igen2500 and ipro2500 IGNITION COIL RETROFIT GUIDE This comprehensive retrofit guide is for replacing the ignition coil on Westinghouse s igen2500 and ipro2500 inverter generators. The purpose of this retrofit is to limit the overspeed of the engine. This will eliminate overheating issues due to engine overspeed. Instructional videos for how to properly replace the ignition coil are available at the links below: Extended video: www.wpowereq.com/retrofit-full Quick video: www.wpowereq.com/retrofit Owners manuals with parts drawings for these inverters are available at www.wpowereq.com Tools recommended for this retrofit: Flat head screwdriver Electric drill Screw driver bit extension Phillips screwdriver bit for drill 10mm socket for drill 8mm socket for drill Ignition Coil Have Questions? Call 855-944-3571 or email info@wpowereq.com
1 Step 1: Using the power drill, remove the top two Phillips head screws on the pull cord side of the generator. It is recommended to use a bit extension to help reach deep set screws. 2 Step 2: Turn the generator to the muffler side and remove the 6 Phillips screws holding the muffler grate in place. 3 Step 3: Turn the generator to the non-pull cord side and remove the top three Phillips screws. Next, remove the spark plug access cover on the top of the unit. 4 Step 4: Turn the generator to the control panel side and remove the 4 Phillips screws indicated in the image to the left. Then remove the Phillips screw holding the OFF- RUN-CHOKE switch in the upper right hand part of the control panel. Once these screws are removed, pull from the bottom of the control panel assembly to detach it. NOTE: Be sure not to remove the 2 screws at the bottom edge of the control panel. 5 Step 5: Pull back the rubber fuel collector under the gas cap and remove the clip with a flathead screwdriver. This clip secures the side panels together.
6 Step 6: On the bottom of the pull cord side of the generator remove the 3 10mm bolts that hold the side cover on. 7 Step 7: Detach the pull cord side cover. Start by pulling the muffler side of the cover and work towards the gas cap side. There is a groove under the gas cap that can be detached by pulling upward and outward. Once the panel is removed let it lean outward so you can access the engine. The recoil does not need to be removed to perform ignition coil replacement. 8 Step 8: In the center of the unit lift up on the gas tank to access the ignition coil assembly. Remove the 8mm bolt that holds the ignition coil to the engine. 9 Step 9: Pull the spark plug boot off of the spark plug on top of the engine. 10 Step 10: Unplug the three wire connections to the ignition coil assembly. Once the ignition coil is detached, discard it.
11 IMPORTANT Step 11: Check to see that the connection from the alternator to the inverter board is connected and secure. If it is unplugged make sure to plug it in. This connector is a two wire located behind the inverter module. NOTE: If there are any connections to the control panel or inverter board that are not connected, make sure to connect them. 12 Step 12: Take the new ignition coil provided and install it by first pushing the spark plug boot onto the spark plug until you hear a click. 13 Step 13: Route the ignition coil wire under the gas tank and then reconnect the 3 connectors that you disconnected in step 10. There should be a 4 wire (orange, blue, red, black), 3 wire (brown, white, black) and 1 wire (yellow). 14 Step 14: Once the wires are connected take the 3 wire connector (brown, white, black) and 1 wire (yellow) and wrap them around the mount where you will screw in the ignition coil. See image to the left for proper placement. The 4 wire connector will stay loose at the bottom. 15 Step 15: Secure the ignition coil assembly with the 8mm bolt that you removed in step 8. NOTE: Be sure not to overtightened as the plastic will break.
16 Step 16: Reattach the pull cord side cover. Start by guiding the top right of the panel around the groove under gas cap. The back side of the rubber fuel collector has a plug that needs to be guided into place before the sides are reconnected. 17 Step 17: Screw in the Phillips screw at the front right of the case to help reattach the clip that was removed in step 5. 18 Step 18: Using a flat head screw driver reattach the clip under the rubber fuel collector that was removed in step 5. 19 Step 19: Screw in the 2 Phillips screws removed in step 1 from the top of the generator on the pull cord side. 20 Step 20: Reinstall the muffler grate by tilting the bottom in first so that the tab lines up. Push in the top two tabs so that the panel is flush. Then screw in the 6 Phillips screws removed in step 2 that hold the muffler grate in place.
21 Step 21: Turn the generator to the non-pull cord side of and screw in the top two Phillips screws. Next, install the spark plug access cover that was removed in step 3. 22 Step 22: Turn the generator to the control panel side and reinstall the control panel assembly by tipping the top forward so that the tabs line up. Screw in the 4 Phillips screws removed in step 4. The two longest screws go on top of panel. Reinstall the OFF-RUN-CHOKE switch in the upper right hand part of the control panel and secure with Phillips screw. IMPORTANT: Make sure the switch is installed in the correct orientation with the off state being vertical. 23 Step 23: Replace the 3 10mm bolts at the bottom of the pull cord side of the generator. 24 Step 24: Make sure to take the generator outside to a well ventilated area and run it to confirm there are no issues with installation. Switch the economy mode on and off and check for major RPM changes. Have Questions? Call 855-944-3571 or email info@wpowereq.com