KG160、KG200、KG270、KG390

CONTENT
Preface……………………………………………………
Before maintenance………………………………………
Safety precaution…………………………………………
External views……………………………………………
Chapter 1 Specification…………………………………
1.1Main specification ………………………………
1.2 Engine parts………………………………………
Chapter 2 Maintenance…………………………………
2.1 Daily maintenance………………………………
2.2 Periodic maintenance……………………………
2.3 Storage……………………………………………
Chapter 3 Disassembly and reassembly …………………
3.1 Disassembly………………………………………
3.2 Reassembly………………………………………
3.3 Recoil starter……………………………………
Chapter 4 Inspection and maintenance …………………
4.1 Cylinder cover……………………………………
4.2 Piston and piston pin……………………………
4.3 Connection rod……………………………………
4.4 Crankshaft and flywheel…………………………
4.5 Camshaft and tappet……………………………
4.6 Timing gear………………………………………
4.7 Crankshaft cover…………………………………
4.8 Cylinder cover and cylinder block………………
4.9 Engine oil ………………………………………
4.10 Oil alarm ………………………………………
4.11 Air filter…………………………………………
4.12 Spark plug………………………………………
4.13 Carburetor………………………………………
4.14 Governor………………………………………
4.15 Fuel filter………………………………………
4.16 Nozzle…………………………………………
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 KG160、KG200、KG270、KG390
Chapter 5 Troubleshooting ……………………………
5.1Main trouble………………………………………
5.2.Remedy for bad starting…………………………

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 KG160、KG200、KG270、KG390

Preface
Thank you for purchasing Kipor gasoline engine.
Kipor gasoline engines are widely applied for
generator sets, water pumps and other industrial
machine, as a result of their excellent performance and
structure.
Kipor KG series gasoline engines feature as follows:
1. Diagonal cylinder. The structure is more compact and
beautiful.
2. Recoil starting. Compare to the hand starting, it is
cheaper, easier starting and more convenient in
maintenance.
3. Light weight, little vibration and low noise. Aluminum
alloy casting, pressing and plastics are applied to reduce
the engine weight and ensure stable engine running.
In order to ensure proper operation, reliable running
and good economic benefit, it is especially important for
you to operate correctly and maintain carefully. This
manual will tell you how to operate and maintain the
machine correctly, it will also give you detail instruction
about the main technical specification, configuration and
troubleshooting.

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 KG160、KG200、KG270、KG390
This service manual couldn’t contain all Kipor gasoline
engine models; we just choose following models: KG160,
KG200,KG270 and KG390. However, this service
manual is applicable for all models of Kipor gasoline
engine.
Remark: as the company’s improvement and
development, the practical product may be inconsistent
with the service manual. If you have any problems,
please contact with us

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 KG160、KG200、KG270、KG390

Before maintenance
Preparations before maintenance:
1. Ask your customer:
(1) When was the last maintenance?
(2) How was the last maintenance?
2. Preparation:
(1) Spare parts and material needed in maintenance
(2) Parts catalog
3. Maintenance record
(1) Worksheet
(2) Inspection record
(3) Measurement
(4) Maintenance data
4. Equipment needed in maintenance
(1) Tools
(2) Measuring equipment
(3) Others

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KG160、KG200、KG270、KG390

Important safety information

Exhaust
 Exhaust gas contains
poisonous carbon
monoxide. Avoid
inhalation of exhaust
gas.
 Never run the engine in
closed garage or
confined area.
 Make sure start the
engine carefully.
 Don’t block the exhaust
pipe.

Oil filling
 Stop the engine before
filling oil.
 Avoid oil overflowing.
 Wipe off the spillage
completely.
 Screw on the oil tank
cover tightly when
changing the oil.

Fire
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KG160、KG200、KG270、KG390
prevention
 Keep the engine away
from smoke or fire.
 Keep the engine away
from dry wood, branch,
cloth or other
inflammable material.
 Keep the engine at
least 1 meter away
from building.
 Keep away from other
dangerous material,
such as rubbish, rag or
explosive.

Protection cover
Rotating parts such as
driving shaft and belt
wheel are very
dangerous, please equip
them with a protection
cover.。

Hot parts
Pay attention to the hot
parts such as muffler.
Keep children and pets
away from the area of
operation.

