Page 1
2.5 HP 1,000 WATT OHV
Model
97906
GENERATOR
SET UP, OPERATING, AND SERVICING
INSTRUCTIONS
Using an engine indoors CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside
a home or garage,
EVEN IF doors and
windows are open.
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Only use OUTSIDE
and far away from
windows, doors, and
vents.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright© 2008 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
Page 2
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
SET UP ..........................................6
OPERATION ..................................6
SERVICE .......................................7
BASIC SPECIFICATIONS ............. 8
UNPACKING .................................. 8
SET UP INSTRUCTIONS ............... 8
LOCATION ..........................................9
GROUNDING ......................................9
FUEL FILTER REPLACEMENT
(IF EQUIPPED) .........................15
CLEANING, MAINTENANCE, AND
LUBRICATION SCHEDULE .......... 15
AFTER INITIAL 20
OPERATION HOUR PERIOD: . 16
EVERY 25 OPERATION
HOURS THEREAFTER: ...........16
EVERY 50 OPERATION
HOURS: ....................................16
EVERY 100 OPERATION
HOURS: ....................................16
EVERY 300 OPERATION
HOURS: ....................................16
STORAGE ........................................16
OPERATING INSTRUCTIONS ...... 9
ENGINE CONTROLS .........................9
STARTING THE ENGINE ................. 10
CHECKING AND FILLING
ENGINE OIL ............................. 10
CHECKING AND FILLING FUEL 10
START PROCEDURE ................. 11
BREAK-IN PERIOD ....................11
EQUIPMENT OPERATION ............... 11
TO POWER 110/120 VOLT AC
TOOLS AND EQUIPMENT: ...... 11
TO CHARGE 12 V LEAD-ACID
TYPE BATTERIES: ..................12
TECHNICAL SPECIFICATIONS .. 13
MOUNTING HOLE PATTERN ..... 13
SHAFT SIZE/TYPE ...................... 13
TROUBLESHOOTING ......................17
GENERATOR PARTS LIST ......... 19
ASSEMBLY DIAGRAM ................ 20
ENGINE PARTS LIST .................. 21
ENGINE DIAGRAM ...................... 22
MOTOR FACE HOLE LAYOUT
DIAGRAM .................................. 23
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 24
EMISSION CONTROL SYSTEM
WARRANTY .............................. 24
SERVICING .................................. 13
MAINTENANCE PROCEDURES ..... 14
ENGINE OIL CHANGE ...............14
AIR FILTER ELEMENT
MAINTENANCE .......................14
SPARK PLUG MAINTENANCE .. 14
Page 2SKU 97906 For technical questions, please call 1-800-444-3353.
Page 3
SAVE THIS MANUAL
Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning
procedures. Write the product’s serial
number in the back of the manual near the
assembly diagram (or month and year of
purchase if product has no number). Keep
this manual and the receipt in a safe and
dry place for future reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
WARNING! Read all instructions.
Failure to follow all instructions
listed below may result in re,
serious injury and/or DEATH.
The warnings and precautions
discussed in this manual cannot
cover all possible conditions and
situations that may occur. It must
be understood by the operator that
common sense and caution are
factors which cannot be built into
this product, but must be supplied
by the operator.
SAVE THESE INSTRUCTIONS
SET UP PRECAUTIONS
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
Gasoline fuel and fumes are amma-1.
ble, and potentially explosive. Use
proper fuel storage and handling procedures. Do not store fuel or other
ammable materials nearby.
Have multiple ABC class re extin-2.
guishers nearby.
Operation of this equipment may cre-3.
ate sparks that can start res around
dry vegetation.
A spark arrestor may be required.
The operator should contact local re
agencies for laws or regulations relat-
ing to re prevention requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.
Page 3SKU 97906 For technical questions, please call 1-800-444-3353.
Page 4
Wear ANSI-approved safety goggles, 5.
heavy-duty work gloves, and dust
mask/respirator during set up.
Use only oil and fuel recommended 6.
in the “Specications” section of this
manual.
People with pacemakers should 5.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to a heart pacemaker could
cause pacemaker interference or
pacemaker failure. Caution is necessary when near the engine’s magneto
or recoil starter.
OPERATING PRECAUTIONS
1. CARBON MONOXIDE
HAZARD
Using an engine indoors
CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon
monoxide. This is a poison you
cannot see or smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are
open.
Use only accessories that are recom-6.
mended by Harbor Freight Tools for
your model. Accessories that may be
suitable for one piece of equipment
may become hazardous when used
on another piece of equipment.
Do not operate in explosive atmo-7.
spheres, such as in the presence of
ammable liquids, gases, or dust.
Gasoline-powered engines may ignite
the dust or fumes.
Stay alert, watch what you are doing 8.
and use common sense when operating this piece of equipment. Do not
use this piece of equipment while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper foot-9.
ing and balance at all times. This enables better control of the equipment
in unexpected situations.
Only use OUTSIDE and far away
from windows, doors, and vents.
Keep children away from the equip-2.
ment, especially while it is operating.
Do not leave the equipment unat-3.
tended when it is running. Turn off
the equipment (and remove safety
keys, if available) before leaving the
work area.
Wear ANSI-approved safety goggles 4.
and hearing protection during use.
Dress properly. Do not wear loose 10.
clothing or jewelry. Keep hair, clothing and gloves away from moving
parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
Parts, especially exhaust system 11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment 12.
during operation.
Page 4SKU 97906 For technical questions, please call 1-800-444-3353.
Page 5
Keep the equipment, engine, and sur-13.
rounding area clean at all times.
