Page 1
Model
97079
PORTABLE GAS GENERATOR
1400/1600 WATT
SET UP, OPERATING, AND SERVICING
INSTRUCTIONS
DANGER
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 PRECAUTIONS .............................................................................................. 4
OPERATING PRECAUTIONS ...................................................................................... 4
SERVICE PRECAUTIONS ............................................................................................ 6
GENERATOR PRECAUTIONS ..................................................................................... 7
BASIC SPECIFICATIONS ............................................................................................. 8
UNPACKING ................................................................................................................. 8
SET UP INSTRUCTIONS .............................................................................................. 8
OPERATING INSTRUCTIONS ...................................................................................... 9
EQUIPMENT OPERATION .......................................................................................... 12
TECHNICAL SPECIFICATIONS .................................................................................. 12
SERVICING .................................................................................................................. 12
STORAGE .....................................................................................................................14
TROUBLESHOOTING ................................................................................................. 15
PARTS LIST ................................................................................................................. 17
ASSEMBLY DIAGRAM ................................................................................................ 20
WARRANTY INFORMATION ....................................................................................... 22
SKU 97079 For technical questions, please call 1-800-444-3353 Page 2
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
CAUTION
Safety warnings continue on next page.
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
DANGER indicates
DANGER
situation which, if not
avoided, will result in death or
serious injury.
WARNING
WARNING
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
CAUTION
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
a hazardous
indicates a
with the safety
Page 3SKU 97079 For technical questions, please call 1-800-444-3353.
Page 4
SET UP PRECAUTIONS
OPERATING PRECAUTIONS
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.
This equipment may not have a spark 3.
arresting mufer included. A spark
arresting mufer is required by law in
California, on some US Forest Service land, and possibly in other areas
or situations. Install an approved
spark arrestor before use if legally required or if engine is to be used near
grass, brush, forests, crops, or any
other ammable materials.
Set up and use only on a at, level, 4.
well-ventilated surface.
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.
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.
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.
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 neces-
Page 4SKU 97079 For technical questions, please call 1-800-444-3353.
Page 5
sary when near the engine’s magneto
or recoil starter.
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.
Use the equipment, accessories, etc., 15.
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.
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 a piece of equipment. Do not use
a 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.
Use this equipment with both hands 10.
only. Using equipment with only
one hand can easily result in loss of
control.
Dress properly. Do not wear loose 11.
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 12.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment 13.
during operation.
Keep the equipment, its engine, and 14.
surrounding area clean at all times.
Do not operate the equipment with 16.
known leaks in the engine’s fuel system.
This product contains or, when used, 17.
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 18.
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 mov-19.
ing parts.
Before use, check for misalignment 20.
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 21.
application. Do not modify the equipment and do not use the equipment
for a purpose for which it is not intended.
Page 5SKU 97079 For technical questions, please call 1-800-444-3353.
Page 6
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its a.
“OFF” position.
Allow the engine to completely b.
cool.
Then, remove the spark plug c.
wire(s) from the spark plug(s).
Store equipment out of the reach of 7.
children.
Follow scheduled engine and equip-8.
ment maintenance.
Refueling:
Do not smoke, or allow sparks, 1.
ames, or other sources of ignition
around the equipment, especially
when refuelling.
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.
Do not rell the fuel tank while the 2.
engine is running or hot.
Do not ll fuel tank to the top. Leave 3.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.4.
SAVE THESE
INSTRUCTIONS.
Have the equipment serviced by a 6.
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.
Page 6SKU 97079 For technical questions, please call 1-800-444-3353.
Page 7
GENERATOR PRECAUTIONS
Set up
Do not connect generator directly into 1.
a home’s utility electrical line. 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.
All connections and conduits from 2.
the Generator to the load must only
be installed by trained and licensed
electricians, and in compliance with
all relevant local, state, and federal
electrical codes and standards, and
other regulations where applicable.
