Harbor Freight Tools 96549 User Manual
GAS ENGINE - 6.5 HP
Model
96549
®
ASSEMBLY AND OPERATION INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
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© 2007 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.
Contents
SPECIFICATIONS ......................................................................................... 3
Save This Manual ............................................................................................... 3
SAFETY WARNINGS AND PRECAUTIONS ................................................ 3
UNPACKING ................................................................................................. 5
MOUNTING ................................................................................................... 6
OPERATION .................................................................................................6
Controls and Indicators ......................................................................................6
Pre-Operation Checks ........................................................................................ 7
TROUBLESHOOTING .................................................................................. 9
General/Basic Troubleshooting .......................................................................... 9
Engine Difficult to Start ...................................................................................... 9
Low Engine Power .............................................................................................10
Engine not Running Smoothly ............................................................................ 10
Engine Excessively Hot ...................................................................................... 11
Abnormal Engine Noise .....................................................................................11
MAINTENANCE ............................................................................................ 12
Scheduled Maintenance ..................................................................................... 12
Cleaning Air Filter ............................................................................................... 12
Cleaning and Replacing Spark Plug ..................................................................12
Changing Oil ......................................................................................................13
Cleaning the Deposit Cup ..................................................................................13
Torque Value for Major Engine Bolts .................................................................. 14
Transporting the Engine ..................................................................................... 14
Storing the Engine ............................................................................................. 14
PARTS LISTS AND ASSEMBLY DIAGRAMS .............................................. 16
Crankcase .......................................................................................................... 16
Crankcase Cover ................................................................................................17
Cylinder Head and Cover ...................................................................................18
Crankshaft, Piston, and Connecting Rod ........................................................... 19
Camshaft and Rocker Valve ............................................................................... 20
Carburetor .......................................................................................................... 21
Fuel Tank ............................................................................................................22
Air Cleaner .........................................................................................................23
Muffler ................................................................................................................24
Recoil Starter .....................................................................................................25
Regulator Control ............................................................................................... 26
Flywheel ............................................................................................................. 27
Ignition Coil ........................................................................................................28
Wiring Diagram ..................................................................................................29
WARRANTY ..................................................................................................29
Emission Control System Warranty .................................................................... 30
For technical questions, please call 1-800-444-3353.
Page 2SKU 96549
SPECIFICATIONS
Power Output 6.5 HP OHV Gas Engine, EPA approved
Displacement / Stroke 196 cc; 4-stroke
Ignition Type Electronic ignition (T.C.I.)
Cooling System Forced air cooling
Idling Carburetor Adjust 1700 +/- 150 RPM
Valve clearance Cold engine – Intake: 0.15 +/- 0.02mm;
Exhaust: 0.20 +/- 0.02 mm
Maximum Power Output 4.8 KW @ 3600 RPM
Maximum Torque 11-N.M./2500-RPM
Distributor Timing Intake valve opening: BTDC10°;
Intake valve closing: ABDC20°
Bore and Stroke 68 x 54 mm
Spark Plug Type BP6ES, BPR6ES (NGK), or NHSPLD F6RTCU; 0.7~0.8 mm gap
Gasoline Type Unleaded
Gasoline Tank Capacity 0.95 gallon (3.6 liters)
Drive Shaft Type Horizontal, ¾” straight, (3/16”) keyed shaft with ball bearings. Direction:
counterclockwise (facing shaft); Length: 2-1/4”; Central thread: 5/16”-24
Start Type Recoil
Speed 3600 RPM
Oil Capacity and Type 0.528 quart (0.5 liters); SAE 10W30 (in freezing weather use 5W30)
Engine Shaft Mounting Square pattern, 4 holes; 8.0-1.25 mm threads x 3-5/8” Bolt Circle
Base Mounting Pattern 3” x 6-3/8”
Weight 33.8 lbs.
Overall Dimensions 12-3/4” L x 14” W x 10-1/4” H
Recommended Applications To drive: pump, sprayer, tiller, chipper, shredder, log splitter
Features Low oil shutdown, automatic
Longer engine life with bearing supported shaft
Meets EPA certification (2007)
Fuel shutoff valve
The Emission Control System for this generator’s engine is warranted for standards
set by the U.S. Environmental Protection Agency. For warranty information, refer to the back
two pages of this manual.
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with
this manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
SAFETY WARNINGS AND PRECAUTIONS
WARNING: When using this Engine, basic safety precautions should always be followed to reduce
the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
Keep work area clean. Dark and cluttered areas invite injuries.1.