Use the equipment, accessories, etc., 14.
in accordance with these instructions
and in the manner intended for the
particular type of equipment, taking
into account the working conditions
and the work to be performed. Use
of the equipment for operations different from those intended could result
in a hazardous situation.
for a purpose for which it is not intended.
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its a.
“OFF” position.
Allow the engine to completely b.
cool.
Do not operate the equipment with 15.
known leaks in the engine’s fuel system.
This product contains or, when used, 16.
produces a chemical known to the
State of California to cause cancer
and birth defects or other reproductive harm. (California Health & Safety
Code § 25249.5, et seq.)
When spills of fuel or oil occur, they 17.
must be cleaned up immediately.
Dispose of uids and cleaning materials as per any local, state, or federal
codes and regulations. Store oil rags
in a bottom-ventilated, covered, metal
container.
Keep hands and feet away from 18.
moving parts. Do not reach over or
across equipment during operation.
Before use, check for misalignment 19.
or binding of moving parts, breakage
of parts, and any other condition that
may affect the equipment’s operation.
If damaged, have the equipment
serviced before using. Many ac-
cidents are caused by poorly maintained equipment.
Use the correct equipment for the 20.
application. Do not modify the equipment and do not use the equipment
Then, remove the spark plug c.
wire(s) from the spark plug(s).
Keep all safety guards in place and in 2.
proper working order. Safety guards
include mufer, air cleaner, mechanical guards, and heat shields, among
other guards.
Do not alter or adjust any part of 3.
the equipment or its engine that is
sealed by the manufacturer or dis-
tributor. Only a qualied service
technician may adjust parts that
may increase or decrease governed engine speed.
Wear ANSI-approved safety goggles, 4.
heavy-duty work gloves, and dust
mask/respirator during service.
Maintain labels and nameplates on 5.
the equipment. These carry important information. If unreadable or
missing, contact Harbor Freight Tools
for a replacement.
This Generator provides unregu-6.
lated power to the battery charging
outlet. Incorporating an inline regu-
lator is strongly recommended. The
charging process must be monitored
at all times. The battery charging
output must not be used to power any
other device or charge any other type
Page 5SKU 97906 For technical questions, please call 1-800-444-3353.
Page 6
of battery without a proper regulating
device.
Have the equipment serviced by a 7.
qualied repair person using only
identical replacement parts. This will
ensure that the safety of the equipment is maintained. Do not attempt
any service or maintenance procedures not explained in this manual
or any procedures that you are uncertain about your ability to perform
safely or correctly.
All connections from the Generator to 2.
a load must be installed by a licensed
electrician in compliance with all local, state, and federal electrical codes
and standards.
The generator must be grounded in 3.
accordance with all relevant electrical
codes and standards before operation.
Insulate all connections and discon-4.
nected wires.
Store equipment out of the reach of 8.
children.
Follow scheduled engine and equip-9.
ment maintenance.
Refueling Precautions:10.
Do not smoke, or allow sparks, a.
ames, or other sources of ignition
around the equipment, especially
when refuelling.
Do not rell the fuel tank while the b.
engine is running or hot.
Do not ll fuel tank to the top. Leave c.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.d.
GENERATOR PRECAUTIONS
Connect the generator only to a load 5.
or electrical system (120 volt or 240
volt) that is compatible with the electrical characteristics and rated capacities of the generator.
Set up the generator outdoors in a 6.
well-ventilated, dry area, away from
building air intakes. The generator should be protected from direct
exposure to rain and snow. Do not
set up the generator on a conductive
surface such as a metal deck.
This generator is not intended to 7.
power sensitive electronic equipment
without the addition of an appropriate
line conditioner
Before connecting generator’s wiring:8.
Turn the engine switch to its “OFF” a.
position.
Set up
Do not connect generator directly 1.
into a home’s electrical lines. Do
not plug a generator into an outlet in
the home. Connecting a generator
directly to a utility power supply can
‘back feed’ along the power lines and
kill or injure utility workers working on
the lines.
Allow the engine to completely cool.b.
Then, remove the spark plug Wire(s) c.
from the spark plug(s).
Operation
Do not attempt to connect or discon-1.
nect load connections while standing
in water or on wet ground.
Page 6SKU 97906 For technical questions, please call 1-800-444-3353.
Page 7
Do not touch electrically energized 2.
parts of the Generator and interconnecting cables or conductors with any
part of the body, or with any non-insulated conductive object.
Use only Class BC or Class ABC re 3.
extinguishers on electrical res.
Do not overload the generator. Over-4.
loading can cause res in the electrical cords, in addition to generator and
appliance damage.
Service
Keep all electrical equipment clean 1.
and dry. Replace any wiring where
the insulation is damaged. Replace
terminals that are worn or corroded.
Keep terminals clean and tight.
SAVE THESE
INSTRUCTIONS.
Page 7SKU 97906 For technical questions, please call 1-800-444-3353.
Page 8
BASIC SPECIFICATIONS
Fuel
Type
Capacity 1.05 Gallons
Type
Engine Oil
Capacity 0.42 Quarts
Horsepower 2.5 HP
Run Time @ 50% Load
Sound Level 65 dB
AC Output
DC Output 16.8V to 17.2V
Note: Additional specications found in
the TECHNICAL ENGINE SPECIFICATIONS chart in this manual.
The emission control system for this
engine is warranted for standards set by
the U.S. Environmental Protection Agency
and by the California Air Resources Board
(also known as CARB). For warranty
information, refer to the last pages of this
manual.