The generator must be earth-ground-3.
ed in accordance with all relevant
electrical codes and standards before
operation.
Insulate all connections and discon-4.
nected wires.
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.
Allow the engine to completely b.
cool.
Then, remove the spark plug c.
Wire(s) from the spark plug(s).
Operation
Do not attempt to connect or discon-1.
nect load connections while standing
in water, or on wet or soggy ground.
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 cracked, cut, abraded, or otherwise degraded. Replace
terminals that are worn, discolored, or
corroded. Keep terminals clean and
tight.
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.
Before connecting generator’s wir-7.
ing:
Turn the engine switch to its a.
“OFF” position.
Page 7SKU 97079 For technical questions, please call 1-800-444-3353.
Page 8
BASIC SPECIFICATIONS
Fuel
Type
Capacity 1.98 Gallons
Type
Engine Oil
Capacity 20 Ounces
Run Time @ 50% Load 7.5 Hours with full tank
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 30W
(above 32° F)
SAE 5W-30
(at 32° F or below)
manual including all text under
subheadings therein before set
up or use of this product.
Risk of accidental
WARNING
starting; resulting
in serious personal injury.
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool, and unplug the spark
plug wire(s) before
assembling or making any
adjustments to the equipment.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Assembly
Prior to use, the Handle (194) must 1.
be attached to the top of the Fuel
Tank (193). To do so, insert the two
mounting holes at the ends of the
Handle onto the two threaded Bolts
at the ends of the Fuel Tank. Secure
the Handle to the Fuel Tank, using
two Nuts (195). (See Figure A.)
NUT (195)
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
NUT (195)
BOLT
FIGURE A
BOLT
FUEL TANK (193)
2. Prior to each use, the Generator must
be properly grounded at its Earth
Terminal Set (142). CAUTION! A
licensed electrician only should
Page 8SKU 97079 For technical questions, please call 1-800-444-3353.
Page 9
attempt to perform this procedure.
(See Figure B.)
FIGURE B
EARTH TERMINAL SET
(142)
OPERATING 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.
Engine Controls
3. A spark arresting mufer is required
by law in California, on some US
Forest Service land, and possibly in
other areas or situations. Install an
approved spark arrestor before use
if legally required or if engine is to
be used near grass, brush, forests,
crops, or any other ammable materials.
FUEL lEVER (192)
FIGURE C
CHOKE SWITCH (47)
FIGURE D
Page 9SKU 97079 For technical questions, please call 1-800-444-3353.
Page 10
FIGURE E
problems are found, do not use
equipment until xed properly.
Checking Engine Oil Level
PULLING HANDLE (174)
12 VDC
IGNITION
SWITCH
(145)
CIRCUIT
BREAKER
FIGURE F
OUTLETS
12 VDC
OUTLET
(143)
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.
(See Figure G.)
FIGURE G
120 VAC
(141)
120 VAC
CIRCUIT
BREAKER
EARTH
TERMINAL
SET
(142)
Starting the Engine
Inspect engine and equipment
looking for damaged, loose,
and missing parts before
set up and starting. If any
DIPSTICK (121)
2. Reinsert the dipstick completely and
remove it to check the oil level. The
oil level should be between the high
and low marks on the Dipstick (121).
(See Figure G.)
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
low marks.
Page 10SKU 97079 For technical questions, please call 1-800-444-3353.
Page 11
Break-in Period
Oil Type:
32° F or above = SAE 30W
Below 32° F = SAE 5W-30.
Then, turn the engine Choke Switch 3.
(47) to its “CHOKE” position. Set the
Choke Switch in the “RUN” position
when starting a warm engine.
(See Figure D.)
Replace the Oil Dipstick (121).4.
CAUTION! Do not run the engine with too
little or too much oil. The engine will
be permanently damaged.
Checking Fuel Level
WARNING! To prevent re,
shut the engine off and wait
for it to cool before adding
fuel. Do not smoke.
To ll the Fuel Tank, unscrew and re-1.
move the Fuel Tank Cap (196).
