Harbor Freight Tools 91523 User Manual

®

Generators

GENERATOR SET

6.5 HP - RECOIL START - 2600W/2800W RATED
Model 91523

OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Website at: http://www.harborfreight.com

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright© 2004 by Harbor F reight 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 F reight Tools.

For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

Item Description

VAC
Electrical Requirements

VDC
Electrical Requirements
Voltm eter Equipped 0-150 Volts (50 Volt Increm ents)
Display Lights Red (Run)
Gasoline Engine 6.5 / U nleaded Gasoline Powered / Recoil Start

Fuel Tank Capacity 3.96 Gallons (15 Liters) / Includes Fuel Gauge
Estim ated Run Time 7.8 Continuous Operating Hours
Approx. Weight 112 Pounds

Current Output: 110/120 Volts @ 20 AM P’s
60 Hz
Continuous/R ated Wattage: 2600
Peak Wattage: 2800
Two 110/120 VAC, 3-Prong Grounding O utlets
One 23 AM P Circuit Breaker
Current Output: 12 V DC @ 10 AM P’s

3600 RPM / 4-Cycle / OHV Air Cooled
196 CC Displacem ent

0.63 Quart (0.6 Liter) O il Capacity
EPA Approved

.

CAUTION: THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC

EQUIPMENT (INCLUDING MEDICAL EQUIPMENT) WITHOUT THE ADDITION OF AN APPROPRIATE
LINE CONDITIONER (SOLD SEP ARA TELY).

This product requires oil and fuel to be added before starting. Attempting to

start the engine without oil WILL ruin the engine and void the warranty .

BEFORE starting the engine, refer to the engine owner’s manual for engine

maintenance information.

SAVE THIS MANU AL

You will need this manual for the safety warnings and precautions, operating, inspec­tion, maintenance and cleaning procedures, parts list and assembly diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front cover.
Keep this manual and in voice in a safe and dry place for future reference.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts Lists on pages
18 and 20 are included. 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.

SKU 91523 PAGE 2

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injur y.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.

2. Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Generators create sparks which
may ignite the dust or fumes.

3. Keep bystanders, children, and visitors awa y while operating a generator.
Provide barriers or shields as needed.

ELECTRICAL SAFETY

4. Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in an y way. Do not use any adapter
plugs. If the tools should electrically malfunction or break down, grounding

provides a low resistance path to carry electricity away from the user.

5. Double insulated tools are equipped with a polarized plug (one blade is

wider than the other). This plug will fit in a polarized outlet only one way . If
the plug does not fit fully in the outlet, reverse the plug. If it still does not
fit, contact a qualified electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation eliminates the need for the

three wire grounded power cord and grounded power supply system.

6. Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if y our
body is grounded.

SKU 91523 PAGE 3

7. Do not expose Generator to rain or wet conditions. W ater entering a
generator will increase the risk of electric shock.

8. Do not abuse the P o wer Cor d. K eep Power Cords away from heat, oil, sharp
edges, or mo ving parts. Replace dama ged Po wer Cords immediatel y. Dam­aged Po w er Cords increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor extension cord
marked “W-A” or “W”. These extension cords are rated for outdoor use, and
reduce the risk of electric shock.

PERSONAL SAFETY

10. Stay alert. Watch what you are doing, and use common sense when oper­ating a generator. Do not use a generator while tired or under the influ­ence of drugs, alcohol, or medication. A moment of inattention while operat-

ing generators may result in serious personal injury.

11. Dress properly. Do not wear loose c lothing or jewelry. Contain long hair .
Keep your hair, clothing, and glo ves a wa y from mo ving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.

12. Av oid accidental starting. Make sure the Po wer Switch is in its “OFF”

position, and disconnect the Spark Plug Wire when not in use.

13. Remove adjusting keys or wrenches before turning the generator on. A
wrench or a key that is left attached to a rotating part of the generator may result
in personal injury.