At high altitudes, the engine’s carburetor, governor (if so equipped), and any
other parts that control the fuel-air ratio will
need to be adjusted by a qualied mechanic to allow efcient high-altitude use
and to prevent damage to the engine and
any other devices used with this product.
89+ octane unleaded
gasoline
SAE 10W30
(above 32° F)
SAE 5W30
(at 32° F or below)
4 Hours, 20 Minutes
with full tank
(2) 120 V~, 60 hz
1,000 W Rated
1,050 W Peak
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
SET UP INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
STARTING:
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool, and disconnect the
spark plug wire(s) before
assembling or making any
adjustments to the equipment.
TO PREVENT
SERIOUS INJURY:
Operate only with proper
spark arrestor installed.
Operation of this equipment
may create sparks that
can start res around dry
vegetation.
A spark arrestor may be
required.
The operator should contact
local re agencies for laws
or regulations relating to re
prevention requirements.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Page 8SKU 97906 For technical questions, please call 1-800-444-3353.
Page 9
Location
The Generator must be installed 1.
outdoors where ventilation is readily
available.
tion must be completed by a licensed
contractor.
OPERATING INSTRUCTIONS
Install the Generator so that the air 2.
inlets and outlets are not blocked by
obstruc tions such as bushes, trees,
or snow drifts. Locating it in the path
of heavy winds or snowdrifts may
require the placement of a barrier for
protection. The air inlet should face
the prevailing wind direction.
Install the Generator on a concrete 3.
slab or other area where water can
not reach it.
Generator placement should allow 4.
four feet of access on all sides for
mainte nance.
Place the Generator as close as pos-5.
sible to the electrical tools and equipment be ing powered to reduce the
length of extension cords.
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Engine Controls
Grounding
Connect a #6 AWG grounding wire 1.
(not included) from the Grounding
Point (55a) on the Generator to a
grounding rod (not included) that has
been driven at least 24 inches into
the ground. The grounding rod must
be a copper or brass rod which can
adequately ground the Generator.
Only a trained and licensed electrician should perform this procedure.
Electrical and other permits may be 2.
required for the installation of emergency power systems. Investigate
local building and electrical codes
before installing this unit. Installa-
Choke
Control
Fuel Valve
(9a)
Spark Plug
Recoil
Start
Handle
Page 9SKU 97906 For technical questions, please call 1-800-444-3353.
Page 10
Power
Switch (52a)
Circuit
Protectors
DC (59a)
AC (53a)
Outlets
(54a)
Oil Drain
Plug
AC
Pilot
Lamp
(56a)
oil level should be between the high
and low marks on the dipstick.
If the oil level is below the low mark 3.
add the appropriate type of oil until
the oil level is between the high and
the low marks.
Oil type:
32° F or above = SAE 10W30
Below 32° F = SAE 5W30
Replace the Oil Dipstick.4.
CAUTION! Do not run the engine with too
little or too much oil. The engine will
be permanently damaged.
Checking and Filling Fuel
12V Battery
Charging
Socket (57a)
Dipstick
(48)
Voltmeter
(58a)
Grounding
Point (55a)
Starting the Engine
Inspect engine and equipment
looking for damaged, loose,
and missing parts before
set up and starting. If any
problems are found, do not use
equipment until xed properly.
Checking and Filling Engine Oil
CAUTION! Your Warranty is VOID if the
engine’s crankcase is not properly
lled with oil before each use. Before
each use, check the oil level. Do not
run the engine with low or no engine
oil. Running the engine with no or
low engine oil WILL permanently
damage the engine.
Remove the dipstick and wipe it off 1.
with a clean rag.
Reinsert the dipstick completely and 2.
remove it to check the oil level. The
Check the fuel level on the built-in 1.
fuel gauge (if available).
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-venti-
lated area away from ignition sources. Do not smoke.
To ll the Fuel Tank, rst wipe off the 2.
Fuel Tank Cap and the surrounding
area.
Unscrew, and remove the Fuel Tank 3.
Cap.
Mix fuel stabilizer (not included) with 4.
89 octane (or better) unleaded gasoline according to fuel stabilizer directions.
Fill the Fuel Tank to about 1 inch 5.
under the neck of the gasoline tank
with the stabilized unleaded gasoline
mixture.
Then replace the Fuel Tank Cap.6.
Page 10SKU 97906 For technical questions, please call 1-800-444-3353.
Page 11
Start Procedure
Before starting the engine:
Follow the Set Up Instruc-a.
tions to prepare the equipment.
Inspect the equipment and b.
engine.
Fill the engine with the prop-c.
er amount and type of fuel
and oil.
Read the Equipment Opera-d.
tion section that follows.
with no load after each start-up to allow the engine to stabilize.
Break-in Period
Breaking-in the engine will help to 1.
ensure proper equipment and engine
operation, and will extend the engine’s lifespan. The warranty is void
if the engine is not broken in properly.
The rst 20 hours of operation is the
break-in period.
During the rst 3 hours of use:2.
Unplug all loads from the Generator 1.
before starting to prevent permanent
damage to any appliances, tools, or
equipment.
Turn the engine fuel valve to its 2.
“OPEN” position.
Turn the engine power switch to its 3.
ON or RUN position.
Then, turn the engine choke lever to 4.
its “CHOKE” position. Set the choke
lever in the “RUN” position when
starting a warm engine.
Grasp the starter handle, and pull 5.
slowly until resistance is felt. While
holding the handle, allow the starter
rope to rewind slowly. Then, pull the
starter handle with a rapid, full arm
stroke. Once again while holding
the handle, allow the rope to rewind
slowly. Repeat as necessary, until
the engine starts.
After the engine starts and warms 6.
up, slowly move the choke lever to its
“RUN” position.
