 Cup, Fuel Filter
41 1 Regulating Assy. Carburetor
5 1 Tank, Fuel
42 1 Gasket, Carburetor In
6 4 Block, Shock Absorber
43 2 Nut, Hex/ Flanged, M5
7 1 Cover, Lower Shell
44 2 Washer, Flat
8 1 Shell, Lower
45 2 Spacer, Filter Case Liner
9 8 Clip, Screw
46 1 Case Assy., Filter
10 4 Feet, Vibration Mounts
47 2 Spring Clip
11 5 Recessed Pan Head Screw, St6. 3x19
48 1 Filter, Adapter Sleeve
12 2 Alignment Pin
49 Starter, Recoil Assy.
13 2 Bolt, Hex, W/ Flange M6x12
50 1 Bolt, Hex Head W/washer, M5x12
14 1 Casing, Lower, Engine
51 1 Inverter Assy
15 4 Washer

16 4 Sleeve, Damping 52 1 Frame, Front Panel

17 1 Seal Cover, Oil Sensor 353 1 Plate Assy, Control

18 1 Key, Woodruff, 3x5x13 54 4 Screw, Pan Head, Recessed, M5x25

19 1 Stator Assy. 55 4 Washer, Flat 5

20 2 Bolt, Hex, W/ Flange M5x30 56 2 Screw, Pan Head Recessed, M6x120

21 1 Flywheel/Rotor Assy. 57 1 Seal Cover, Lower Shell

22 1 Nut, Hex/flanged M10x1.25-8 58 1 Screw, M6x14

23 1 Fan 59 1 Cover, Upper Shell
24 1 Jaw Seat, Starting
60 1 Screw, Pan Head M4x12
25 5 Bolt, Hex, Flanged, M6x16
61 1 Switch, Fuel On/off
26 1 Coupler, Starting Jaw
62 3 Screw, Pan Head, Recessed, M6x14
27 1 Bolt, Hex/flanged, M8x14
63 1 Shell, Upper
28 1 Cover Assy, Cowling And Inlet
64 1 Switch, Ignition, On/off
29 1 Plug, Rubber
65 1 Cover, Switch
30 1 O-ring, Rubber, 20x1.8
66 2 Screw, Recessed Pan Head/ St4.2x9.5 Tapping
31 1 Coil, Ignition
67 1 Valve, Fuel
32 2 Tapping Screw, Recessed Pan/hd Str. 8x14
68 1 Hose, Oil Discharge
33 1 Pin, Mounting (Pothook Pillar)
69 1 Shield, Pipe Spring
34 1 Pot Hook
70 1 Hose, Fuel Pumpi Oil Inj.
35 1 Cleaner, Air

36 1 Cover, Air Filter 71 1 O-ring

37 6 Screw, Pan Head, Tapping Str.8x32 72 1 Cover, Oil W/dipstick

Diagnostic Repair Manual 51

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX1600 (Continued)

52 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description Control Plate Assembly

73 2 Stud/bolt Item Qty. Description

74 1 Filter, Fuel 1 3 Nut, Hex/ Flanged, M5

75 1 Pipe, Fuel Pump Outlet 2 1 Ignition .led Indicator

76 1 Gaspipe, Fuel Pump 3 1 Rectifier 1010a

77 1 Pipe-b, Fuel Pump Inlet 4 1 Bolt, Ignition Apparatus

78 1 Pump Assy., Fuel 5 1 Bolt, Hex, With Flange

79 1 Screw, Pan Head , Recessed, 6 1 Bolt, Hex, With Flange

80 10 Clamp, Fuel Hose 7 1 Control Plate Assembly

81 1 Casing, Upper Engine 8 2 Washer, Flat

82 4 Screw, Tapping-pan Head Recessedst4.2x16 9 1 Screw, Recessed Pan Head

83 1 Sleeve, Resperator Adaptor 10 1 12vdc Plug Assy.

84 1 Shim, Muffler 11 1 Switch, Flexpower

85 1 Muffler Assy. 12 1 120v Outlet Assy.