14. Do not overreach. Keep proper footing and balance at all times.

15. Use safety equipment. Al wa ys wear e ye protection. Wear ANSI appro ved
safety impact eye goggles. Dust mask, non-skid safety shoes, hard hat, or
hearing protection must be used for appropriate conditions.

16. Do not force the generator. Use the Correct generator for your application.
The correct generator will do the job better and safer at the rate for which it is
designed.

17. Do not use the generator if the Power Switch does not turn it on or off . Any
generator that cannot be controlled with the P o w er Switch is dangerous and m ust
be replaced.

SKU 91523 PAGE 4

GENERATOR USE AND CARE

18. Make sure the Po wer Switch is in its “OFF” position and disconnect the
spark plug wire before making any adjustments, changing accessories, or
storing the generator . Such pre v entiv e saf ety measures reduce the risk of

starting the generator accidentally .

19. Store idle generators out of reach of children and other untrained persons.
Generators are dangerous in the hands of untrained users.

20. Maintain generators with care. Do not use a damaged generator. Tag dam­aged generators “Do not use” until repaired.

21. Check for misalignment or binding of moving parts, breakage of parts, and

any other condition that may affect the generator’s operation. If damaged,
have the generator serviced before using. Many accidents are caused by

poorly maintained generators.

22. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one generator may become hazard­ous when used on another generator .

SERVICE

23. Maintain labels and nameplates on the Generator and Engine. These carry
important information. If unreadable or missing, contact Harbor F reight Tools for
a replacement.

24. Generator service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk
of injury .

25. When servicing a generator, use only identical replacement parts. Follow

instructions in the
manual. Use of unauthorized parts or failure to f ollo w maintenance instructions

may create a risk of electric shock or injury.

“Inspection, Maintenance, And Cleaning”

section of this

SKU 91523 PAGE 5

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

HEART PACEMAKER PRECAUTION

WARNING! People with pacemakers should consult their physician(s)
before using this product. Electromagnetic fields in close proximity to a heart
pacemaker could cause interference to or failure of the pacemaker.

INSTALLATION PRECAUTIONS

1. Ensure installation meets all applicable safety, and local and national electrical
codes. Have installation performed by a qualified, licensed electrician and
building contractor.

2. All electrical work, including the earth-ground connection, should be completed
by a licensed electrician.

3. Any separate fuel storage or Generator supply facility must be built or installed in
full compliance with all relevant local, state, and federal regulations.

4. It is recommended to use the Generator only in well ventilated out-

door areas. A running gasoline engine will generate Carbon Monox­ide, a colorless, odorless gas that, if inhaled, can cause serious injury
or death. If the generator is installed indoors, exhaust fumes must be

piped out of the building using leak-free, heat-resistant piping. Pipes and
silencer should not use any flammable materials, nor should they be
installed near the same. Generator exhaust fumes must be within legal
limits and installation must always meet local building codes.

5. If the generator is installed outdoors, it must be weatherproofed and should be
soundproofed. It should not be run outdoors without protection to the Generator
and wiring conduit.

6. The Generator weighs 112 lbs. Two or more people should assist when moving
or lifting this product. Never lift the Generator using the engine or alternator lifting
lugs. Connect lifting equipment to the F r ame of the Generator .

7. Bef ore lifting the Gener ator , ensure the lift rigging and supporting structure are in
good condition, and are rated to lift such a load.

8. Keep all personnel away from the suspended generator during relocating.

SKU 91523 PAGE 6

9. The supporting floor/ground surface should be level, and strong enough to safely
hold the weight of the Generator . If the floor/ground surface is not level, strong
cross members should be placed under the full length of the Generator Frame at

its low side.

10. For trailer installation, the Generator should be mounted on the center point of the
trailer, o ver the wheels. The trailer must be capable of supporting the weight of
the Generator and all contents (tools, etc.)

11. Install sound- and weather-proofing only when it is not raining or snowing to avoid
trapping moisture within the Generator’ s area.