Do not apply a heavy load to the •
equipment.
Do not operate the engine at its •
maximum speed.
After the rst 20 hours of use:3.
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
schedule explained in the MAINTENANCE AND SERVICING section.
Equipment Operation
To Power 110/120 Volt AC Tools and
Equipment:
Prior to powering tools and equip-1.
ment, make sure the Generator’s
rated watt age capacity (1000 W) is
adequate to supply all electrical loads
that the unit will power. If powering
exceeds the Generator’s capacity, it
may be necessary to group one or
more of the tools and/or equipment
for connection to a separate Generator.
IMPORTANT: Allow the engine to run 7.
at no load until warm (1-5 minutes)
Start the Generator with no loads 2.
attached. Once the Generator is
running, connect the Power Cords
of 110/120 volt AC tools and equip-
Page 11SKU 97906 For technical questions, please call 1-800-444-3353.
Page 12
ment into the 110/120 volt AC Outlets
(54a). The Generator has an AC Circuit Protector (53a) to protect the unit
in case of an overload. If an overload
occurs, the Breaker will switch to its
“OFF” position and cause the Generator to shut down. Press the Circuit
Protector button (53a) to reset the
Generator.
battery to be charged rst; red clamp
to positive terminal (+), and black
clamp to negative terminal (-), then
plug the Battery Charging Cord into
the Battery Charging Socket (57a).
Do not leave a battery unattended 8.
while it is charging.
When nished using the Generator, 3.
turn the Power Switch (52a) to its
“OFF” position. Turn the Fuel Valves
(9a) to their “OFF” positions. Discon-
nect all electrical powered tools and
equipment from the Generator’s AC
Outlets.
To prevent accidents, turn off the 4.
engine and disconnect its spark plug
wire after use. Wait for the engine to
cool, clean external parts with clean
cloth, then store the equipment out
of children’s reach according to the
Storage instructions in this manual.
To Charge 12 V Lead-acid Type
Batteries:
Batteries contain
corrosive acid that
can cause severe injury;
always wear ANSI-approved
safety goggles and work
gloves when handling.
WARNING! To prevent serious injury to people or property
damage; do not charge a battery
higher than its maximum rated
charge. Over-charging a battery
can cause it to explode; spraying
the area with corrosive acid.
The Generator has a DC Circuit Pro-9.
tector (59a) to protect the unit in case
of an overload. If an overload occurs,
the Breaker will switch to its “OFF”
position and cause the Generator
to shut down. Press the DC Circuit
Protector button (59a) to reset the
Generator.
After the battery has been charged, 10.
disconnect the plug from the charg-
ing outlet rst, then disconnect the
clamps from the battery. Turn the
Power Switch and the Fuel Valves to
the “OFF” positions.
Installing an inline regulator is recom-5.
mended before charging.
Lead-acid batteries are hazardous. 6.
Follow all instructions, safety precautions, and charging procedures included with the battery.
Start the Generator with no loads 7.
attached. Connect the clamps on
the Battery Charging Cord (1a) to the
Page 12SKU 97906 For technical questions, please call 1-800-444-3353.
Page 13
TECHNICAL
SPECIFICATIONS
Engine Type 4 Stroke OHV
Bore x Stroke 52 x 38 mm
Compression Ratio 7.8:1
Displacement 79cc
Rotation viewed from PTO
(power takeoff - the output shaft)
Fuel
Engine Oil
Spark Plug
Valve
Clearance
Speed Maximum 3,600 RPM
Type
Capacity 1.05 Gallons
Type
Capacity 0.42 Quarts
Type
Gap 0.6 - 0.7mm
Intake 0.15mm
Exhaust 0.2mm
Counterclockwise
89+ octane unleaded
gasoline
SAE 10W30
(above 32° F)
SAE 5W30
(at 32° F or below)
E6TC
DENSO-W2OFP-U
SHAFT SIZE/TYPE
MOUNTING HOLE PATTERN
mm
mm
M8 size thread hole, 4/5” depth
SERVICING
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
STARTING:
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool, and disconnect the
spark plug wire(s) before
performing any inspection,
maintenance, or cleaning
procedures.
Page 13SKU 97906 For technical questions, please call 1-800-444-3353.
Page 14
TO PREVENT
SERIOUS INJURY
FROM EQUIPMENT FAILURE:
Do not use damaged
equipment. If abnormal noise,
vibration, or excess smoking
occurs, have the problem
corrected before further use.
Air Filter Element Maintenance
Wipe off the air cleaner cover.1.
The air cleaner cover is held in place 2.
by a wing nut or clamps. Remove it.
Remove the air lter element.3.
Cleaning:4.
Maintenance Procedures
Many maintenance procedures,
including those not detailed
in this manual, will need to
be performed by a qualied
technician for safety. If you
have any doubts about your
ability to safely service the
equipment or engine, have a
qualied technician service the
equipment instead.
Note: Warranty is void if proper mainte-
nance and servicing procedures are
not followed.
Engine Oil Change
CAUTION! Oil is very hot during opera-
tion and can cause burns. Wait for
engine to cool before changing oil.
Place a drain pan (not included) un-1.
derneath the crankcase’s drain plug.
For “paper” lter elements:
To prevent injury from dust and
debris, wear ANSI-approved safety
goggles, NIOSH-approved dust
mask/respirator, and heavy-duty
work gloves. In a well-ventilated
area away from bystanders, use
pressurized air to blow dust out
of the air lter from the side opposite the lter’s normal air ow (the
“clean” side of the lter).
If this does not get the lter reason-
ably clean, replace it.