86 3 Bolt, Hex Head, Flanged, M6x55 13 3 Nut, I- Type Hex

87 1 Rubber Seal, Back Window 14 3 Washer, Spring, Standard

88 1 Window, Back (Exhaust Cover) 15 3 Washer, Flat, M4

89 4 Screw, Recessed Pan Head/ M5x20 16 1 Peg, Ground Connection

90 1 Retaining Clip, Shell 17 1 Decal, Control Plate

91 1 Baffle, Thermal

Diagnostic Repair Manual 53

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX2000

54 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description Item Qty. Description

1 1 Engine Assembly 38 1 Carburetor Assy.

2 1 Cap, Fuel Filler 39 1 Gasket, Carburetor (In)

3 1 Cover, Fuel Filler Port 40 6 Nut, Hex. With Flange, M6
4 1 Cup, Fuel Filter
41 2 Spacer, Oil Splash Cover
5 1 Tank, Fuel
42 1 Oil Splash Sub-assy.
6 4 Block, Shock Absorber
43 2 Clip, Spring
7 1 Cover, Upper Shell
44 1 Air Tube
8 1 Shell, Upper
45 1 Handle , Recoil Assy.
9 8 Clip, Screw
46 1 Cord, Recoil Assy.
10 4 Shock Absorber, Foot Of Chassis
47 1 Stop, Handle
11 5 Screw, Philips, St6, 3x19
48 1 Recoil Assy.
12 2 Mounting Pin, Bottom
49 1 Inverter Sub Assy
13 5 Bolt, Hex Head W/flange M6x12
50 1 Brace, Control Panel
14 1 Wrapper, Side
51 1 Control Panel W/ Decal
15 4 Gasket

16 4 Reducer Ring, Vibration 52 4 Screw, Crossed Pan Head, M5x25

17 1 Key, Woodruff, 3x5x13 53 4 Washer

18 1 Stator Assy. 54 2 Screw, Crossed Pan Head, M6x130

19 4 Bolt, Hex Head W/flange M5x30 55 1 Seal, Cover

20 1 Flywheel Rotor Assy 56 1 Screw, M6x14

21 1 Nut, Hex Screw, W/ Flange 57 1 Cover, Upper Shell

22 1 Fan Blades 58 1 Screw, Cross Pan Head, M4x12

23 1 Seat, Starting Jaw 59 1 Switch, Fuel On/off
24 3 Bolt, Hex Head W/flange M6x16
60 3 Screw, Cross Pan Head, M6x14
25 1 Jaw, Starter
61 1 Shell, Upper
26 1 Cover
62 1 Switch, Ignition, On/off
27 1 Rubber Set, High Pressure
63 1 Cover, Switch
28 1 Ignition Coil
64 2 Screw, Philips, St4,2x9.5
29 2 Screw, Philips, St4. 8x22
65 1 Valve, Fuel
30 1 Mounting Pin, Top
66 1 Hose, Oil Discharge
31 1 Hook
67 2 Clamp, Hose
32 1 Air Cleaner
68 1 Hose, Fuel Pump Oil Injection A
33 1 Cover, Air Filter
69 1 O-ring
34 6 Bolt, Hex Head W/flange, M5x16
70 1 Dipstick
35 1 Gasket, Carburetor, (Out B)

36 1 Spacer 71 2 Studs

37 1 Gasket, Carburetor, (Out A) 72 1 Filter, Gas

Diagnostic Repair Manual 55

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iX2000 (Continued)

56 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description

73 1 HOSE, FUEL PUMP

74 1 HOSE, FUEL PUMP AIR

75 1 HOSE, FUEL PUMP OIL INJECTION B

76 1 FUEL PUMP ASSY.

77 1 SCREW, PHILIPS, ST4.8X19

78 1 WRAPPER, ENGINE, UPPER

79 6 SCREW, PHILIPS, ST4.2X13

80 1 REDUCER

81 1 GASKET, MUFFLER

82 1 MUFFLER ASSY.