FIRE AND EXPLOSION PRECAUTIONS

1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper

fuel storage and handling procedures. Always have multiple ABC class fire

extinguishers nearby.

2. Keep the Generator and surrounding area clean at all times.

3. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of
fluids and cleaning materials as per any local, state, or federal codes and regula­tions. Store oil rags in a covered metal container.

4. Ne v er store fuel or other flammable materials near the Generator.

5. Do not smoke, or allow sparks, flames or other sources of ignition around the
Engine and Fuel Tank. Fuel vapors are explosive.

6. Keep grounded conductive objects, such as tools, away from exposed, live elec­trical parts and connections to avoid sparking or arcing. These ev ents could
ignite fumes or vapors.

7. Do not refill the Fuel Tank while the Engine is running or while the Engine is still

hot. Do not operate the Generator with known leaks in the fuel system.

8. Excessive buildup of unburned fuel gases in the exhaust system can create a
potentially explosive condition. This buildup can occur after repeated failed start
attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust
system drain plugs, if equipped, and allow the gases to dissipate before attempt­ing to restart the Generator.

9. Use only engine manufacturer recommended fuel and oil.

SKU 91523 PAGE 7

MECHANICAL PRECAUTIONS

1. ALWAYS make sure the Power Switch is in its “OFF” position. Disconnect the
spark plug wire, and allow the Engine to completely cool before carrying out
maintenance.

2. Check for damaged parts. Before using the Generator, any part that appears
damaged should be carefully checked to determine that it will operate properly
and perform its intended function. Check for alignment and binding of moving
parts, any broken parts or mounting fixtures, and any other condition that may
affect proper operation. Any part that is damaged should be properly repaired or
replaced by a qualified technician.

3. The Generator is designed with guards for protection from moving parts. In any
case, care must still be taken to protect personnel and equipment from other
mechanical hazards when working around the generator.

4. Do not operate the Generator with safety guards removed. While the Generator
is running, do not attempt to reach around the safety guards for maintenance or
any other reason.

5. Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts.
Be aware that when engine parts are moving fast they cannot be seen clearly.

6. Keep access doors on enclosures closed and locked when access is not re­quired.

7. When working on or around the Generator always wear protective clothing in­cluding ANSI approved safety gloves, safety eye goggles, and safety hat.

8. Do not alter or adjust any part of the Generator that is assembled and supplied
by the manufacturer.

9. Always follow and complete scheduled Engine and Generator maintenance.

CHEMICAL PRECAUTIONS

1. Avoid contact with hot fuel, oil, exhaust fumes, and hot solid surfaces.

2. Avoid body contact with fuels, oils, and lubricants used in the Generator. If
swallowed, seek medical treatment immediately. Do not induce vomiting if fuel is
swallowed. For skin contact, immediately wash with soap and water. For eye
contact, immediately flush eyes with clean water and seek medical attention.

SKU 91523 PAGE 8

NOISE PRECAUTIONS

(

)

1. Prolonged exposure to noise levels above 85 dBA is hazardous to hearing.
Always wear ANSI approved ear protection when operating or working around
the Generator when it is running.

ELECTRICAL PRECAUTIONS

1. All connections and conduits from 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.

2. The Gener ator m ust be earth-grounded for fixed installations in accordance with
all relevant electrical codes and standards before operation.

3. If an extension cord (not included) is used, make sure to use only UL approved

®

cords having the correct gauge and length. (See Figure A.)

REQUIRED MINIMUM EXTENSION CORD GAUGE – 120 VOLT

NAMEPLATE

AMPERES

At Full Load

0 - 25

Feet

0 - 5 16 16 16 12 12

5.1 - 8 16 16 14 10 -

8.1 - 12 14 14 12 - -

12.1 - 15 12 12 10 - -

15.1 - 20 10 10 10 - -

EXTENSION CORD LENGTH

25 - 50

Feet

50 -100

Feet

100 – 150

Feet

150– 200

Feet

FIGURE A

4. Do not attempt to connect or disconnect load connections while standing in
water, or on wet or soggy ground.

5. Do not touch electrically energized parts of the Generator and interconnecting
cables or conductors with any part of the body, or with any non-insulated
conductive object.