Fill the Fuel Tank to about 1 inch 2.
below the ller neck with unleaded
gasoline.
Then replace the Fuel Tank Cap 3.
(196).
While holding the engine down rmly 4.
with one hand, grasp the Pulling
Handle (174), and pull slowly until
resistance is felt. While holding the
Handle, allow the Starter Rope to
rewind slowly. Then, pull the Pulling
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.
(See Figure E.)
Once the Engine warms up, slowly 5.
move the Choke Switch (47) to its
“RUN” position. (See Figure D.)
IMPORTANT: 6. Allow the Engine to run
at no load for ve minutes after each
start-up so that the Engine can stabilize.
Start Procedure
Before starting the engine:
Follow the Set Up Instructions a.
to prepare the equipment.
Inspect the equipment and b.
engine.
Fill the engine with the proper c.
amount and type of both fuel
and oil.
Read the Equipment Opera-d.
tion section that follows.
Turn the engine Fuel Lever (192) to its 1.
“OPEN” position. (See Figure C.)
Turn the engine Ignition Switch (145) 2.
to its ON or RUN position.
(See Figure F.)
Break-In Period
Breaking-in the engine will help to 1.
ensure extended engine life.
The operational break-in period will 2.
last about 3 hours of use. During this
period:
Do not apply a heavy load to the •
equipment.
Do not operate the engine at its •
maximum speed.
The break-in period will last about 20 3.
hours of use. After this period:
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
Page 11SKU 97079 For technical questions, please call 1-800-444-3353.
Page 12
schedule explained in the MAINTENANCE AND SERVICING section.
Equipment Operation
To power 120 VAC tools and applianc-1.
es, plug its Power Cord(s) into one or
both of the 120 VAC Outlets (141) of
the Generator. When nished using
the tool(s)/appliance(s), disconnect
the Power Cord(s) from the 120 VAC
Outlet(s). (See Figure F.)
To power a 12 VDC tool or appliance, 2.
plug its Power Cord into the 12 VDC
Outlet (143) of the Generator. When
nished using the tool/appliance, disconnect the Power Cord from the 12
VDC Outlet. (See Figure F.)
NOTE: 3. This Generator is equipped
with a 120 VAC Circuit Breaker (144)
and a 12 VDC Circuit Breaker (144).
In the event of a circuit overload, the
Generator will automatically shut off
electrical power to the appropriate
Outlet (141, 143). In this case, turn
off the Ignition Switch (145). Wait
approximately ve minutes. Press
the appropriate Circuit Breaker. Then
restart the Engine. (See Figure F.)
To prevent accidents, turn off the En-4.
gine and remove its Spark Plug Cap
(157) 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.
TECHNICAL SPECIFICATIONS
4 HP
4 Stroke OHV
Engine Type
Displacement 118cc
Engine Family 7CLGS.1191CF
Generator Output
Spark Plug Type/Gap
Continuous Run Time
at 50% Load
Low Oil Shutdown
Capability
Fuel
Engine Oil
Receptacles
Overload Protection
Type
Capacity 1.98 Gallons
Type
Capacity 20 Ounces
Single Cylinder
Air Cooled
Recoil Start
Rated: 1400 Watts
Maximum: 1600 Watts
®
NGK
6RTCU
0.028” to 0.031”
7.5 Hrs.
Yes
89+ octane unleaded
gasoline
SAE 30W
(above 32° F)
SAE 5W-30
(at 32° F or below)
120 VAC (Qty. 2)
12 VDC (Qty. 1)
15 Amp Circuit
Breakers (Qty. 2)
SERVICING
WARNING
Risk of serious
personal injury
from accidental starting. Turn
the Ignition Switch (145) of the
Generator to its “OFF”
position, wait for the engine to
cool, and remove the Spark
Plug Cap (157) before
performing any inspection,
maintenance, or cleaning
procedures.