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 KG160、KG200、KG270、KG390
Operation conditions
 Operate the engine stably on
the level.
 Don’t lean the engine during
operation.
Caution:
 A tilting engine will cause
poor lubricant or even
machine fault.
 Prevent oil spilling during
transportation. Make sure
screw on the oil tank cover tightly and turn off the
carburator switch. (Don’t turn it on until starting the
engine).
 Don’t move the engine during operation.
 When transport the engine on rugged road for a long
distance, make sure the fuel has been draint out
completely.

Check before maintenance

 Check the fuel pipe
connection and fuel leakage.
 Check the bolts and nuts.
Screw them on tightly.
 Check the oil level.
 Refill in oil if necessary. Pay
attention that the oil level
should not be too high.
 Put on the working clothes
when starting the engine.
Avoid your clothes being
caught by rotating parts.
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 KG160、KG200、KG270、KG390

Chapter 1
Front view Rear view
Specification

1.1 Main specification

Model KG160 KG200 KG270 KG390

Type Single cylinder, air cool, 4-stroke, diagonal
cylinder, OHV
Bore×stroke
68×45 68×54 77×58 88×64
mm
Displacement
163 196 270 389
ml
Max. power 3/3000 3.6/3000 5/3000 7/3000
/rotate speed
kW/r/min　 3.3/3600 4/3600 5.5/3600 7.7/3600
Max. torque/
10.8/ 16.5/ 22.6/250
rotate speed 9.1/2500
2500 2500 0
N.m/r/min
Min. fuel
consumption　 395 374
g/(kW·h)
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 KG160、KG200、KG270、KG390
Lube
consumption g/ 6.8
(kW·h)
Lowest rotate
speed (at zero 1440±140
load) r/min
Compression
8.5
ratio
Ignition
advanced BBDT 25°
angle
Rotate
direction (face Clockwise
to the flywheel)
Valve
0.10～0.15
clearance mm
Spark plug
0.7～0.8
clearance mm
Starting type Recoil start Recoil start or
electric start
Fuel type Automotive unleaded gasoline
Lube oil type SAE10W30
Fuel tank
3.6 6 6.5
capacity　L
Lube oil
0．6 1.1
capacity L
Overall
305×365 320×380 380×435 405×452
dimension
×340 ×340 ×416 ×435
(LXWXH) mm
Net weight　　
14 16 25 31
kg

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1.2 Engine parts

Chapter 2 Maintenance
2.1 Daily maintenance
Check and screw on the nuts and bolts;
Check the oil level;
Check oil leakage;
Wipe off the mud and oil on the engine surface.

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 KG160、KG200、KG270、KG390
Keep the engine clean.
E
Interval v The Every Every
Every
er first three six
year or
y month months months
300
ti or 20 or 60 or 100
hours
m hours hours hours
Item e
Check
○
● Oil the oil
Change ○ ○
Check
the oil ○
Oil tank
level
Change ○ ○
Check ○
● Air filter Clean ○（1）
Change ○*
Deposition
● Clean ○
cup
Clean-
○
● Spark plug adjust
Change ○

Spark
Clean ○
catcher
● Clean-
Idle ○（2）
adjust
Valve Clean-
● ○（2）
clearance adjust
● Fuel tank Clean ○（2）

● Fuel pipe Check Every two years (change if necessary)（2）

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2.2 Periodic maintenance

To ensure the best quality and reliability, make sure
perform periodic maintenance as per the above table.
Consult with your dealer for professional technology and
tools.
Remark: “●”Emission-related items
“*”Replace the paper air filter element only
Standard dual-filter-element type: every year or 300 hours
(1) Service more frequently when used in dusty area.
(2) These items should be serviced by your servicing
dealer, unless you have the proper tools and the
mechanically proficient.
(3)For commercial use, log hours of operation to
determine proper maintenance intervals.