6. Connect the generator only to a load or electrical system (110/120 volt) that is
compatible with the electrical characteristics and rated capacities of the Genera­tor.

7. Before servicing equipment powered by the Generator, disconnect the equipment
from its power input.

SKU 91523 PAGE 9

8. Keep all electr ical equipment clean 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.

9. Insulate all connections and disconnected wires.

10. Guard against electric shock. Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.

INSTALLATION

1. NOTE: Pr ior to powering tools and equipment, make sure the Generator’s rated
voltage, wattage, and amperage capacity (115V - 20AMPs) 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.

2. Electrical and other permits may be required for the installation of emergency
power systems. Investigate the local building and electrical codes before install­ing this unit. Installation must be completed by licensed contractors.

3. WARNING! The Generator weighs approximately 112 pounds. Use care
and the proper lifting or hoisting equipment when moving it to the installation
location. Always connect hoist lines to the Frame (41) of the Generator .

GENERAL LOCATION

1. It is recommended to locate and install the Generator outdoors where cooling air
is readily available.

2. Install the Generator so that the air inlets and outlets are not blocked by obstruc­tions 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,
in normal weather conditions, should face the prevailing wind direction.

3. Install the Generator on a concrete slab or other area where rain drainage or
flood waters can not reach it.

4. Generator placement should allow four feet of access to all sides for mainte­nance.

SKU 91523 PAGE 10

5. Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.

6. If the Generator in located indoors the Engine exhaust must be ventilated to the
outdoors using leak-proof, heat resistant, flexible, metal, flex tubing.

GENERATOR SUPPORT AND MOUNTING

1. Mount the Generator on a concrete slab capable of supporting the weight of the
Generator. The slab must e xtend on all sides be y ond the Frame (41) by at least
one foot. Contact a cement contractor for slab specifications if necessary. Attach
the Frame to the concrete slab using 3/8” diameter expansion anchor bolts (not
supplied).

GROUNDING THE GENERATOR

1. NOTE: It is recommended that only a trained and licensed electrician perform
this procedure.

2. Connect a #6 AWG grounding wire (not included) from the Ground Connector (8)
on the Generator to a grounding rod (not included) that has been driven at least
24 inches deep into the earth. The grounding rod must be an earth-driven cop­per or brass rod (electrode) which can adequately ground the Generator.

(See Figure B, next page.)

OPERATING INSTRUCTIONS

NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagrams on pages 19 and 21.

Pre-Start Checks:

1. Check to make sure the Engine Power Switch (2) is in its “OFF” position.
(See Figure B, next page.)

2. IMPORTANT! Prior to first using the Generator , the Engine MUST be filled

with approximatel y 3/4 (0.63) quart of a high quality SAE 10W-30 grade
engine oil. To do so, unscrew and remo ve the Engine’ s Oil Dipstic k (65A) located

at the bottom of the Engine Crankcase. Fill the Engine’s Crankcase until the oil

level is level with the upper marked line on the Dipstick. Then, screw the Dip-

stick back into the Oil Fill Hole. (See Figure C, next page.)

SKU 91523 PAGE 11

ENGINE
POWER
SWITCH

(2)

GROUND CONNECTOR

(8)

#6AWG

GROUNDING WIRE

(NOT INCLUDED)

GROUNDING ROD

(NOT INCLUDED)

FIGURE B

FUEL GAUGE (34)

FUEL TANK CAP

(33)

FUEL TANK

(30)

OIL DIPSTICK

(65A)

FIGURE C

SKU 91523 PAGE 12

3. Before the first use, remo ve the Fuel Tank Cap (33) and fill the Fuel Tank (30) with

nleaded gasoline. Then, replace the Fuel Tank Cap. Thereafter , chec k the

Engine’s Fuel Gauge (34) for the amount of unleaded gasoline in the Fuel Tank. If
necessary , refill the Fuel Tank with unleaded gasoline; the Generator must be
turned off and cooled down before refilling the fuel tank. (See Figure C.)