83 2 BOLT, HEX HEAD W/FLANGE, M6X60

84 1 SEAL, EXHAUST COVER

85 1 COVER, EXHAUST

86 4 SCREW, CROSS PAN HEAD, M5X20

87 1 CLIP, RETAINING, CHASSIS

88 1 O-RING, RUBBER

89 2 WASHER

90 10 CLIP, HOSE, FUEL

91 1 BOLT, HEX HEAD W/FLANGE, M6X80

92 1 SCREW, PHILIPS W/WASHER, M5X12

93 2 PIN, GUIDE, A

94 2 PIN, GUIDE, B

95 2 WASHER/ GASKET, HOOK

96 1 SCREW, PHILIPS

97 1 BOLT, HEX WITH FLANGE

98 2 NUT, M4

99 8 WASHER, LOCK, M4

100 8 WASHER, FLAT, M4

101 1 OUTLET, 120 VAC 20 AMP

102 1 DISPLAY, LED

103 1 DIODE, RECTIFIER

104 1 PANEL, FRONT

105 2 WASHER, STAR LOCK M6

106 2 SCREW M4X12

107 1 SWITCH, FLEXPOWER

108 1 BREAKER, DC CIRCUIT

109 1 HOLDER, DC COMPONENTS

110 1 RECEPTACLE, 12 VDC

Diagnostic Repair Manual 57

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iQ2000

58 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description Item Qty. Description

1 8 Bolt (M6x12) 36 1 Rubber Seal

2 1 Starter Assembly 37 1 Generator Fan

2.1 1 Handle 38 2 Piston Pin Retainer Clip
2.2 1 Handle Guide
39 1 Piston Pin
3 5 Bolt (M6x15)
40 1 Connecting Rod Assembly
4 1 Nut
41 1 Piston Ring Set
5 1 Blower Housing
42 1 Piston
6 2 Nut (M12)
43 1 Camshaft Assembly
7 4 Bolt (M5x12)
44 2 Valve Lifter
8 1 Engine Cooling Fan
45 2 Pushrod
9 1 Starting Hub
46 1 Spark Plug
10 2 Oil Seal
47 6 Exhaust Stud
11 1 Crankcase
48 7 Spring Strip
12 1 Ignition Coil Assembly
49 1 Muffler Boot
13 13 Bolt (M6x20)

14 2 Bearing 50 5 Self-tapping Screw

15 1 Protector Cover Seal 2 51 1 Muffler Shroud

16 1 Protector Cover Seal 1 52 2 Nut (M6)

17 1 Crankshaft Assembly 53 1 Muffler Assembly

18 2 Woodruff Key 54 1 Exhaust Gasket

19 4 Dowel Pin 55 1 Muffler Wrapper Front

20 1 Crankcase Gasket 56 1 Setting Flash Board

21 1 Oil Level Switch 57 1 Muffler Protector Seal
22 1 Oil Level Switch Plate
58 1 Rubber Air Duct
23 1 Crankcase Cover
59 6 Nut (M6)
24 1 Trigger Assembly
60 1 Breather Pipe
25 3 Bolt (M6x12)
61 1 Cylinder Head Cover Assembly
26 1 Stator Assembly
62 1 Cylinder Head Cover Gasket
27 2 Bolt (M6x35)
63 1 Cylinder Head Air Shroud
28 1 Rotor Assembly
64 4 Bolt(M6x50)
29 1 Alternator Boot
65 1 Cylinder Head Assembly
30 1 Zip-tie
66 1 Cylinder Head Gasket
31 4 Bolt (M6x22)
67 2 Carburetor Bolt
32 1 Rotor And Stator End Cover
68 1 Insulator Gasket
33 1 Spark Arrestor Clamp

34 1 Spark Arrestor Base 69 1 Carburetor Insulator

35 1 Spark Arrestor 70 1 Carburetor Gasket

Diagnostic Repair Manual 59

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iQ2000 (Continued)

60 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description

71 1 Fuel Canister

72 1 Carburetor Assembly

73 1 Connector Spring/clamp

74 2 Spacer Support

75 2 Screw (M5x35)

76 2 Screw (M4x8)

77 2 Screw (M3x6)

78 1 Stepper Motor Cover

79 1 Stepper Motor Assembly

80 1 Stepper Motor Seat

81 1 Stepper Motor Support

82 1 Starter Connector

83 1 Air Cleaner Gasket

84 1 Air Cleaner Pipe

85 1 Air Cleaner Pipe Gasket

86 1 Breather Pipe

87 1 Air Cleaner Assembly

88 1 Air Filter Element

89 1 Air Cleaner Cover

90 2 Valve Adjusting Nut

91 2 Valve Adjusting Screw

92 2 Valve Rocker Arm

93 1 Screw Rocker Arm Shaft

94 2 Valve Lock Clip

95 2 Valve Spring Retainer

96 1 Valve Oil Seal

97 2 Valve Spring

98 1 Intake Valve

99 1 Exhaust Valve

100 1 Oil Filler Cap Assembly

101 1 Bolt (M6x8)

102 1 Vacuum Fitting

103 1 Metal Filter

Diagnostic Repair Manual 61

Section 3 Disassembly

NOTE: Go to [Link] ([Link] for the most

current diagrams. Use model and/or serial number.

