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
Symptom Probable Cause Possible Remedy
Engine runs excessively
hot.
Symptom Probable Cause Possible Remedy
Noise of piston banging, or
other metal-on-metal
Engine Excessively Hot
1. Ignition timing off.
2. Engine oil low.
3. Exhaust pipe or muffler
clogged.
4. Flow guard is leaking.
5. Cooling fan loose, damaged,
or clogged.
6. Cylinder, piston, or piston
ring is worn resulting in air flow
between cylinder and crankcase.
7. Engine speed maximum set
too high.
8. Crankshaft main bearing burnt.
Abnormal Engine Noise
1. Piston, piston ring, or cylinder
worn.
2. Tie rod, piston pin and hole
worn.
3. Crankshaft main bearing worn.
4. Piston ring broken.
5. Carbon deposits in combustion
chamber.
6. Spark plug gap too small.
7. Using wrong gasoline.
8. Engine running too hot.
9. Incorrect valve clearance.
10. Flywheel not tightly
connected to crankshaft.
1. Adjust ignition advance angle.
2. Fill with oil.
3. Clean out exhaust pipe and
muffler.
4. Repair leakage.
5. Clean, repair, or replace fan.
6. Replace damaged parts.
7. Re-adjust engine speed
governor.
8. Replace main bearing.
1. Replace worn parts.
2. Replace worn parts.
3. Replace main bearing.
4. Replace piston ring.
5. Clean combustion chamber.
6. Adjust electrode clearance.
7. Empty gas tank and refill with
proper gasoline.
8. See Troubleshooting
Excessively Hot Engine.
9. Readjust valve clearance.
10. Retighten flywheel.
For technical questions, please call 1-800-444-3353.
Page 11SKU 96549
MAINTENANCE
Before performing maintenance procedures, it may be helpful to locate the items to be
serviced in the photos on page 5. Many Engine maintenance, adjustments, and repairs must
be completed by a qualified, small engine mechanic.
Scheduled Maintenance
Frequency
Item
Engine oil Check Replace Replace
Air Filter Check Clean Clean Replace
Spark Plug Clean & Adjust Replace
Spark Eliminator Clean
Idling Check & Adjust*
Valve Clearance Check & Adjust**
Fuel Tank & Filter Clean
Fuel Line Check
Deposit Cup Clean
* Proper Idle: 1700 ± 150 RPM ** Valve Clearance
Each
Use
First
month or
20 hours
(cold engine)
Each
50
hours
Every 6
months or
100 hours.
Intake:
Exhaust:
Cleaning Air Filter
Using compressed air, blow the dust from both elements and the
Filter Base on the Engine. If the Filter Elements cannot be cleaned,
wash the foam element with mild soap and water, and dry. Purchase
a new paper Filter Element if necessary. Reinstall Filter Elements, Air
Filter Housing, and Nut.
Each year
or 300
hours.
0.15 ± 0.02mm
0.20 ± 0.02mm
Cover
Cleaning and Replacing Spark Plug
1.
2.
Caution: Using other than the recommended Spark Plug replacement type can damage the
Remove the Spark Plug (10C) with a socket wrench (not sup-
plied).
Wait for the Engine to cool to avoid burning hands.
.027” to .031”
Clean Spark Plug with a steel brush. If the insulator is damaged, replace Spark
Plug.
Engine (see Specifications on page 2).
For technical questions, please call 1-800-444-3353.
Page 12SKU 96549
3.
Measure the Spark Plug electrode gap with a feeler gauge (not supplied). It should be
between 0.7 to 0.8 mm. If adjustment is necessary, bend the side electrode carefully,
then re-measure. If Spark Plug Gasket is damaged, replace it.
4.
1.
2.
3.
4.
Replace Spark Plug by hand for the first few turns, then tighten with the socket wrench
completely. A Spark Plug with a new Gasket requires 1/2 more turns to tighten than
the used Gasket which requires 1/8 to 1/4 turns to tighten.