To Star t The Engine:

1. Make sure the electrical powered tools/equipment that will be used are not
plugged into the Generator while the Engine is started.

2. Turn the 120 volt AC Circuit Breaker (5) to its “ON” position. (See Figure D.)

3. Open the Fuel Valv e (40). (See Figure E.)

4. Close the Choke Lever (21A) to about 1/8” clearance. (See Figure E.)

CIRCUIT BREAKER

FIGURE D

CLOSED OPEN

FUEL V ALVE (40)

CHOKE LEVER

(21A)

(5)

ON

OFF

OFF

ON

SKU 91523 PAGE 13

FIGURE E

5. Turn the Engine Power Switch (2) to its “ON” position. (See Figure F.)

ENGINE
POWER

SWITCH

(2)

ON

OFF

FIGURE F

6. Hold the Start Handle (41A) loosely and pull it slowly several times to allow the
gasoline to flow into the Engine’s carburetor. Then hold the Start Handle firmly
and pull the rope hard and fast. Pull the rope all the way out, using two hands if
necessary. If necessary pull the rope several times until the Engine starts.

FUEL T ANK (32)

(See Figure G.)

7. Allow the Engine to run for several seconds. Then, open the Choke Lever (21A)
all the way. (See Figure E.)

120 VOL T

DUAL

OUTLETS

(6)

START

HANDLE

(41A)

FIGURE G

SKU 91523 PAGE 14

Powering 120 Volt AC Tools And Equipment:

1. Prior to powering tools and equipment, make sure the Generator’s rated voltage,
and amperage capacity (110/120VAC @ 20 AMPs) 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 .

CAUTION: THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC

EQUIPMENT (INCLUDING MEDICAL EQUIPMENT) WITHOUT THE ADDITION OF AN APPROPRIATE
LINE CONDITIONER (SOLD SEP ARA TELY).

2. Once the Gener ator is running, simply connect the P o w er Cords of 110/120 v olt
AC powered tools and equipment into the 110/120 volt AC Dual Outlets (6).

(See Figure G.)

3. NOTE: The Generator features an AC Non-Fuse Circuit Breaker (5) to protect the
AC circuit in case of an overload. Should an overload occur, the Breaker will
“trip” to its “OFF” position, causing the Generator to automatically shut down. In
this case, refer to Step #1 above in this section. Then, reset the circuitry system
by turning the Circuit Breaker to its “ON” position. Restart the Generator and
continue powering the remaining tools and equipment. (See Figure D.)

4. When finished using the Generator, tur n the Engine Power Switch (2) to its
“OFF” position. Turn the Fuel Valve (40) to its “OFF” position. Then, disconnect
all electrical powered tools and equipment from the Generator’ s 110/120 volt AC
Duel Outlets (6). (See Figures E, F, and G.)

5. After the Engine and Generator have completely cooled, store the Generator in a
safe, clean, dry location (if not already installed in one).

Powering 12 Volt DC Tools And Equipment:

1. Prior to powering a tool or equipment, make sure the Gener ator’s rated voltage,
and amperage capacity (12VDC @10 AMPs) 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 .

2. Connect the Power Cord of a 12 VDC po wered tool or equipment to the DC
Terminals (7). NOTE: Make sure to connect the positive (+) lead of the Power
Cord to the positive (+) Terminal on the Generator, and connect the negative (-)
lead of the Po wer Cord to the negative (-) T erminal on the Generator .

(See Figure H, next page.)