For technical questions, please call 1-800-444-3353.
Page 3SKU 96549
2.
Observe work area conditions. Do not use the Engine in damp or wet locations. Do
not expose to rain. Keep work area well lit. Do not use powered tools in the presence
of flammable gases or liquids.
3.
4.
5.
6.
7.
8.
9.
Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
Store idle equipment. When not in use, the Engine must be stored in a dry location
to inhibit rust. Always lock up tools and keep out of reach of children.
Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving
parts. Wear restrictive hair covering to contain long hair.
Use the right tool for the job. Do not attempt to force the Engine to do the work of
a larger industrial tool. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the rate for which it was intended.
Do not modify the Engine for a purpose for which it was not intended.
Use eye and ear protection. Always wear ANSI-approved impact safety goggles and
ear plugs when working with the Engine.
Do not overreach. Keep proper footing and balance at all times. Do not reach over
or across running machines.
Maintain this equipment with care. Keep the Engine clean for better and safer per-
formance. Follow instructions for lubricating and changing accessories.
10.
11.
12.
13.
14.
15.
Remove adjusting keys and wrenches. Remove keys and adjusting wrenches from
the Engine before starting.
Avoid unintentional starting. Be sure the power switch and gas valve are in the Off
position when not in use.
Check for damaged parts. Check for alignment and binding of moving parts; any
broken parts or mounting fixtures; and any other condition that may affect proper opera-
tion. Any part that is damaged should be properly repaired or replaced by a qualified
technician. Do not use the Engine if the switch does not turn On and Off properly.
Do not operate the Engine while tired or under the influence of drugs, alcohol,
or medication. Read warning labels if taking prescription medicine to determine if
your judgment or reflexes are impaired while taking drugs. If there is any doubt, do
not operate the equipment.
Maintenance. For your safety, service and maintenance should be performed regularly
by a qualified technician.
People with pacemakers should consult their physician(s) before use. Electro-
magnetic fields in close proximity to heart pacemaker could cause pacemaker interfer-
ence or pacemaker failure. Caution is necessary when near coil, spark plug cables, or
distributor of running engine. Engine should be off during distributor adjustment.
For technical questions, please call 1-800-444-3353.
Page 4SKU 96549
16.
Fire Hazard! Do not fill gas tank when the Engine is running. Do not operate if
gasoline has been spilled. Clean spilled gasoline before starting the Engine. Do not
operate near a pilot light or open flame.
17.
18.
19.
20.
21.
22.
Operate the Engine in well-ventilated areas only. Carbon Monoxide is produced
during operation and is deadly in a closed environment. Early signs of Carbon Monoxide poisoning resemble the flu, with headaches, dizziness, or nausea. If you develop
these symptoms, there may be inadequate ventilation in the work area or the engine
may not be working properly. Get fresh air immediately.
Avoid burns from the Engine. Certain parts of the Engine become very hot during
use. Do not touch the Engine until it cools down.
Install this product on a appropriate surface. Locate on a flat, level, and solid surface that is capable of supporting the weight of the engine and the machinery that it
is powering.
Do not operate the Engine with the safety guards removed. While the engine is
running, do not attempt to reach around the safety guards for maintenance or any other
reason.
If the Engine 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 flam-
mable materials, nor should they be installed near the same. Engine exhaust fumes
should be within legal limits.
Engine fuel and fumes are flammable, and potentially explosive. Do not smoke,
or allow sparks, flames or other sources of ignition around the engine, fuel tanks,
or batteries. Use proper fuel storage and handling procedures. Always have multiple
ABC class fire extinguishers nearby.
23.
24.
25.
Warning: The warnings, cautions, and instructions discussed in this instruction manual can-
Never store fuel or other flammable materials near the Engine.
Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts,
and other moving parts. Be aware that when engine parts are moving fast they can-
not be seen clearly.
The Engine can produce high noise levels. Prolonged exposure to noise levels
above 85 dBA is hazardous to hearing. Always wear ANSI-approved hearing protection when operating or working around the Engine when it is running.
not 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.
For technical questions, please call 1-800-444-3353.
Page 5SKU 96549
MOUNTING
1.
2.
Mount the Engine using the four mounting holes at the base (hardware not supplied).
Select a flat, level location able to withstand the weight, vibration, and the load device
connected to the Engine. If installed indoors, proper exhaust ventilation tubing must
be installed. If installed outdoors, a weatherproof housing is recommended.
Install the Engine load.