2.3 Store the engine

Proper storage preparation is essential for keeping your
engine troublefree and looking good. The following steps
will help to keep rust and corrosion from impairing your
engine’s function and appearance, and will make the
engine easier to start when you use it again.
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 KG160、KG200、KG270、KG390
2.3.1 Cleaning
Clean all exterior surface, touch up any damaged paint,
and coat other areas that may rust with a light film of oil.
Caution:
(1) Using a garden hose or pressure washing equipment
can force water into the air cleaner or muffler opening.
Water in the air cleaner will soak the air cleaner, and water
that passes through the air cleaner of muffler can enter the
cylinder, causing damage.
(2) Water contacting a hot engine can cause damage.
(3) If the engine has been running, allow it to cool for at
least half an hour before washing.
2.3.2 Fuel
Gasoline will oxidize and deteriorate in storage. Old
gasoline will cause hard starting, and it leaves gum
deposits that clog the fuel system. If the gasoline in your
engine deteriorates during storage, you may need to have
the carburetor and other fuel system components serviced
or replaced.
The length of time that gasoline can be left in your fuel tank
and carburetor without causing functional problems will
vary with such factors as gasoline blend, your storage
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 KG160、KG200、KG270、KG390
temperatures, and whether the fuel tank is partially or
completely filled. The air in a partially filled fuel tank
promotes fuel deterioration. Very warm storage
temperatures accelerate fuel deterioration. Fuel
deterioration problems may occur within a few months, or if
you fill in old gasoline.
The distributor’s limited warranty doesn’t cover fuel system
damage or engine performance problems resulting from
neglected storage preparation.
You can extend fuel storage life by adding a fuel stabilizer
that is formulated for that purpose, or you can avoid fuel
deterioration problems by draining the fuel tank and
carburetor.
2.3.3 Adding a fuel stabilizer to extend fuel
storage life
When adding a fuel stabilizer, fill the fuel tank with fresh
gasoline. If only partially filled, air in the tank will promote
fuel deterioration during storage. If you keep a container of
gasoline for refueling, be sure that it contains only fresh
gasoline.
1. Add fuel stabilizer following the manufacturer’s
instruction.
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 KG160、KG200、KG270、KG390
2. After adding a fuel stabilizer, run the engine outdoors for
10 minutes to be sure that treated gasoline has replaced
the untreated gasoline in the carburetor.
3. Stop the engine, and move the fuel valve level to the
OFF position.
2.3.4 Draining the fuel tank and carburetor
1. Place an approved gasoline container below the
carburetor, and use a funnel to avoid spilling fuel.
2. Remove the carburetor drain bolt and sediment cup, and
then turn the fuel valve level to ON position.
Warning:
■Gasoline is highly flammable and
explosive.
■ You can be burnt or seriously injured
when handling fuel.
■ Keep heat, sparks and flame away.
■ Handle fuel only outdoors.
■ Wipe up spills immediately.
3. After all the fuel has drained into the carburetor, reinstall
the drain bolt and sediment cup. Tighten them securely.
2.3.5 Engine oil
1. Change the engine oil
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 KG160、KG200、KG270、KG390
2. Remove the spark plug
3. Pour a tablespoon (5-10 cc) of clean engine oil into the
cylinder
4. Pull the starter rope several times to distribute the oil in
the cylinder
5. Reinstall the spark plug
6. Pull the starter rope slowly until resistance is felt. This
will close the valves so moisture can’t enter the engine
cylinder. Return the starter rope gently.

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 KG160、KG200、KG270、KG390

Chapter 3 Disassembly and reassembly

3.1 Disassembly
· Prepare necessary tools.
· Record the maintenance in a notebook.
· Use some detergent to clean the parts.
· Place the parts in the container.
· Drain out the used oil.
· Put the nuts, bolts and relevant parts together.
Don’t disassemble the non-removable parts.

3.1.1 Oil tank

1）Turn off the carburetor switch.
2）Loose the hose clip.
3）Disassemble the oil tank. (Picture 1)

（ 图
3.1.2 Exhaust muffler 2）
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 KG160、KG200、KG270、KG390
1）Screw off the nuts.
2）Disassemble the muffler. (Picture 2)

Picture 2

3.1.3 Muffler cover（KG160A-a）

1）Screw off the bolts.
2）Disassemble the muffler cover. (Picture 3)

Picture 3

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 KG160、KG200、KG270、KG390
1）Disassemble the upper cover of air filter.
2）Take out the filter element.
3）Disassemble the lower cover of air filter.
4）Disassemble the seat of air filter.
5）Disassemble the carburetor washer.
（ 图
3）

3.1.5Carburetor
1) Disassemble the idle spring and governor rod.
2) Disassemble the carburetor, carburetor gasket,
carburetor insulation block and inlet pipe gasket. (Picture
4)

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3.1.6 Recoil starter

Disassemble the recoil starter if necessary.