Changing Oil
Run the Engine for five minutes to warm up the oil, then shut off the Engine.
Place a drain pan under the Drain Plug.
Remove the Dip Stick and unscrew the Drain Plug.
Allow all the oil to drain out into the pan. Pour the used oil into a container with a lid.
Deliver used oil to a recycling center. Do not dump oil into the earth or storm drain.
Dispose of oil properly.
5.
6.
7.
1.
2.
3.
4.
5.
Replace Drain Plug and securely tighten.
Add 1/2 quart of 10W30 motor oil through a funnel (not included) into the Dip Stick fill
hole. Fill until the oil reaches the Upper Level line of the fill hole.
Replace the Dip Stick carefully.
Cleaning the Deposit Cup
Push the Gas Valve to the closed (left) position.
Using a wrench (not supplied), loosen and remove the Bolt
under the Deposit Cup. Place a pan below the Deposit
Cup to catch any remaining gasoline.
Remove the Deposit Cup and O-ring, and wash them in
cleaning solvent.
Reinstall the Deposit Cup.
Push the Gas Valve to the open (right) position and check
for gas leaks from the Deposit Cup. Reinstall the Deposit Cup and tighten hardware.
For technical questions, please call 1-800-444-3353.
Page 13SKU 96549
Torque Value for Major Engine Bolts
Item Torque Value (ft-lb)
Cylinder Head Bolts 18
Flywheel Bolt 52~59
Crankcase Cover Bolts 18
Connecting Rod 9
Transporting the Engine
1.
2.
3.
1.
2.
3.
Press the Gas Valve to the left (closed) position.
Wait until the engine is cool before lifting and moving.
Keep the Engine level while carrying with another person.
Storing the Engine
Replace the Engine oil with new oil before storing as described on page 13.
Remove the Spark Plug as described on page 12. Add a spoonful of new Engine oil
through the Spark Plug mounting hole, into the cylinder. Rotate the driveshaft to dis-
tribute the oil evenly. Replace the Spark Plug. Wipe up any spilled oil.
With a gas can and funnel (neither included) underneath the Deposit Cup, unscrew the
Drain Plug of the Deposit Cup and drain all the gasoline from the Gas Tank. The Gas
Valve must be open. When drained, replace the Drain Plug. See illustration above,
left.
4.
5.
Pull the Starter Pull Cord slowly, and when it engages keep pulling until the arrow on
the starting sleeve aligns with the hole of the starter. See illustration above, right. This
ensures that the inlet and outlet valves are closed, preventing a buildup of moisture
and rust within the engine.
Cover the Engine with a waterproof cover.
For technical questions, please call 1-800-444-3353.
Page 14SKU 96549
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THESE PARTS
LISTS AND ASSEMBLY DIAGRAMS 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.
ORDERING PARTS
When ordering parts from the following Parts Lists and Diagrams be sure to indicate
which Parts List you are ordering from by including the alpha digit (A-N) of the Parts List and
the name of the engine subsystem, as well as the Part Number. Including this information
will assure that the correct part is received. Not all parts are available for order, some are just
listed to show an accurate representation of the mechanical aspects of the Engine.
Record Product’s Serial Number 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.
For technical questions, please call 1-800-444-3353.
Page 15SKU 96549
PARTS LISTS AND ASSEMBLY DIAGRAMS
Crankcase Assembly Diagram
Note: When ordering parts from this list, specify: Parts List A, CRANKCASE ASSEMBLY
and the ITEM No.
Crankcase Parts List
Part Description Qty
1A Drain Plug 2
2A Washer 2
3A Bearing, 6205 1
4A Seal, Oil, Crankshaft 1
5A Crankcase 1
6A Sway Bar, Regulator 1
7A Washer 2
8A Pin, Split 1
9A Nut, M10 1
10A Sensor, Oil 1
Note: Some parts on this Parts List and the Parts Lists that follow are listed and shown for
illustration purposes only and are not available individually as replacement parts.