For foam lter elements: a.
Wash the element in warm water
and mild detergent several times.
Rinse. Squeeze out excess water
and allow it to dry completely. Soak
the lter in lightweight oil briey, then
squeeze out the excess oil.
Install the new lter or the cleaned 5.
lter. Secure the Air Cleaner Cover
before use.
Remove the drain plug and, if pos-2.
sible, tilt the crankcase slightly to help
drain the oil out. Recycle used oil.
Replace the drain plug (and gasket, if 3.
supplied) and tighten it.
Rell the oil to the proper level follow-4.
ing the instructions under the Starting
the Engine section.
Spark Plug Maintenance
Disconnect spark plug wire from 1.
end of plug. Clean out debris from
around spark plug.
Using a spark plug wrench, remove 2.
the spark plug.
Inspect the spark plug: 3.
If the electrode is oily, clean it using a
clean, dry rag.
Page 14SKU 97906 For technical questions, please call 1-800-444-3353.
Page 15
If the electrode has deposits on it,
polish it using emery paper.
If the white insulator is cracked or
chipped, the spark plug needs to be
replaced.
Take note of the fuel lter’s orienta-4.
tion.
Place a suitable container under the 5.
fuel lter.
When installing a new spark plug, ad-4.
just the plug’s gap to the specication
on the Technical specication chart.
Do not pry against the electrode or
the insulator, the spark plug can be
damaged.
Install the new spark plug or the 5.
cleaned spark plug into the engine.
Gasket-style: Finger-tighten until the
gasket contacts the cylinder head,
then about 1/2-2/3 turn more.
Non-gasket-style: Finger-tighten until
the plug contacts the head, then
about 1/16 turn more.
Apply dielectric spark plug boot 6.
protector (not included) to the end of
the spark plug and reattach the wire
securely.
Disconnect the fuel lines leading to 6.
and from the fuel lter and allow fuel
to drain onto the container.
Install new fuel lter in the same 7.
orientation. Make sure to properly
secure both fuel lines.
Clean up and properly dispose of all 8.
fuel.
Wait for at least one hour before use 9.
to allow all residual fuel vapors to
dissipate. To prevent FIRE, do not
start the engine while the smell of
fuel hangs in the air. Remember to
open the fuel valve before restarting
the engine. It may take a little longer
than usual to start the engine be-
cause the fuel needs to rell the fuel
line and new lter.
Fuel Filter Replacement (if equipped)
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Replace the fuel lter in a
well-ventilated area away from ignition sources. Do not smoke.
Wait for engine to cool completely 1.
before proceeding.
Wear protective gear including, ANSI-2.
approved safety goggles, NIOSHapproved dust mask/respirator, and
nitrile gloves.
Close fuel valve leading from gas 3.
tank completely.
Cleaning, Maintenance, and
Lubrication Schedule
Note: This maintenance schedule is
intended solely as a general guide.
If performance decreases or if equipment operates unusually, check systems immediately. The maintenance
needs of each piece of equipment will
differ depending on factors such as
duty cycle, temperature, air quality,
fuel quality, and other factors.
Note: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular operation of the engine and equipment.
Page 15SKU 97906 For technical questions, please call 1-800-444-3353.
Page 16
After Initial 20 Operation Hour Period:
Change engine oil.a.
Every 25 Operation Hours Thereafter:
Clean/replace air lter element.a.
Inspect/clean spark plug.b.
Every 50 Operation Hours:
Change engine oil.a.
Replace fuel lter (if equipped).b.
Every 100 Operation Hours:
Replace spark plug.a.
Replace air lter element.b.
Note: All maintenance procedures sched-
uled for 25, 50, and 100 operation
hours should be performed at least
yearly.
the carburetor. Wait for engine to
cool before proceeding.
Clean out area around spark plug. c.
Remove spark plug and pour one
tablespoon of engine oil into cylinder
through spark plug hole.
Reinstall spark plug, but leave spark d.
plug wire disconnected.
Pull recoil starter to distribute oil in e.
cylinder. Stop after one or two revolutions when you feel the piston start
the compression stroke (when you
start to feel resistance).
Disconnect battery cables.f.
Apply a thin coat of rust preventive oil 3.
to all uncoated metal parts.
Cover and store in a dry, well-ventilat-4.
ed area out of reach of children.
Every 300 Operation Hours:
Clean fuel tank and carburetor.a.
Clean carbon build-up from combus-b.
tion chamber.
Storage
Wait for engine to cool, then clean 1.
engine with clean cloth.
When the equipment is to remain idle 2.
for longer than 20 days, prepare the
engine for storage as follows:
Change engine oil and empty fuel a.
tank.
Either leave fuel tank empty or b.
rell fuel tank with fresh unleaded
gasoline mixed with a fuel stabilizer
intended for long term engine stor-
age (not included). After lling, run
engine for about 5-10 minutes to circulate the treated gasoline through
Before starting the engine after stor-5.
age, keep in mind that untreated gasoline will deteriorate quickly. Drain
the fuel tank and lter, and change
to fresh fuel if untreated gasoline has
been sitting for a month, if treated
gasoline has been sitting beyond the
fuel stabilizer’s recommended time
period, or if the engine does not start
properly.
Page 16SKU 97906 For technical questions, please call 1-800-444-3353.
Page 17
Troubleshooting
Problem Possible Causes Probable Solutions
Engine will not
start
FUEL RELATED:
No fuel in tank or fuel valve closed.1.
Choke not in start position, 2.
especially with cold engine.
Low quality or deteriorated, old 3.
gasoline.
Carburetor not primed. 4.