3.1.7Air conduct cover

Disassemble the air conduct cover.

3.1.8 Air deflector and air induced plate

Disassemble the air deflector and air induced plate.

3.1.9 Ignition coil

Disassemble the ignition coil.

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 KG160、KG200、KG270、KG390

3.1.10 Speed governor and speed control

device
Disassemble the speed governor and speed control
device if necessary. Damaged governor level will cause
engine fault. Check the governor spring before
disassembly.

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 KG160、KG200、KG270、KG390
3.1. 11 Governor handle/Switch（KG160A-a）

3.1.12 Cylinder cover

Disassemble the cylinder cover.

3.1.13 Cylinder cap

Disassemble the cylinder cap. ·Place the cylinder
combustion surface upwards.

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3.1.14 Valve rock arm

Disassemble the valve rock arm.

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3.1.15 Flywheel
1）Screw off the flywheel nut.
2）Disassemble the starting claw and impeller.
3）Disassemble the flywheel.
·Make sure use the special tools.
·Screw on the impeller bolt tightly.

3.1.16 Starting motor（KG390）

Disassemble the starting motor.

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 KG160、KG200、KG270、KG390
3.1.17 Crankcase cover
1）Disassemble the crankcase cover.
Remarks:
Disassemble the bolts, nuts and screws in order from
small size to big size, and outside to inside. Tighten to
the specified torque.
Be careful not to damage the oil seal during disassembly.

3.1.18 Camshaft
1）Draw out the camshaft
·Check the timing label.
·Don’t mix the inlet valve tappet and exhaust valve
tappet. Store them in different place.

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 KG160、KG200、KG270、KG390

3.1.19 Balance shaft（KG390）

Take out the balance shaft.

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 KG160、KG200、KG270、KG390
3.1.20 Piston connection rod
1）Disassemble the connection rod bolts.
2）Remove the connection rod big head.
3）Remove the crankshaft.
·Clear the carbon on the cylinder cover before drawing
out the piston.
·Make sure the main bearing in place during
disassembly.

3.1.21Crankshaft
1）Remove the flywheel key.
2）Draw out the crankshaft.
·Be careful not damage the oil seal during disassembly.

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 KG160、KG200、KG270、KG390
3.2 Reassembly
Before reassembly:
·Clean and check all the parts.
·Lubricate the moving parts and rotating parts with fresh
oil.
·Use the new gasket and O seal.
·Use liquid sealant to prevent oil leakage.
·Check the clearance of oil film, thrust and other parts.
·Check the auxiliary aiming mark before reassembly.
·Use the correct model of bolt, nut and gasket. Tighten
them to specified torque. (Pay special attention to
aluminum alloy parts)
·Smear some oil on the screw thread and flange surface.

3.2.1 Speed governor and control device

Reassemble the speed governor and control device.

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 KG160、KG200、KG270、KG390

3.2.2 Crankshaft
1）Reassemble the crankshaft.
2）Reassemble the flywheel key.
·Install the crankshaft in correct position.
·Smear some grease lubricant on the oil seal lip.
·Smear some oil on the crankshaft main journal and
connection rod journal.

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 KG160、KG200、KG270、KG390

3.2.3 Piston and connection rod

1 ） Turn the crankshaft to top dead center and
reassemble the piston connection rod. The mark on the
piston top should face to crankcase cover.
2）Reassemble the connection rod big head cover.
·Smear some oil on the crankshaft pin.
·Check the piston ring direction.
·Smear some oil on the piston surface and cylinder
cover.
·Check the main bearing position.
Tighten torque of connection rod bolt N·m
KG160
14～16
KG200
KG270
20～22
KG390

Check the location surface of connection rod bolt.

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 KG160、KG200、KG270、KG390

3.2.4 Camshaft, balance shaft

1）Install the valve tappet.
2）Install the camshaft.
3）Install the balance shaft（KG390）
·Don’t mix the inlet valve tappet and exhaust valve
tappet.
·Check the matching mark on the gear.