Damaged equipment can fail,
causing serious personal
injury. Do not use damaged
equipment. If abnormal noise,
REV 09f
Page 12SKU 97079 For technical questions, please call 1-800-444-3353.
Page 13
vibration, or excess smoking
occurs, have the problem
corrected before further use.
Maintenance Procedures
Many maintenance procedures,
including any 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.
Cleaning:3.
Wash the Air Filter Element (69) in
warm water and mild detergent several times. Rinse. Squeeze out excess water and allow it to dry completely. Soak the Filter in lightweight
oil, then squeeze out the excess oil.
(See Assy. Diagram.)
Install the clean Air Filter Element 4.
(69). Secure the Air Cleaner Cover
(71) with the two Bolts (72) and two
Nuts (73) before use.
(See Assy. Diagram.)
Spark Plug Maintenance
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
(77). (See Assy. Diagram.)
Remove the Drain Plug (77) and, if 2.
possible, tilt the Crankcase slightly to
help drain the oil out. Recycle used
oil.
Replace the Drain Plug (77) and 3.
tighten it.
Rell the oil to the proper level follow-4.
ing the instructions under the “Start-
ing the Engine” section.
Air Filter Element Maintenance
Remove the two Bolts (72) and two 1.
Nuts (73) that secure the Air Cleaner
Cover (71) in place.
(See Assy. Diagram.)
Remove the Air Filter Element (69). 2.
(See Assy. Diagram.)
Remove Spark Plug Cap (157) from 1.
end of Spark Plug (26). Clean out
debris from around Spark Plug. (See
Assy. Diagram.)
Using a spark plug wrench, remove 2.
the Spark Plug (26).
(See Assy. Diagram.)
Inspect the Spark Plug (26): 3.
If the electrode is oily, clean it using a
clean, dry rag.
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. (See Assy. Diagram.)
When installing a cleaned or new 4.
Spark Plug (26), adjust the Plug’s
gap to the specication on the “Tech-
nical Specication” chart. Do not pry
against the electrode, the Spark Plug
can be damaged.
Install the cleaned or new Spark Plug 5.
(26) into the engine. Finger-tighten
until the gasket of the Plug contacts
the cylinder head, then tighten about
1/2-2/3 turns more.
Page 13SKU 97079 For technical questions, please call 1-800-444-3353.
Page 14
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.
After 20 Operation Hour Break-in
Period:
Change engine oil.a.
After Every 25 Operation Hours:
Clean/replace Air Filter Element a.
(69).
Inspect/clean Spark Plug (26).b.
After Every 50 Operation Hours:
Change engine oil.a.
After Every 100 Operation Hours:
Replace Spark Plug (26).a.
Replace Air Filter Element (69).b.
Note: All maintenance procedures sched-
uled for 25, 50, and 100 operation
hours should be performed at least
yearly.
After Every 300 Operation Hours:
Clean Fuel Tank (193) and Carbu-a.
retor assembly.
Clean carbon build-up from com-b.
bustion 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 (193).
Either leave Fuel Tank (193) empty b.
or rell Fuel Tank with fresh unleaded gasoline mixed with a fuel
stabilizer intended for long term
engine storage (not included).
After lling, run Engine for about 5-
10 minutes to circulate the treated
gasoline through the Carburetor.
Wait for engine to cool before proceeding.
Clean out area around Spark Plug c.
(26). Remove Spark Plug and
pour one tablespoon of engine oil
into cylinder through Spark Plug
hole.
Replace Spark Plug (26), but leave d.
Spark Plug Cap (157) disconnected.
Pull the Pulling Handle (174) to e.
distribute oil in cylinder. Stop after
one or two revolutions when you
feel the piston start the compression stroke (when you start to feel
resistance).
Apply a thin coat of rust preventive oil 3.
to all metal parts.
Cover and store in a dry, well-venti-4.
lated area out of reach of children.
Before starting the engine after stor-5.
age, keep in mind that untreated
gasoline will deteriorate quickly.