Dirty fuel passageways blocking fuel 5.
ow.
Carburetor needle stuck. Fuel can 6.
be smelled in the air.
Too much fuel in chamber. This can 7.
be caused by the carburetor needle
sticking.
Clogged fuel lter8.
IGNITION (SPARK) RELATED:
Spark plug wire not connected 1.
securely.
Spark plug electrode wet or dirty.2.
Incorrect spark plug gap.3.
Spark plug wire or spark plug 4.
broken.
Incorrect spark timing or faulty 5.
ignition system.
COMPRESSION RELATED:
Cylinder not lubricated. Problem 1.
after long storage periods.
Loose or broken spark plug. 2.
(Hissing noise will occur when trying
to start.)
Loose cylinder head or damaged 3.
head gasket. (Hissing noise will
occur when trying to start.)
Engine valves or tappets 4.
misadjusted or stuck.
FUEL RELATED:
Fill fuel tank and open fuel valve.1.
Move choke to start position if 2.
engine is cold.
Use only fresh 89+ octane unleaded 3.
gasoline.
Prime carburetor by pressing 4.
priming bulb specied number of
times (if equipped).
Clean out passageways using 5.
fuel additive. Heavy deposits may
require further cleaning.
Gently6. tap side of carburetor oat
chamber with screwdriver handle.
Turn choke to run position. Remove 7.
spark plug and pull the start handle
several times to air out the chamber.
Reinstall spark plug and set choke
to start position.
Clean or replace fuel lter8.
IGNITION (SPARK) RELATED:
Connect spark plug wire properly. 1.
Clean spark plug.2.
Correct spark plug gap.3.
Replace spark plug wire and/or 4.
spark plug.
Have qualied technician diagnose/5.
repair ignition system.
COMPRESSION RELATED:
Pour tablespoon of oil into spark 1.
plug hole. Crank engine a few times
and try to start again.
Tighten spark plug. If that does not 2.
work, replace spark plug. If problem
persists, may have head gasket
problem, see #3.
Tighten head. If that does not 3.
remedy problem, replace head
gasket.
Adjust valve clearance. If that does 4.
not work, clean or replace valves/
tappets.
Follow all safety precautions whenever diagnosing or servicing the
equipment or engine.
Page 17SKU 97906 For technical questions, please call 1-800-444-3353.
Page 18
Troubleshooting
Problem Possible Causes Probable Solutions
Engine misres
Engine stops
suddenly
Engine knocks
Engine backres
Spark plug wire loose.1.
Incorrect spark plug gap or 2.
damaged spark plug.
Defective spark plug wire.3.
Old or low quality gasoline. 4.
Incorrect compression.5.
Low oil shutdown. 1.
Fuel tank empty or full of impure or 2.
low quality gasoline.
Defective fuel tank cap creating 3.
vacuum, preventing proper fuel ow.
Improper idle speed.4.
Faulty magneto, incorrect timing, or 5.
clogged carburetor.
Old or low quality gasoline. 1.
Engine overloaded. 2.
Incorrect spark timing, deposit 3.
buildup, worn engine, or other
mechanical problems.
Impure or low quality gasoline. 1.
Engine too cold. 2.
Choke not open after engine warm. 3.
Engine not properly adjusted for 4.
high altitude operation.
Intake valve stuck, choke stuck, 5.
incorrect timing, clogged carburetor,
or overheated engine.
Check wire connections.1.
Re-gap or replace spark plug. 2.
Replace spark plug wire.3.
Use only fresh 89+ octane unleaded 4.
gasoline.
Diagnose and repair compression. 5.
(Use Engine will not start:
COMPRESSION RELATED
section.)
Fill engine oil to proper level. Check 1.
engine oil before EVERY use.
Fill fuel tank with fresh 89+ octane 2.
unleaded gasoline.
Test/replace fuel tank cap. 3.
Properly adjust idle speed.4.
Have qualied technician diagnose 5.
and service engine.
Fill fuel tank with fresh 89+ octane 1.
unleaded gasoline.
Do not exceed equipment’s load 2.
rating.
Have qualied technician diagnose 3.
and service engine.
Fill fuel tank with fresh 89+ octane 1.
unleaded gasoline.
Use cold weather fuel and oil 2.
additives to prevent backring.
Move choke to run position after 3.
engine warms up.
Qualied technician must adjust 4.
engine at altitudes greater than
5,000 feet above sea level.
Have qualied technician diagnose 5.
and service engine.
Follow all safety precautions whenever diagnosing or servicing the
equipment or engine.
Page 18SKU 97906 For technical questions, please call 1-800-444-3353.
Page 19
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT
HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/
OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTS THERETO.