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 KG160、KG200、KG270、KG390

3.2.5 Crankcase cover

（1）Place a piece of asbestos-packing gasket between
the cylinder block and crankcase cover.
（ 2 ） Reassemble the crankcase cover. (Tighten the
bolts in order).
·Install the oil seal tools.
·Smear some grease lubricant on the oil seal lip.

3.2.6 Air deflector（KG160、KG200）

Reassemble the air deflector.

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 KG160、KG200、KG270、KG390

3.2.7 Flywheel
1）Reassemble the flywheel.
2 ） Reassemble the impeller, starting claw and flywheel
nut.

Tighten torque of flywheel nut N·m

KG160
80～90
KG200
KG270
120～130
KG390
Screw on the flywheel nuts with special tools to install the
flywheel.

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 KG160、KG200、KG270、KG390

3.2.8 Cylinder cover

1）Install the cylinder cover gasket.
2）Reassemble the cylinder cover.
·Make sure the mark on the spring (with white paint) face
towards the cylinder cover.

Tighten torque of cylinder cover bolt N·m

Model Torque
KG160
28～32
KG200
KG270
42～46
KG390

3.2.9 Push rod

Reassemble the push rod.
·Make sure the push rod is in place.

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 KG160、KG200、KG270、KG390

3.2.10 Valve rocker

1）Reassemble the valve rocker.
2）Adjust the valve clearance.
Inlet valve clearance: 0.10±0.02mm
Exhaust valve clearance: 0.15±0.02mm

Tighten torque of valve rocker N·m

KG160
KG200
20～23
KG270
KG390

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 KG160、KG200、KG270、KG390

3.2.11 Air induced plate

Screw on the bolts of air induced plate.

3.2.12 Cylinder cover

Reassemble the cylinder cover.
·Check the gasket position.

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 KG160、KG200、KG270、KG390

3.2.13 Ignition coil

Reassemble the ignition coil.

3.2.14 Governor arm

Reassemble the governor arm.

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 KG160、KG200、KG270、KG390

3.2.15 Carburetor
Reassemble the carburetor in correct order: inlet pipe
gasket, carburetor insulation block, carburetor gasket,
carburetor, and finally carburetor washer.

3.2.16 Air filter

Reassemble the air filter in correct order: disassemble
the upper cover of air filter element firstly, then install the
governor spring, idle adjusting spring, governor rod, and
finally reassemble the air filter element and upper cover
of air filter.

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 KG160、KG200、KG270、KG390

3.2.17 Governor supporting

plate（KG160、KG200）
1）Disassemble the upper cover of air filter and the filter
element.
2 ） Screw off the tighten nut of governor arm. Then
check the air throttle, it should be completely open.
3）Turn off the governor, and then tighten the bolts and
nuts.
4）Check whether the governor arm and air throttle work
well.
Start the engine and adjust the engine maximum speed
by the adjusting screw.

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 KG160、KG200、KG270、KG390

3.2.18 Air conduct cover

1）Install the air conduct cover.

3.2.19 Starting motor（KG390）

Install the starting motor.

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 KG160、KG200、KG270、KG390

3.2.20 Oil tank

1）Install the oil tank.
2）Clip one end of oil pipe on the carburetor inlet port.
3）Insert the anode cap into spark plug.
4）Connect and fix the controlling line.

3.2.21 Exhaust muffler

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 KG160、KG200、KG270、KG390
Install the exhaust muffler. It is not necessary to
disassemble the muffler cover.

3.3 Recoil starter

If the recoil starter is damaged or needs lubricant,
please follow below instruction for disassembly and
reassembly.
3.3.1 Disassembly
1 ） Disassemble the recoil starter and fan cover with a
socket wrench.
2）Pull out the starter rope for 50cm, and make a
slipknot (Picture a). Loose the ”8” knot of starter handle
and disassemble it.
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 KG160、KG200、KG270、KG390

3）Disassemble the other parts (picture b).

4）Disassemble the starter reel (picture c). Screw off the

starter reel slowly to take out the spring. Pay attention

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 KG160、KG200、KG270、KG390
not to screw off the spring too fast, otherwise, the spring
may jump out. (Put the spring back if it jumped out
(picture d).)

(d)

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 KG160、KG200、KG270、KG390
3.3.2 Reassembly
1 ） Check the spring position, it should be engage with
the mark on the panel, 4mm away from the pulling panel
shaft.