The Engine load must be perfectly aligned with the Engine drive shaft to prevent undue
wear on the shaft and bearings. A qualified technician should perform this operation.
OPERATION
Controls and Indicators
Spark Plug (10C)
Fuel Tank Cap (11G)
Muffler (4J)
Muffler (4J)
Air Filter
Drive Shaft
(8B)
Engine Switch (6K)
Oil Plug (1B)Dip Stick
Drain Plug
Oil Plug (1B)
Filter Cup
(7G)
Drain Plug
Throttle
(18F)
Choke
(15F)
Gas Valve
Starter Pull
Cord (16K)
For technical questions, please call 1-800-444-3353.
Page 6SKU 96549
Pre-Operation Checks
Caution: Failure to add oil to the Engine before use will damage the Engine and void
the factory warranty. Engine oil is the key factor in engine performance. Do not use
Engine oil with additives. Do not use two-stroke gasoline-oil. Using these products will
shorten Engine life. See Specifications on page 2 for recommended oil type.
1.
2.
3.
Check that all mounting nuts and bolts are tight.
Check oil level (See illustration below, left.) If needed, add oil. Unscrew the oil Dip Stick
(8B) and wipe clean. Insert the Dip Stick back into the hole without screwing it in. Remove it again and check the oil level. Full is indicated by oil on the Upper Level mark.
Use a siphon to avoid spilling the oil. Carefully screw the plastic Dip Stick back into the
metal Engine crankcase to avoid stripping the plastic threads on the Dip Stick.
Check Air Filter. (See illustration above, right.) Unscrew Air Filter Wing Nut (1H) and
remove the Air Filter Cover (2H) and Filter Elements. If dirty or dusty, clean (refer to
the Maintenance Section).
Caution: To avoid damaging the Engine, never run it without the Air Filter Assembly (11H)
attached.
4.
Remove the fuel Filter Cup (7G), clean and replace it before filling. Fill the Fuel Tank
(11G), outdoors, with up to 0.95 of a gallon of unleaded gasoline containing at least
86 octane. Do not top-off tank. Replace Fuel Cap (10G). Clean up any spilled gas
with a dry cloth.
Fire Hazard! Do not fill Gas Tank when the Engine is running, or near a pilot light or
open flame. Do not smoke. Do not operate if gasoline has been spilled. Clean spilled
gasoline before starting the engine.
For technical questions, please call 1-800-444-3353.
Page 7SKU 96549
Starting the Engine
During this procedure, it may be helpful to refer to the photos of the Engine Controls on
page 6.
1.
2.
Note: If the Engine is already hot, it is not necessary to close the Choke.
3.
4.
5.
6.
7.
Stopping the Engine
Push the Gas Valve to the open (right) position.
Close the Choke (15F) by pulling it to the left.
Push the Throttle Lever (18F) to the slow (right) position , then move
it back slightly.
Turn the Engine Switch (6K) to the On position.
Gently pull the Pull Cord Handle (16K) until it engages. Then pull it hard and all the
way out. Slowly guide the Pull Cord back into the starter.
The Engine should start. Try again if it does not start. Refer to the Troubleshooting
section if problems persist. Let the engine run for five minutes to warm up.
Push the Choke to the right
Push the Throttle Lever to the fast position (left).
1.
2.
3.
Push the Throttle Lever to the slow (right) position.
Turn the Engine Switch to the Off position.
Push the Gas Valve to the closed (left) position.
For technical questions, please call 1-800-444-3353.
Page 8SKU 96549
TROUBLESHOOTING
General/Basic Troubleshooting
Symptom Probable Cause Possible Remedy
Engine will not start. 1. On/Off Switch in Off position.
2. Gas Valve in closed position.
3. Choke set to open position.
4. Gas Tank empty.
5. Spark plug dirty.
6. Technical problem.
Engine runs rough,
pinging noises.
Engine stops by itself,
but has gas.
Engine does not reach
full speed.