Exploded View – iQ2000 (Continued)

62 Diagnostic Repair Manual

 Section 3 Disassembly

Item Qty. Description Item Qty. Description

1 1 Assembly Fuel Tank W/vent 27 1 Assembly Control Panel

A 1 Fuel Cap Vented On/off A 2 Grommet Wire Sleeve

B 1 Fuel Fill Level Insert B 8 Screw Bhsc M5-0.8 X 10mm

C 1 Fuel Fill Filter Screen C 1 Back Box Top 2kw Inverter

D 1 Fuel Tank Assy W/o Vent D 1 Assy Pcb 2kw Display Panel

2 1 Fuel Fill Spill Guard E 3 Screw Pphm M3-0.5 X 5 Zp

3 1 Exhaust Air Out Panel F 1 Enclosure Control Panel

4 4 Fastener Ribbed Shank Chrstm T G 4 Screw Bhss M6-1.0 X 12mm

5 1 Foam, Alternator Cover H 5 Nut Hex Lock M4-0.7 Ny Ins

6 14 Nut Clip-on M6 X 1 J 5 Washer Flat M4

7 1 Enclosure Side Service K 1 Assy Pcb Invrtgen Pwr Bar

8 10 Screw Bfhsc M5-0.8 X 12 Blk Zp L 1 Outlet 20a 120v Dplx

9 1 Enclosure Service Door M 1 Weldment Control Panel

10 1 Knob Service Door N 1 Screw Pphm M5-0.8 X 8 Zinc

11 1 Hose Fuel Formed 2kw 4.5-6mm P 1 Washer Flat M5

12 1 Pump,impulse Q 1 Switch, Rocker, 3 Position

13 2 Screw Hhfcs M6-1.0 X 20 G8.8 R 1 Switch, Self Reset

14 2 Fuel Hose 6 X 10 X 55mm Long S 10 Washer Lock #10

15 1 Filter,fuel,gt990 T 1 Nut Hex Lock M5-0.8 Nyins Zinc

16 1 Evap Hose Formed Nom 251 28 10 Screw Bhss M6-1.0 X 12mm

17 1 Fuel Hose Formed 6id X 10od 29 1 Power Head Assembly

18 1 Power Dial Assy Inverter 30 1 Enclosure Side - Recoil

19 3 Screw Bfhsc M5-0.8 X 16 Blk Zp 31 1 Dial On/off Selector

20 1 Bracket Mounting Inverter 32 1 Screw Bfhsc M3-0.5 X 16 Blk Zp

21 1 Extrdtite M5 X 10 Lg 33 1 Washer Lock Ext #5 Steel Bz

22 1 Washer Lock Special #10 35 3 Engine Stop

23 8 Screw Hhfcs M6-1.0 X 10 G8.8 36 1 Alternator Stop

24 1 Inverter Module 2kw 37 4 Angled Vibration Mounts

25 1 Airfoil Intake 38 1 Enclosure Base W/o Aux Tank

26 6 Nut Hex Fl Whiz M6-1 39 4 Mounting Foot

43 2 Grommet .75 X .09 X .50

45 2 Rubber Isolator

46 9 Clamp Hose Band .41

47 1 Clamp Hose Band .31

49 4 Screw Hhfc M6-1x12 8.8 W/patch

Diagnostic Repair Manual 63

Section 3 Disassembly

This page intentionally left blank.

64 Diagnostic Repair Manual

Section 4 Electrical Data
Introduction
Go to [Link] ([Link] for the most current wiring
diagrams and electrical schematics. Use model or serial number.