2）Wind the starter rope on the starter reel, and pull the
rope out at the 2.5 turn (picture e). Make sure the hook
on the starter reel engage with the spring. Then you can
install the starter reel correctly. (Pay attention to avoid
the mistake described in picture d).

3 ） Wind the starter rope for 4 turns according to the

below direction (picture f). Do secure the starter reel
tightly to avoid rope inversion. Then tie a slipknot.

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 KG160、KG200、KG270、KG390

4 ） Reassemble the parts in picture b, then install the

handle and loose the slipknot. The reassembly order is
just opposite from the disassembly order.
For security, please check the reassembly procedure
again and make sure all parts have been reassembled
correctly.
3.3.3 Check after reassembly
1 ） Pull out the starter rope for several times, each
time for a little.
（ 1 ） If it is hard to pull the rope, please check
whether all parts have been reassembled correctly.
（2）If the pallet fail to work, please check the spring.
2）Completely pull out the rope.
（ 1 ） If the starter reel is seized or the starter rope
can’t retract, please wind the spring for another turn.
（2）If the starter rope retracts weakly or the handle
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 KG160、KG200、KG270、KG390
drops, please lubricate the friction parts. If it still doesn’t
work, please wind the starter rope for another turn.
(check according to procedure (1).)
（3）If the starter rope can’t be retained in the starter
reel after the spring separates from the starter hook,
please reassemble the starter for another time.

Chapter 4 Inspection and maintenance

4.1 Cylinder cover
4.1.1 Combustion chamber surface
Disassemble the cylinder cover, inlet valve and
exhaust valve. Clear the combustion chamber surface,
and check for crack or damage. Check the crack by dye
penetration.

4.1.2 Inlet/exhaust valve seat

Assemble the valve seat by freezing assembly
mode, and clear the carbon on the valve seat.
Excessive wear or corrosion will cause insufficient
compression.
You can freeze the valve seat by liquid nitrogen.

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 KG160、KG200、KG270、KG390

KG160、KG200、KG270、KG390
Standard Maintenance limited
Angle 45° —
Width 1.5—3.0 —

4.1.3 Inlet/exhaust valve and valve pipe

1 ） Check the valve rod for wear and distortion, and
change it if necessary. Don’t mix the inlet valve and
exhaust valve.
2 ） Check the valve sinking, and change the wearing
valve.
Caution：
1. The inlet/exhaust valve pipe is equipped with valve rod
seal. Please change the valve rod seal for maintenance.
2. Lubricate the valve rod before installing the
inlet/exhaust valve.

4.1.4 Valve spring

1）Check the valve spring for crack or corrosion.
2）Check the valve spring inclination.
3）Measure the spring rigidity by a rigidity tester.
·Pay attention that the mark on the valve spring (white
paint) should face to cylinder cover.

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 KG160、KG200、KG270、KG390
4.1.5 Piston top clearance
1）Disassemble the cylinder cover, and put three pieces
of fuse at the three points of piston top. The fuse height
is φ1.2×10mm.
2 ） Reassemble the cylinder cover gasket and cylinder
cover. Screw on the cylinder cover bolt according to the
specified order and torque.
3）Run the crankshaft to squash the fuse.
4 ） Disassemble the cylinder cover and take out the
squashed fuse.
Measure the thickness of the squashed fuse.
Another way to measure the thickness without
disassembling the cylinder cover is that: tie the fuse with
a piece of thread and pull it through the spark plug hole.
(Refer to following picture). Then squash the fuse and
measure its thickness. (Refer to the above mentioned
procedure).

5）Take the average value of three measured thickness

as the piston top clearance,
KG160、KG200、KG270
Model
、KG390
Item Standard
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 KG160、KG200、KG270、KG390
Piston top clearance 0.5～0.7

4.1.6 Inlet/exhaust valve rocker and push rod

1）Valve rocker
Check the exhaust valve adjusting gasket. Don’t run
the machine until you install this gasket, otherwise, the
exhaust valve spring will drop off.
2）Push rod
Check the length and distortion of push rod.

4.1.7 Valve clearance

1 ） Disassemble the cylinder cover bolt, cylinder cover
and cylinder gasket.
Caution:
Adjust the valve clearance by the adjusting nut of rocker
shaft. Pay attention that the engine should be at cool.