GENERATOR PARTS LIST
Part Description Qty
1a Battery Charging Cord (not
shown)
2a Fuel Tank Cap 1
3a Fuel Tank Filter 1
4a Flange Bolt M6x20 4
5a Gasket 4
6a Screw Gasket 4
7a Anti-Vibration Gasket 4
8a Fuel Tank 1
9a Fuel Valve 1
10a Fuel Pipe Clamp 2
11a Oil Pipe 1
12a Engine 1
13a Exhaust Pipe Gasket 1
14a Exhaust Pipe 1
15a Lock Nut M8 2
16a Flange Bolt M6x12 2
17a Mufer Gasket 1
18a Mufer 1
19a Flange Bolt M6x12 1
20a Front Cover 1
21a Gasket 4
22a Flange Bolt M8x20 4
23a Rotor Assembly 1
24a Stator Assembly 1
25a Wiring Cover 1
26a Rear Cover 1
27a Rectier 1
28a Gasket 4
29a Spring Gasket 4
1
GENERATOR PARTS LIST
Part Description Qty
30a Bolt 4
31a Gasket 1
32a Spring Gasket 1
33a Bolt M8x170 1
34a Magneto Cover 1
35a Gasket 2
36a Spring Gasket 2
37a Bolt M5x8 2
38a Lock Nut M8 6
39a Gasket 8
40a Spring Gasket 8
41a Bolt M8x40 8
42a Cushion 2
43a Frame 1
44a Anti-Vibration Feet 4
45a Flex Tube 1
46a Circuit Cover 1
47a Bolt M4x10 2
48a Capacitor 1
49a Bolt M4x10 1
50a Panel 1
51a Bolt M6x25 4
52a Power Switch 1
53a AC Circuit Protector 1
54a AC Outlet 2
55a Grounding Point 1
57a Battery Charging Socket 1
59a DC Circuit Protector 1
60a Rubber Gasket 1
61a Bracket for Capacitor 1
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts in both parts lists are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
REV 09b
Page 19SKU 97906 For technical questions, please call 1-800-444-3353.
Page 20
ASSEMBLY DIAGRAM
REV 09b
Page 20SKU 97906 For technical questions, please call 1-800-444-3353.
Page 21
ENGINE PARTS LIST
Part Description Qty
1 Flange Bolt M6x12 4
2 Head Cover 1
3 Apron Plate 1
4 Breather Tube 1
5 Head Cover Packing 1
6 Flange Bolt M8x55 2
7 Flange Bolt M8x55 2
8 Flange Bolt M6x16 2
9 Flange Bolt M6x16 2
10 Rocker Assembly 1
11 Exhaust Valve Spring Retainer 1
12 Intake Valve Spring Retainer 1
13 Valve Spring 2
14 Apron Plate 1
15 Push Rod 1
16 Push Rod 1
17 Cylinder Head 1
18 Carburetor Stud Bolt 2
19 Intake Pipe Gasket 1
20 Carburetor Insulating Plate 1
21 Carburetor Gasket 1
22 Carburetor 1
23 Carburetor Spacer 1
24 Air Filter Housing 1
25 Flange Nut M6 2
26 Apron Plate 1
27 Air Filter 1
28 Air Filter Cover 1
29 Air Filter Cover Bolts 2
30 Exhaust Pipe Stud Bolt 2
31 Mufer Gasket 1
32 Spark Plug 1
33 Mufer 1
34 Flange Nut M8 2
35 8x14 Dowel Pin 1
36 Exhaust Valve 1
37 Intake Valve 1
38 Piston Ring Set 1
39 Piston 1
40 Piston Pin 1
41 Piston Pin Clip 18mm 2
42 Connecting Rod Assembly 1
43 Connecting Rod Assembly 1
44 Connecting Rod Assembly 2
45 Cylinder Head Gasket 1
46 Oil Seal 1
47 Flange Bolt M8x25 6
48 Dipstick 1
49 Crankcase Cover 1
50 Ball Bearing 6303 1
51 8x14 Dowel Pin 2
52 Case Cover Packing 1
53 Camshaft 1
ENGINE PARTS LIST
Part Description Qty
54 Valve Lifter 2
55 Crankshaft 1
56 Key 1
57 Ball Bearing 6203 1
58 Shroud 1
59 Flange Bolt M6x12 1
60 Governor Gear 1
61 Rocker 1
62 8mm Lock Pin 1
63 Flange Bolt M6 2
64 Control Arm 1
65 Governor Spring 1
66 Control Assembly 2
67 Flange Bolt M6x8 2
68 Drain Bolt Plug 1
69 Drain Plug Washer 1
70 Crank Case 1
71 Ignition Coil 1
72 Flange Bolt M6x20 2
73 Crankcase Cover 1
74 Flywheel 1
75 Cooling Fan 1
76 Starter Pulley 1
77 Flywheel Nut M14x1.25 1
78 Flywheel Side Plate 1
79 Flange Bolt M6x12 4
80 Flywheel Side Plate 1
81 Fan Cover 1
82 Flange Bolt M6x12 4
83 Recoil Starter 1
84 Flange Bolt M6x10 3
85 Flange Bolt M6x12 2
86 Oil Level Switch 1
87 Amplier 1
88 Governor Rod 1
89 Throttle Return Spring 1
Page 21SKU 97906 For technical questions, please call 1-800-444-3353.
Page 22
ENGINE DIAGRAM
Page 22SKU 97906 For technical questions, please call 1-800-444-3353.
Page 23
LIMITED 1 YEAR / 90 DAY
WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products meet
high quality and durability standards, and
warrants to the original purchaser that
for a period of ninety days from date of
purchase that the engine/motor, the belts
(if so equipped), and the blades (if so
equipped) are free of defects in materials
and workmanship. Harbor Freight Tools
also warrants to the original purchaser,
for a period of one year from date of purchase, that all other parts and components
of the product are free from defects in materials and workmanship (90 days if used
by a professional contractor or if used as
rental equipment). This warranty does not
apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents,
repairs or alterations outside our facilities,
normal wear and tear, or to lack of maintenance. We shall in no event be liable for
death, injuries to persons or property, or
for incidental, contingent, special or consequential damages arising from the use
of our product. Some states do not allow
the exclusion or limitation of incidental or
consequential damages, so the above
limitation of exclusion may not apply to
you. THIS WARRANTY IS EXPRESSLY
IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING
THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty,
the product or part must be returned to us
with transportation charges prepaid. Proof
of purchase date and an explanation of the
complaint must accompany the merchan-
dise. If our inspection veries the defect,
we will either repair or replace the product
at our election or we may elect to refund
the purchase price if we cannot readily
and quickly provide you with a replacement. We will return repaired products at
our expense, but if we determine there is
no defect, or that the defect resulted from
causes not within the scope of our warranty, then you must bear the cost of returning
the product.