Diagnostic Repair Manual 65

Section 4 Electrical Data

Wiring Diagram, iQ2000 Drawing No. 0L4354-B

66 Diagnostic Repair Manual

 Section 4 Electrical Data

Wiring Diagram, iQ2000 Drawing No. 0L4354-B

Diagnostic Repair Manual 67

68
AC RECPTACLES
Section 4 Electrical Data

1 RED
Wiring Diagram, iX800

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 5
LED MODULE

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

RED
C2 1 2

PINK
ORANGE
YELLOW
LOW OIL FUEL
LEVEL SHUTOFF
SWITCH SWITCH
TRIGGER
ASSEMBLY

STEPPER
MOTOR IGNITION
COIL
SPARK
PLUG

Diagnostic Repair Manual

 RED
DC CHARGE OUTLET

RED

WHITE BLACK
DC CIRCUIT BREAKER
WHITE
DC
RECTIFER

Diagnostic Repair Manual

AC RECPTACLES
DC COIL WINDING RED

RED

FLEX POWER SWITCH

C1
ORANGE 6

MAIN COIL WINDING C4 BROWN 2

INVERTER
Wiring Diagram, iX1600 and iX2000

ORANGE 5
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 5
LED MODULE

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

RED
C2 1 2

PINK
BLUE

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

STEPPER IGNITION
MOTOR COIL
SPARK
PLUG

69
Section 4 Electrical Data
70
Bu AWG14 Bu AWG14
Breaker 8A
DC R AWG14
Winding
Bu AWG14 Bu AWG14 +

R/W QVR0.75
DC12V
Bl AWG14
-
Section 4 Electrical Data

- +

Bl/W QVR0.75
USB
Grounding
W AWG14
*HQHUDWRU W AWG14
R AWG14
R AWG14
Parallel

R AWG14

Breaker 15A
R AWG20
Control
power W AWG22
INV2200DMN Drawing No. 10000001954-A

winding W AWG22
R AWG20
W AWG22
R AWG16 Br AWG22 Overload light !

XQLW
R AWG16 Bl AWG22 Running lights P
Main

&RQWURO
winding Gr AWG22
R AWG16
Economy switch

&RQWURO
3DQHO

Bl *+ Br ,+ Y/G 34+
Bl AWG18
Engine switch O -+ Br/R ,.+ Bl/W *2+
C.D.I magneto Bu LB Y
O AWG18 /+ 1/+ 3+
Bu AWG18 Gr 0+ W 2+ W 2+
R AWG18 Oil light R .+ G 4+ Zr 5+
R/W 

Y AWG18
AWG22
PM2200i
AWG22
AWG22

AWG18

AWG18

AWG18
Bu

Bl AWG22
R
Y

Br
Bl

R/W
Bl AWG18
(QJLQH      !"
2LO6HQVRU # $(  

Ignition 67
6SDUN 6WHSSLQJ PRWRU B A4 
SOXJ Coil $%
&' )& 1 1  
Wiring Diagram and Electrical Schematic, GP2200i, Craftsman 2200i C0010020/Premier 2200i

Diagnostic Repair Manual

 CONTROL PANEL BLOCK
14 AWG

14 AWG Circuit breaker 20A Parallel receptacle

Circuit breaker 20A
GENERATOR BLOCK
14AWG
Br R 14 AWG
14AWG
Br AC receptacle
L 14 AWG

Diagnostic Repair Manual

14AWG Inverter
Br
20AWG
Main coil
20AWG W
22AWG
22AWG
R
22AWG W ESC switch
B
O 22AWG
O
Sub coil
O

Ignition module
B Oil warning indicator light
20AWG Overload indicator light
R
Ignition coil 20AWG AC pilot light
G/Y
4-22AWG
WL
20AWG RL O Br 20AWG
Y Indicator light
Triggered coil

20AWG
3A Bussmann
BUSSMANN
L
AC coil 20AWG USB receptacle
L
INV3000DMN INV 60HZ 120 VAC Drawing No. 10000017588-A

Flameout switch

B Black
Br Brown
L B
G Green
L Blue 20AWG
O Orange
R Red
W White
Wiring Diagram and Electrical Schematic, GP3000i, Craftsman 3000i C00010030/PRO-3000i

Y Yellow
B/W Black/White
Stepper motor speed Ignition coil ENGINE BLOCK
G/Y Green/Yellow
Spark plug Oil sensor
R/W Red/White