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 KG160、KG200、KG270、KG390

Valve clearance mm
KG160、KG200、KG270、KG390
Item Mode
l Standard
Valve clearance 0.10～0.15
2）Insert a feeler gauge between the rocker and valve to
measure the valve clearance.
Inlet:0.10±0.02mm
Valve clearance
Exhaust: 0.15±0.02mm
3）Adjust according to following order:
a. Fix the rocker with a spanner, and loosen the
adjusting nut of rocker shaft.
b. Loosen the rocker to specified valve clearance.
c. Fix the rocker with a spanner, and tighten the
adjusting nut of rocker shaft.
d. Check the valve clearance for another time.

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4.2 Piston and piston pin
4.2.1 Piston
1 ） Check piston top and combustion chamber surface,
clear up the gathered carton on them, please be careful
and don’t hurt the surface. Check whether there is any
injury on the surface of combustion chamber.
2 ） Check piston outside diameter, if damage of piston
surface or ring groove exceeds the limitation valve,
please change for a new piston.

4.2.2 Piston pin

Measure the outside diameter of piston pin, if the
measured valve exceeds the maintenance limitation, or
has been grinded severely into echelon form, then you
should replace the piston pin.

Model
KG1
Item KG200 KG270 KG390
60

0
Φ18 Φ20
Standard Φ18  0.01 0 0
 0.006  0.006

4.2.3 Check the piston pin hole

1）If the piston pin hole changes color or be damaged,

please change the piston.
2 ） Measure the inside diameter, if the measured value
exceed the maintenance limitation, please change the
piston.

4.2.4 Piston ring

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1）Use special tools to assemble or disassemble piston
ring. Don’t pull the piston ring too hard.
2 ） Pay attention that the marked side of piston ring
should be upwards.
3）Make sure that the piston ring can run smoothly.
4 ） Stagger the piston ring opening for 120°, avoiding
contacting the piston pin.

4.3 Connection rod

4.3.1 Check the connection rod
1）Clamp measurement in the big head hole and small
head hole of connecting rod to check the its depth of
parallelism and distortional deformation. If the depth of
parallelism exceeds promised limitation, please replace
connecting rod.
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KG160
Item KG270 KG390
KG200
Parallelism/Distortion 0.008 0.010 0.008

4.3.2 Connect the piston and connection rod

Adjust the piston, and face the piston top mark to the
connection rod mark. (Refer to the following picture). So
that when installing the piston into the cylinder cover, the
piston top mark is downward.

4.4 Crankshaft, main bearing and flywheel

4.4.1 Crankshaft
1）Painting test
Clean crankshaft, check whether there is crack by
painting infiltrating or magnetic inspection. If there is
crack or severe damage, please replace the crankshaft.
2）Measure the connection rod journal and main journal
of crankshaft.
Check the damage of connection rod journal and main
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 KG160、KG200、KG270、KG390
journal. If the damage exceeds the limitation valve,
please change the crankshaft.
3 ） Press the rolling bearing of flywheel onto the
crankshaft.(If the bearing loosens, please change the
crankshaft).

4.4.2 Flywheel
1）Flywheel ring gear（KG390）
Heat the flywheel ring gear to 180℃ and install it on the
flywheel.

4.5 Camshaft
4.5.1Camshaft
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 KG160、KG200、KG270、KG390
1）Check the thrust clearance of camshaft.
4.5.2 Valve tappet
1）Check the valve tappet. The tappet center line should
be deviated from the camshaft center, so that to avoid
nonuniform wear. If the tappet is damaged severely or
contacts with camshaft nonuniformly, please change the
tappet.
2 ） Check the tappet surface for wearing or damage.
Please change the tappet if it is damaged.
Caution:
Separate the inlet valve tappet and exhaust valve tappet
during disassembly or reassembly.

4.6 Timing gear

4.6.1 Check the timing gear
1）Check every gear carefully, and change the damaged
ones.
2）Align the timing mark for reassembly.