This warranty gives you specic legal
rights and you may also have other rights
which vary from state to state.
3491 Mission Oaks Blvd. • PO Box
6009 • Camarillo, CA 93011 • (800)
444-3353
EMISSION CONTROL
SYSTEM WARRANTY
California and United States Emission Control
Defects Warranty Statement
The California Air Resources Board (herein CARB), the United
States Environmental Protection Agency (herein EPA), and Harbor
Freight Tools (herein HFT) are pleased to explain the emission control system warranty on your 1995 and later Small Off-Road Engine
(herein engine). In California, the engine must be designed, built
and equipped to meet the State’s stringent anti-smog standards.
Elsewhere within the United States, new off-road, spark-ignition
engines certied for model year 1997 and later, must meet similar
standards set forth by the EPA. HFT must warrant the emission
control system on your engine for the periods of time described
below, provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the
carburetor or fuel-injection system, and the ignition system. Also
included may be hoses, belts, connectors and other emissionrelated assemblies.
Where a warrantable condition exists, HFT will repair your
engine at no cost to you including diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
The 1995 and later engines are warranted for two (2) years.
If any emission-related part on your engine is defective, the part
will be repaired or replaced by HFT.
Harbor Freight Tools Emission Control Defects
Warranty Coverage
Engines are warranted for a period of two (2) years relative to
emission control parts defects, subject to the provisions set forth
below. If any emission related part on your engine is defective, the
part will be repaired or replaced by HFT.
Page 23SKU 97906 For technical questions, please call 1-800-444-3353.
Page 24
Owner’s Warranty Responsibilities
As the engine owner, you are responsible for the performance •
of the required maintenance listed in your Owner’s Manual.
HFT recommends that you retain all receipts covering maintenance on your engine, but HFT cannot deny warranty
solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance.
As the engine owner, you should, however, be aware that •
HFT may deny you warranty coverage if your engine or a part
has failed due to abuse, neglect, improper maintenance, or
unapproved modications.
You are responsible for shipping your engine to a HFT war-•
ranty station as soon as a problem exists. Contact the HFT
Customer Service department at the number below to make
shipping arrangements. The warranty repairs should be
completed in a reasonable amount of time, not to exceed
30 days.
If you have any questions regarding your warranty rights
and responsibilities, you should contact the Harbor Freight Tools
Customer Service Department at 1-800-444-3353.
Harbor Freight Tools Emission Control Defects
Warranty Provisions
Length of Coverage1.
HFT warrants to a rst retail purchaser and each subsequent
purchaser that the engine is free from defects in materials
and workmanship that cause the failure of warranted parts
for a period of two (2) years after the date of delivery to the
rst retail purchaser.
No Charge Repair or Replacement2.
Repair or replacement of any warranted part will be performed
at no charge to the owner if the work is performed through a
warranty station authorized by HFT. For emissions warranty
service, contact the HFT Customer Service Department at
1-800-444-3353.
Consequential Damages Coverage3.
Coverage under this warranty shall also extend to the failure
of any engine components caused by the failure of any war-
ranted part while it is still covered under this warranty.
Coverage Exclusions4.
Warranty claims shall be led in accordance with the provi-
sions of the HFT warranty policy explained in the box at the
top of the previous page. HFT shall not be liable for any loss
of use of the engine, for any alternative usage, for any damage
to goods, loss of time, or inconvenience. Warranty coverage
shall also be excluded for any part which fails, malfunctions,
or is damaged due to failure to follow the maintenance and
operating instructions set forth in the Owner’s Manual includ-
ing, but not limited to:
Use of parts which are not authorized by HFTa)
Improper installation, adjustment or repair of the engine b)
or of any warranted part unless performed by an authorized warranty center
Failure to follow recommendations on fuel use contained c)
in the Owner’s Manual
Improper or inadequate maintenance of any warranted d)
parts
Repairs performed outside of the authorized warranty e)
service dealers
Alterations by changing, adding to or removing parts f)
from the engine.
Service and Maintenance5.
Component parts which are not scheduled for replacement
as required maintenance or are scheduled only for regular
inspection to the effect of “repair or replace as necessary”
are warranted for the warranty period. Any warranted part
which is scheduled for replacement as required maintenance
is warranted for the period of time up to the rst scheduled
replacement point for that part. Any replacement part, provided it is equivalent in durability and performance, may be
used in performance of maintenance or repairs. The owner
is responsible for commissioning a qualied technician/mechanic to perform all required maintenance, as outlined in
the Inspection, Cleaning, and Maintenance section in this
manual.
Warranted Parts6.
Fuel Metering System1)
Carburetor and its internal parts.i)
Fuel pump (if so equipped).ii)
Cold start enrichment system.iii)
Air Induction System2)
Intake pipe/manifold.i)
Air cleaner.ii)
Ignition System3)
Spark plug.i)
Magneto ignition system.ii)
Catalyst System (if so equipped)4)
Exhaust pipe stud.i)
Mufer.ii)
Catalytic converter (if so equipped).iii)
Miscellaneous Items Used in Above Systems5)
Vacuum, temperature and time sensitive valves i)
and switches.
Hoses, belts, connectors, and assemblies.ii)
Page 24SKU 97906 For technical questions, please call 1-800-444-3353.
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