Drain the Fuel Tank (193) and change
Page 14SKU 97079 For technical questions, please call 1-800-444-3353.
Page 15
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.
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 (especially with 2.
cold engine).
Low quality or deteriorated, old gasoline.3.
Carburetor not primed.4.
Dirty fuel passageways blocking fuel ow.5.
Carburetor needle stuck. Fuel can be 6.
smelled in the air.
Too much fuel in chamber. This can be 7.
caused by the carburetor needle sticking.
IGNITION (SPARK) RELATED:
Spark plug wire not connected securely.1.
Spark plug electrode wet or dirty.2.
Incorrect spark plug gap.3.
Spark plug wire broken.4.
Incorrect spark timing or faulty ignition 5.
system.
COMPRESSION RELATED:
Cylinder not lubricated. Problem after long 1.
storage periods.
Loose or broken spark plug. (Hissing noise 2.
will occur when trying to start.)
Loose cylinder head or damaged head 3.
gasket. (Hissing noise will occur when
trying to start.)
Engine valves or tappets misadjusted or 4.
stuck.
Engine misres Spark plug wire loose.1.
Incorrect spark plug gap or damaged spark 2.
plug.
Defective spark plug wire.3.
Old or low quality gasoline.4.
Incorrect compression.5.
Incorrect Timing6.
FUEL RELATED:
Fill fuel tank and open fuel valve.1.
Move choke to start position if engine is 2.
cold.
Use only fresh 89+ octane unleaded 3.
gasoline.
Prime carburetor by pressing priming bulb 4.
specied number of times (if equipped).
Clean out passageways using fuel additive. 5.
Heavy deposits may require further cleaning.
Gently6. tap side of carburetor oat chamber
with screwdriver handle.
Turn choke to run position. Remove spark 7.
plug and pull the start handle several times
to air out the chamber. Reinstall spark plug
and set choke to start position.
IGNITION (SPARK) RELATED:
Connect spark plug wire properly.1.
Clean spark plug.2.
Correct spark plug gap.3.
Replace spark plug wire.4.
Have qualied technician diagnose/repair 5.
ignition system.
COMPRESSION RELATED:
Pour tablespoon of oil into spark plug hole. 1.
Crank engine a few times and try to start
again.
Tighten spark plug. If that does not work, 2.
replace spark plug. If problem persists, may
have head gasket problem, see #3.
Tighten head. If that does not remedy 3.
problem, replace head gasket.
Adjust valve clearance. If that does not 4.
work, clean or replace valves/tappets.
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. (Use 5.
Engine will not start: COMPRESSION
RELATED section.)
Adjust timing.6.
Page 15SKU 97079 For technical questions, please call 1-800-444-3353.
Page 16
Engine stops suddenly Low oil shutdown.1.
Fuel tank empty or full of impure or low 2.
quality gasoline.
Defective fuel tank cap creating vacuum, 3.
preventing proper fuel ow.
Faulty magneto.4.
Engine knocks Old or low quality gasoline.1.
Engine overloaded.2.
Incorrect spark timing, deposit buildup, worn 3.
engine, or other mechanical problems.
Engine backres Impure or low quality gasoline.1.
Engine too cold.2.
Intake valve stuck or overheated engine.3.
Fill engine oil to proper level. Check engine 1.
oil before EVERY use.
Fill fuel tank with fresh 89+ octane unleaded 2.
gasoline.
Test/replace fuel tank cap.3.
Have qualied technician service magneto.4.
Fill fuel tank with fresh 89+ octane unleaded 1.
gasoline.
Do not exceed equipment’s load rating.2.
Have qualied technician diagnose and 3.
service engine.
Fill fuel tank with fresh 89+ octane unleaded 1.
gasoline.
Use cold weather fuel and oil additives to 2.
prevent backring.
Have qualied technician diagnose and 3.
service engine.
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.
Page 16SKU 97079 For technical questions, please call 1-800-444-3353.