SKU 91523 PAGE 15

3. If using

only

a 12 volt DC tool or equipment, turn the 110/120 volt AC Circuit

Breaker (5) to its “OFF” position. (See Figure D.)

4. Start and run the Engine as previously discussed in this manual.

5. When finished using the Generator, tur n the Engine Power Switch (2) to its
“OFF” position. Turn the Fuel Valve (40) to its “OFF” position. Then, disconnect
the electrical powered tools’ po wer cord from the Gener ator’ s DC Terminals (7).

(See Figure H.)

6. After the Engine and Generator have completely cooled, store the Generator in a
safe, clean, dry location (if not already installed in one).

7. NOTE: The Generator features a 10 AMP DC Fuse (9) to protect the DC circuit in
case of an overload. Should an overload occur the Fuse will burn out, causing
the Generator to automatically shut down. In this case, refer to Step #1 in this
section. Then, reset the circuitry system by replacing the burnt Fuse with a new
10 AMP DC Fuse. Restart the Generator and continue powering the remaining
tool or equipment. (See Figure H.)

POSITIVE (+) DC TERMINAL (7)

NEGATIVE (-) DC TERMINAL (7)

FIGURE H

SKU 91523 PAGE 16

10 AMP

DC FUSE

(9)

INSPECTION, CLEANING, AND MAINTENANCE

1. CAUTION! Always make sure the Engine Power Switch (2) is in its “OFF”
position. Disconnect the spark plug wire from the engine. And allow suffi­cient time for the Engine and Generator to completely cool before perform­ing any inspection, maintenance, or cleaning.

2. Before each use, inspect the general condition of the Generator. Check for
loose screws, misalignment or binding of moving parts, cracked or broken parts,
damaged electrical wiring, and any other condition that may affect its safe opera­tion. If an Engine problem occurs, always have the Engine immediately checked
out by a

Do not use damaged equipment.

3. Before each use, check to make sure the Engine’s oil level and gas level is

adequate. If necessary, fill the Engine’s Crankcase until the oil level is even with
the Oil Fill Hole, and fill the fuel tank.

4. Before each use, With a soft brush, cloth, or vacuum, remove all debris from the
Generator. Then, use a premium quality, lightweight machine oil to lubricate all
moving parts.

qualified service technician

before further use.

5. Every 20 hours of use, drain the old Engine oil and replace with approximately

3/4 (0.63) quart of a high quality SAE 10W-30 grade engine oil.

6. Every 300 hours of use, have a qualified, certified technician perform thorough
maintenance on the Generator and its Engine.

7. For long term storage, either drain fuel into a suitable container or add a fuel
preservative/stabilizer (not included) to prevent breakdown of the fuel.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE PARTS LIST AND ASSEMBLY DIA­GRAM IN THIS MANU AL AS A REFERENCE TOOL ONLY . NEITHER THE MANUF ACTURER OR DISTRIB U­TOR MAKES ANY REPRESENTA TION OR W ARRANTY 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
EXPRESSL Y STATES THAT ALL REP AIRS 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 THERET O, OR ARISING OUT OF HIS OR HER INSTALLA TION OF REPLACEMENT

P ARTS THERETO .

SKU 91523 PAGE 17

PARTS LIST

Part # Description Qty. Part # Description Qty.