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4.7 Crankcase cover

Check the crankcase cover gasket of oil resistant asbest
packing sheet, if it is damaged or distorted, please
change it. Tighten the crankcase cover bolt according to
the following torque.
Fix the crankcase cover with two location pins.
Tighten torque: N·m
Model
KG160、KG200、KG270、K
Item G390
Crankcase cover 20～23
4.7.1 Oil seal of crankshaft and camshaft
Please use special tools to replace the oil seal. Pay
attention not roll the oil seal edge when pushing it into
the crankcase cover or cylinder block.

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4.8 Cylinder cover and cylinder block

4.8.1 Cylinder cover
The cylinder cover is built inside the cylinder block which
is made of aluminum alloy.
Measure the inside diameter of cylinder cover. If the
measured value exceeds the limitation value, please
change the piston for a bigger size.

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 KG160、KG200、KG270、KG390

4.9 Engine oil

1）Remove the oil ruler and draining screw to drain out
the dirty oil.
2) Tighten the draining screw.
Tighten torque: 23N·m
3）Fill in fresh oil.
Engine oil capacity
KG160、KG200 0.6L
Engine oil
capacity
KG270、KG390 1.1L
Use the SAE10W—30 engine oil. Choose the oil viscidity
according to the local ambient temperature. (Refer to the
following picture).

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 KG160、KG200、KG270、KG390

It is suggested for you to choose SE or SG engine oil in

API grade.
4）Check the oil level, refill it to the upper limitation if it is
insufficient.
Caution:
Check the oil level when the engine is on level.

4.10 Oil alarm

If you check the oil alarm and change the engine oil in
the same time, it is no longer need to drain out the
engine oil.
1 ） Turn off the engine switch and earth the engine.
Make sure the alarm light is on and the engine stops.
2）Stop the engine. Don’t disconnect the two leads of oil
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level switch. It is normal if they are conducted.
3 ） Check it again after draining out the engine oil. It is
normal if the leads are conducted.。

4.11 Air filter

〈Double element, silent, cyclone dust〉
1 ） Disassemble the nut, air filter cover, butterfly nut,
black flame resistant sponge and papery filter element.
2 ） Clean the black sponge filter element with
conditioning oil and dry it with compression air. Soak the
element in the engine oil for a while and then reassemble
it.
3）Blow in the element with compression air. Change the
element if it is badly polluted.
Caution:
Too much engine oil inside the black sponge element will
block the filter.

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〈Damp-dry〉
1）Screw off the nut and air filter cover, then take out the
air filter element.
2）Clean the element with conditioning oil and then dry
it.
3 ） Soak the filter in the conditioning oil and then
reassemble it.
Caution:
Too much engine oil inside the black sponge element will
block the filter.

〈Oil-bath〉
1）Clean the oil sump with conditioning oil and then dry
it.
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2）Fill in the conditioning oil and install the oil sump.
3 ） Clean the black sponge filter element with
conditioning oil and dry it with compression air. Soak the
element in the engine oil for a while and then reassemble
it.
Caution:
Too much engine oil inside the black sponge element will
block the filter.

4.12 Spark plug

1）Remove the carbon on the spark plug electrode with
a wire.
Check the seal washer for damage.
2 ） Check the clearance between the center electrode
and side electrode with a spark plug gauge. Curve the
electrode to adjust the clearance.

4.13 Carburetor (idle)

1）Start the engine and preheat it for ten minutes.
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2 ） After preheating, set the engine at the maximum
speed by the adjusting screw when it is at idle.
3）Adjust the idle speed by the stop screw of throttle.

4.14 Governor
1）Disassemble the fuel tank.
2 ）Turn the tighten nut of governor arm left, and check
whether the throttle is totally open.
3 ） Turn the governor arm left to shut off the governor.
Tighten the bolts and nuts.
4）Check the governor arm and throttle.
5）Reassemble the fuel tank.
Start the engine, and adjust the engine maximum
rotation speed by the adjusting screw.
Max. rotation speed 3000～3600rpm

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4.15 Fuel filter

Turn the fuel switch to OFF. Disassemble the oil cup
and clear it with conditioning oil. Install the O-ring
correctly and then tighten the oil cup.
Tighten torque:
Caution:
·No smoke or fire.
·Check for fuel leakage.

4.16 Nozzle
1）Drain out the fuel and disassemble the fuel tank.
2）Loosen the fuel supplying pipe clip and disassemble
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the fuel supplying pipe.
3 ） Disassemble the nozzle and clear it. (clear the
strainer and check it for damage).

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