Page 17
PARTS LIST
Part # Description Qty.
1 Mufer Vent Panel 1
2 Bolt M6×12 13
3 Cylinder head cover
Assy
4 Gasket, cylinder head
cover
5 Air duct 1
6 Pusher 2
7 Lock nut 2
8 Sleeve 2
9 Valve rocker 2
10 Adjusting bolt for valve
gap
11 Valve rocker assy 2
12 Pusher guide 1
13 Bolt M8×55 4
14 Intake valve guide 1
15 Exhaust valve guide 1
16 Circip 2
17 Valve spring 2
18 Spring seat, intake valve 1
19 Spring seat, exhaust
valve
20 Cap 1
21 Stud M8×34 2
22 Exhaust gasket 1
23 Mufer 1
24 Nut M8 2
25 Heat insulation 1
26 Spark plug 6RTCU 1
27 Support panel assy 1
28 Nut M6 1
29 Regulating part 1
30 Lock bolt 1
31 Back spring 1
32 Fine regulating tab 1
1
1
2
1
Part # Description Qty.
33 Pulling rod 1
34 Regulating spring 1
35 Lock bolt 1
36 Regulating control sys-
tem
37 Set pinφ10×16 2
38 Exhaust valve 1
39 Intake valve 1
40 Gasket, cylinder head 1
41 Cylinder head Assy 1
42 Lead wind cover 1
43 Stud M6×113 2
44 Inlet gasket 1
45 Connecting block 1
46 Carburetor gasket 1
47 Choke switch 1
48 Throttle unit 1
49 Spring, mixture adjust-
ment screw
50 Mixture adjustment
screw
51 Idle adjustment screw 1
52 Choke stem 1
53 Choke 1
54 Choke unit 1
55 Mixture chamber body 1
56 Main nozzle 1
57 Float needle 1
58 Main jet 1
59 Float 1
60 Float chamber gasket 1
61 Float chamber 1
62 Float chamber drain
Screw
63 Washer 2
64 Float chamber 1
1
1
1
1
Page 17SKU 97079 For technical questions, please call 1-800-444-3353.
Page 18
Part # Description Qty.
65 Screw 1
66 Carburetor assy. 1
67 Air cleaner gasket 1
68 Air cleaner housing 1
69 Filter element 1
70 Filter Support 1
71 Air cleaner cover 1
72 Bolt 2
73 Nut M6 2
74 Bolt M6×30 3
75 Set pinφ8.7×φ6.2×19 2
76 Support panel 1
77 Drain plug 2
78 Washer 2
79 Bearing 62/22 1
80 Oil seal, crankshaft 1
81 Crankcase 1
82 Regulating sway bar 1
83 Washer 1
84 Split pin 1
85 Regulating shaft 1
86 Snap ring 1
87 Washer, driven gear 1
88 Driven gear, regulator 1
89 Pin 2
90 Flying block 2
91 Driven gear, regulator
1
assy
92 Washer 1
93 Sliding sleeve 1
94 Extension spring 1
95 Camshaft Assy 1
96 Tappet 2
97 Woodruff key 1
98 Drive gear
99 Crankshaft 1
100 Timing driving gear 1
Part # Description Qty.
101 Crankshaf assy. 1
102 Shank 1
103 Connecting rod cover 1
104 Bolt 2
105 Connecting rod 1
106 Piston pin circlip 2
107 Piston 1
108 Piston pin 1
109 Piston ring (Ⅰ) 1
110 Piston ring (Ⅰ) 1
111 Side rail 2
112 Expander 1
113 Scraper ring set 1
114 Piston ring set 1
115 Gasket, crankcase 1
116 Bearing 62/22 1
117 Set pin 2
118 Crankcase cover 1
119 Oil seal, crankshaft 1
120 Seal 1
121 Dipstick 1
122 Dipstick with seal 1
123 Bolt M6×28 7
124 Washer 1
125 Right cover, generator 1
126 Rotor Assy 1
127 Bearing 6204-2ZN 1
128 Stator Assy 1
129 Washer 1
130 Generator support panel 1
131 Nut M6 4
132 Bottom rubber 4
133 Bolt M6×25 4
134 Stay, generator 1
135 Washer 6mm 1
136 Bolt, M10×26 4
137 Bolt, M10×265 1
Page 18SKU 97079 For technical questions, please call 1-800-444-3353.