1 Bolt w/Lock Washer (M6 x 12) 9 22 Bolt (M6 x 172) 4
2 Engine Power Switch 1 23 Bolt (M5x20) 4
3 Control Panel 1 24 Connection Board 1
4 Voltmeter 1 25 Nut (M5) 4
5 Circuit Breaker 1 26 Stator 1
6 Outlet 2 27 Rotor 1
7 DC Terminal 2 28 Cooling Fan 1
8 Ground Connector 1 29 Heat Insulation Board 1
9 DC Fuse 1 30 Fuel Tank 1
10 Pilot Light 1 31 Fuel Filter 1
11 Shock Absorber 4 32 Seal Ring 1
12 Shock Absorber Foot 4 33 Fuel Tank cap 1
13 Lock Washer Nut 4 34 Fuel Gauge 1
14 Stator Cover 1 35 Bolt (M6x12) 2
15 Alternator Back Cover 1 36 Lock Washer Bolt (M6x12) 4
16 Capacitor 1 37 Spacer 4
17 Bolt (M5 x 16) 4 38 Rub Washer 4
18 Rectifier 1 39 Bush 4
19 Bolt (M5x16) 3 40 Fuel Valve 1
20 Cable Sheath 1 41 Frame 1
21 Bolt (M8 x 242) 1 42 Switch Box Cover 1
43 Engine 1

NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.

SKU 91523 PAGE 18

PARTS LIST A

Part # Description Qty. Part # Description Qty.

1A Muffler 1 42A Starting Case Assy. 1
2A Cylinder Head Bolt 4 43A Spiral Spring 1
3A Cylinder Head Cover Bolt 4 44A Starting Wheel 1
4A Cylinder Head Cover 1 45A Circlip 1
5A Lock Nut 2 46A Starting Ratchet 2
6A Adjusting Screw 2 47A Friction Plate Screw 1
7A Rocker Arm 3 48A Cover 1
8A Rocker Arm Bolt 2 49A Starter Pulley 1
9A Valve Push Rod Guiding Board 1 50A Cooling Fan 1
10A Valve Push Rod 2 51A Flywheel Magneto 1
11A Cylinder Head 1 52A Cylinder Block 1
12A Carburetor Shield 1 53A Speed Control Lever 1
13A Carburetor Packing I 1 54A Governor Arm 1
14A Carburetor Assembly 1 55A Governor Spring 1
15A Air Cleaner Case 1 56A Governor Support 1
16A Air Cleaner Seal 1 57A Bolt (M6 x 15) 2
17A Bolt (M6) 4 58A Oil Alert Nut 1
18A Air Cleaner Cover 1 59A Plug (M10 x 15) 2
19A Air Cleaner Element 1 60A Plug Washer 2
20A Air Cleaner Separator 1 61A Oil Alert 1
21A Choke Lever 1 62A Bolt (M6) 2
22A Carburetor Packing II 1 63A Crankshaft 1
23A Stud Bolt (M6 x 109) 2 64A Crankshaft Gear 1
24A Intake Valve 1 65A Oil Dipstick 2
25A Exhaust Valve 1 66A Oil Dipstick Seal Ring 2
26A Cylinder Head Gasket 1 67A Gear Casing 1
27A Exhaust Pipe Stud 2 68A Bolt (M8 x 35) 6
28A Spark Plug 1 69A Gear Case Packing 2
29A Valve Guide 2 70A Bearing 2
30A Valve Spring 2 71A Camshaft Assy. 1
31A Rocker Shaft Circlip 2 72A Locating Pin 4
32A Anti-Wear Valve Stem Protector 2 73A Oil Seal 2
33A Cylinder Head Cover Packing 1 74A Connecting Rod Bolt 2
34A Governor Spring 1 75A Connecting Rod Cap 1
35A Bolt 1 76A Connecting Rod 1
36A High Tension Line 1 77A Piston 1
37A Ignition Coil 1 78A Compression Ring I 1
38A Nut (Special 14mm) 1 79A Compression Ring II 1
39A Starter Ratchet Spring 2 80A Oil Scraper Ring 1
40A Start Rope 1 81A Piston Pin 1
41A Start Handle 1 82A Piston Pin Circlip 2

NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.

SKU 91523 PAGE 20

ASSEMBLY DIAGRAM A

NOTE:

(Example: 1A - Muffler)

suffix “A” behind the part number .

and Assembly Diagram A include the

When ordering parts from Parts List A

SKU 91523 PAGE 21

NOTE: Some parts are listed and shown f or illustration

purposes only, and are not available individually as replacement parts.