71
Section 4 Electrical Data
72
CONTROL PANEL BLOKC
12 AWG

12 AWG Circuit breaker 25A

Parallel receptacle
Circuit breaker 20A
GENERATOR BLOCK Circuit breaker 30A
14AWG R 12 AWG
Br

14AWG
Br AC receptacle
L 12 AWG
Section 4 Electrical Data

Br 14AWG Inverter
20AWG W 22AWG
Main coil
20AWG
22AWG ESC switch
R
22AWG W
22AWG
B
O O
Sub coil
O

Ignition module
B Oil warning indicator ligh
20AWG
R Overload indicator light
Ignition coil
20AWG
G/Y AC pilot light
4-22AWG
WL
20AWG
20AWG R L O Br
Triggered coil Y Indicator ligh

20AWG
3A Bussmann
BUSSMANN
L
AC coil 20AWG USB receptacle
L

Flameout switch

B Black
Br Brown L B
G Green
20AWG
L Blue
O Orange
R Red
W White
Y Yellow
B/W Black/White ENGINE BLOCK
Stepper motor speed Ignition coil
G/Y Green/Yellow
Wiring Diagram and Electrical Schematic, GP3500iO 60HZ 120 VAC Drawing No. 10000017616-A

Spark plug Oil sensor

R/W Red/White

Diagnostic Repair Manual

 Section 4 Electrical Data

Wiring Diagram and Electrical Schematic, iQ3500 Drawing No. 10000033847-A

GROUP A

SCHEMATIC - DIAGRAM / WIRING - DIAGRAM

REVISION: A iQ3500 60HZ 120VAC
DATE: 3/28/18 PAGE 1 OF 2 DRAWING #: 10000033847

Diagnostic Repair Manual 73

Section 4 Electrical Data

Wiring Diagram and Electrical Schematic, iQ3500 Drawing No. 10000033847-A

GROUP A

SCHEMATIC - DIAGRAM / WIRING - DIAGRAM

REVISION: A iQ3500 60HZ 120VAC
DATE: 3/28/18 PAGE 2 OF 2 DRAWING #: 10000033847

74 Diagnostic Repair Manual

Electrical Formulas
To Find Known Values 1-phase 3-phase
EXI E x I x 1.73 x PF
Kilowatts (kW) Volts, Current, Power Factor
1000 1000
ExI E x I x 1.73
KVA Volts, Current
1000 1000
kW x 1000 kW x 1000
Amperes kW, Volts, Power Factor
E E x 1.73 x PF
Watts Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF
2 x 60 x Frequency 2 x 60 x Frequency
No. of Rotor Poles Frequency, RPM
RPM RPM
RPM x Poles RPM x Poles
Frequency RPM, No. of Rotor Poles
2 x 60 2 x 60
2 x 60 x Frequency 2 x 60 x Frequency
RPM Frequency, No. of Rotor Poles
Rotor Poles Rotor Poles
HP x 0.746 HP x 0.746
kW (required for Motor) Motor Horsepower, Efficiency
Efficiency Efficiency
E E
Resistance Volts, Amperes
I I
Volts Ohm, Amperes IxR IxR
E E
Amperes Ohms, Volts
R R
E = Volts I = Amperes R = Resistance (Ohms) PF = Power Factor

Term Symbol Measurement Constant Shift Result

Current I Amps
Voltage Resistance Current
Wattage P Watts E Increase
 Decrease

Voltage E Volts
Voltage Resistance Current
Resistance R Ohms
E Decrease
 Increase

Resistance Voltage Current
R Decrease
 Decrease

E P Resistance Voltage

Current

R Increase Increase

I R I E Current Resistance

Voltage

003003 I Decrease Decrease

Current Resistance Voltage

I Increase
 Increase

Power Voltage Power
P Increase
 Increase

Power Voltage Power
P Decrease
 Decrease

Power Current Power
P Increase
 Increase

Power Current Power
P Decrease
 Decrease

Part No. 0H5039 Rev. C 09/24/2018

©2018 Generac Power Systems, Inc. Generac Power Systems, Inc.

All rights reserved S45 W29290 Hwy. 59
Specifications are subject to change without notice. Waukesha, WI 53189
No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722)
consent from Generac Power Systems, Inc. [Link]