1. Gasoline wrong type.
2. Gasoline has water.
1. Low oil level auto shut off.
2. Technical problem.
1. Choke closed.
2. Air filters clogged.
3. Technical problem.
Engine Difficult to Start
Symptom Probable Cause Possible Remedy
Engine difficult to start
–Cylinder compression OK
–Spark OK
Engine difficult to start
–Cylinder compression OK
–Spark OK
–Gas supply OK
Engine difficult to start
–Cylinder Compression OK
–Gas supply OK
–Ignition coil spark OK
Engine difficult to start
–Gas supply OK
–Ignition system OK
Fuel supply blocked:
1. Air vent in Gas Cap clogged.
2. Gas Valve plugged up
3. Main jet cloged or misadjusted
4. Needle valve improperly
closed or start hole is clogged
5. Floater in fuel tank is damaged
or sticking
Fuel system problem:
1. Gas dirty, has water, or is old
2. Engine cylinder flooded
3. Gas wrong type
1. Spark plug has carbon buildup
or dirt on and around electrodes
2. Electrodes are burned
3. Improper spark gap
1. Piston ring worn
2. Piston ring is sticking
3. Piston ring broken
4. Spark plug loose or without a
gasket
5. Air leakage between cylinder
block and cylinder
6. Air leakage in valve
1. Turn to On position.
2. Push to open position.
3. Set to closed position.
4. Fill Gas Tank.
5. Remove spark plug and clean.
6. Service by qualified mechanic.
1. Replace with 89 octane gas.
2. Empty tank and replace gas.
1. Check oil level; Add if needed.
2. Service by qualified mechanic.
1. Open Choke.
2. Clean air filter elements.
3. Service by qualified mechanic.
1. Clean Gas Cap air vent
2. Unclog Gas Valve
3. Clean and/or readjust
4. Take apart needle valve and
repair, clean, and blow out
5. Repair floater
1. Drain gas and replace
2. Drain extra gas, dry spark plug
electrodes
3. Drain gas and replace
1. Remove spark plug and clean
2. Replace spark plug
3. Adjust spark plug electrodes
1. Replace piston rings
2. Clean out carbon fouling
3. Replace piston ring
4. Tighten with a gasket
5. Check cylinder gasket and
bolts
6. Check valve clearance and
thickness, repair if required
For technical questions, please call 1-800-444-3353.
Page 9SKU 96549
Symptom Probable Cause Possible Remedy
When pressing Throttle
for higher speed, engine
responds slowly; speed is
decreased; or engine stops.
Low Engine Power
Incorrect Ignition timing. Re-adjust ignition advance angle.
Fuel supply problem:
1. Fuel line is clogged or has air
2. Main jet not adjusted properly
3. Carburetor needle valve hole
and main jet clogged
4. Gas valve clogged
5. Carbon buildup in combustion
chamber.
6. Air filter is clogged.
7. Intake pipe leaking.
Low compression:
1. Piston, piston ring, or cylinder
worn.
2. Air leakage from surface where
cylinder block contacts cylinder
head.
3. Valve clearance incorrect.
4. Valve tightness poor.
1. Clean line. Bleed line of air.
2. Readjust jet.
3. Clean needle valve hole and
main jet
4. Clean or replace gas valve.
5. Clean combustion chamber.
6. Clean filter elements.
7. Repair or replace.
1. Replace damaged part.
2. Replace cylinder gaskets.
3. Adjust valve.
4. Repair or replace valve.
Engine not Running Smoothly
Symptom Probable Cause Possible Remedy
Engine pinging. 1. Piston, ring, or cylinder worn.
2. Piston pin and pin hole are
worn excessively.
3. Tie rod small head is worn.
4. Main crankshaft roller bearing
worn.
Abnormal combustion. 1. Engine too hot.
2. Carbon fouling in combustion
chamber.
3. Wrong gasoline type.
Spark plug not firing
correctly
Engine stops suddenly. 1. Gas tank empty.
1. Water in carburetor float
chamber.
2. Spark plug electrode gap
wrong.
3. Incorrect ignition timing.
4. Ignition coil malfunction.
2. Carburetor clogged
3. Floater is leaking.
4. Needle valve sticks.
5. Spark plug dirty or damaged.
6. Spark plug connector wire
damaged or disconnected.
7. Low oil auto-shutdown.
8. Ignition coil damaged.
9. Cylinder or valve damaged.
1. Replace worn part.
2. Replace piston and/or pin.
3. Replace tie rod.
4. Replace roller bearing.
1. Troubleshoot overheating (see
page 11).
2. Clean chamber.
3. Drain gas from system and
replace with correct type.
1. Clean Carburetor.
2. Adjust spark plug gap.
3. Re-adjust.
4. Repair or replace coil.
1. Fill gas tank.
2. Clean carburetor and check
fuel line.
3. Repair or replace.
4. Disassemble floater chamber
and clean.
5. Replace spark plug.
6. Check and repair spark plug
wire.
7. Fill with oil.
8. Repair or replace.
9. Disassemble, check, and
repair.
For technical questions, please call 1-800-444-3353.
Page 10SKU 96549
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