Page 19
Part # Description Qty.
138 Brush Assy 1
139 Bolt 3
140 Voltage regulator 1
141 120 VAC Outlet 1
142 Earth terminal set 1
143 12 VDC Outlet 1
144 Circuit Breaker 1
145 Ignition switch 1
146 Control panel case 1
147 Control panel 1
148 BoltM6×16 1
149 BoltM6×70 1
150 BoltM6×35 2
151 Oil protect pane 1
152 Spring ring 8
153 Bolt M6×12 8
154 Screw M6×25 2
155 Engine stop cable 1
156 Ignition coil 1
157 Spark plug cap 1
158 Ignition coil assy 1
159 Flywheel 1
160 Flywheel fan 1
161 Starting ange 1
162 Nut M14×1.5 1
163 Diode 1
164 Fan hood assy 1
165 Set screw 1
166 Spring lid 1
167 Friction spring 1
168 Ratchet 2
169 Ratchet spring 2
170 Starter rolls 1
171 Spiral spring 1
172 Casing 1
173 Rope 1
174 Pulling handle 1
Part # Description Qty.
175 Bolt M6×8 3
176 Recoil starter 1
177 Recoil starter assy 1
178 Plastic clip 1
179 Crankcase side plate
1
assy
180 Bolt M6×20 1
181 Air cleaner side pane
1
assy
182 Air cleaner cover panel 1
183 Pan screw M3×6 4
184 Grommet 1
185 Bolt M6×40 2
186 Nut M6 2
187 Bolt M6×30 3
188 Fuel tank support panel 1
189 Pipe clamp 2
190 Outlet pipe 1
191 Pan screw M5×12 2
192 Fuel Lever 1
193 Fuel tank 1
194 Handle 1
195 Nut M8 2
196 Fuel ller cap 1
197 Packing ring 1
198 Filler cup 1
Page 19SKU 97079 For technical questions, please call 1-800-444-3353.
Page 20
ASSEMBLY DIAGRAM
Page 20SKU 97079 For technical questions, please call 1-800-444-3353.
Page 21
ASSEMBLY DIAGRAM - CONT.
Page 21SKU 97079 For technical questions, please call 1-800-444-3353.
Page 22
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
merchandise. 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.
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.
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 main-
tenance 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.
Page 22SKU 97079 For technical questions, please call 1-800-444-3353.
Page 23
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
1. Length of Coverage
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.
2. No Charge Repair or Replacement
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.
3. Consequential Damages Coverage
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.
4. Coverage Exclusions
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.
5. Service and Maintenance
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.
6. Warranted Parts
1) Fuel Metering System
Carburetor and its internal parts.i)
Fuel pump (if so equipped).ii)
Cold start enrichment system.iii)
2) Air Induction System
Intake pipe/manifold.i)
Air cleaner.ii)
3) Ignition System
Spark plug.i)
Magneto ignition system.ii)
4) Catalyst System (if so equipped)
Exhaust pipe stud.i)
Mufer.ii)
Catalytic converter (if so equipped).iii)
5) Miscellaneous Items Used in Above Systems
Vacuum, temperature and time sensitive valves i)
and switches.
Hoses, belts, connectors, and assemblies.ii)
Record Product Serial No. Here:
_____________________________
Note: If product has no serial number,
record month and year of purchase
instead.
Note: Some parts are listed and shown
for illustration purposes only, and
are not available individually as
replacement parts.
Page 23SKU 97079 For technical questions, please call 1-800-444-3353.
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