Part Description Qty
11A Bolt, M6x14 2
12A Regulating Shaft 1
13A Washer, Drive Gear 1
14A Pin 2
15A Drive Gear, Regulator 1
16A Fly Block 2
17A Drive Gear Assembly Regulator 1
18A Snap Ring 1
19A Washer 2
20A Sliding Sleeve 1
For technical questions, please call 1-800-444-3353.
Page 16SKU 96549
Crankcase Cover Assembly Diagram
Note: When ordering parts from this list, specify: Parts List B, CRANKCASE COVER AS-
SEMBLY and the ITEM No.
Crank Case Cover Parts List
Part Description Qty
1B Oil Plug with Seal 1
2B Oil Plug 1
3B Seal 2
4B Crankcase Cover 1
5B Bearing, 6250 1
6B Gasket, Crankcase 1
Part Description Qty
7B Pin, Set 2
8B Dipstick 1
9B Dipstick with seal 1
10B Oil Seal, Crankshaft 1
11B Bolt, M8x32 7
For technical questions, please call 1-800-444-3353.
Page 17SKU 96549
Cylinder Head and Cover Assembly Diagram
Note: When ordering parts from this list, specify: Parts List C, CYLINDER HEAD AND COVER
ASSEMBLY and the ITEM No.
Cylinder Head and Cover Parts List
Part Description Qty
1C Bolt, M6x12 6
2C Air duct 1
3C Intake Valve Guide 1
4C Lead Wind Cover 1
5C Stud, M6x109 2
6C Pin, Set 10x16 2
7C Gasket, Cylinder Head 1
8C Cylinder Head Assembly 1
Part Description Qty
9C Stud, M8x34 2
10C Spark Plug, F6TC 1
11C Exhaust Valve Guide 1
12C Circle Clip 1
13C Bolt 4
14C Gasket, Cylinder Head Cover 1
15C Cylinder Head Cover Assembly 1
For technical questions, please call 1-800-444-3353.
Page 18SKU 96549
Crankshaft, Piston, and Connecting Rod Assembly Diagram
Note: When ordering parts from this list, specify: Parts List D, CRANKSHAFT, PISTON, AND
CONNECTING ROD ASSEMBLY and the ITEM No.
Crankshaft, Piston, and Connecting Rod Parts List
Part Description Qty
1D Piston Ring (I) 1
2D Piston Ring (II) 1
3D Side Rail 2
4D Expander 1
5D Scraper Ring Set 1
6D Piston Ring Assembly 1
7D Piston Pin Circle Clip 2
8D Piston 1
9D Piston Pin 1
Part Description Qty
10D Connecting Rod 1
11D Connecting Rod Cover 1
12D Bolt 2
13D Connecting Rod Assembly 1
14D Woodruff Key 1
15D Drive Gear 1
16D Crankshaft 1
17D Timing Drive Gear 1
18D Crankshaft Assembly 1
For technical questions, please call 1-800-444-3353.
Page 19SKU 96549
Camshaft and Rocker Valve Assembly Diagram
Note: When ordering parts from this list, specify: Parts List E, CAMSHAFT AND ROCKER
VALVE ASSEMBLY and the ITEM No.
Camshaft and Rocker Valve Parts List
Part Description Qty
1E Lock Nut 2
2E Sleeve 2
3E Valve, Rocker 2
4E Bolt, Adjusting, Valve Gap 2
5E Valve, Rocker, Assembly 2
6E Pusher Guide 1
7E Pusher 2
8E Tappet 2
Part Description Qty
9E Spring, Extension 1
10E Camshaft Assembly 1
11E Valve, Exhaust 1
12E Valve, Intake 1
13E Spring, Valve 2
14E Spring Seat, Intake Valve 1
15E Spring Seat, Exhaust Valve 1
16E Cap 1
For technical questions, please call 1-800-444-3353.
Page 20SKU 96549
Carburetor Assembly Diagram
Note: When ordering parts from this list, specify: Parts List F, CARBURETOR ASSEMBLY
and the ITEM No.
Carburetor Parts List
Part Description Qty
1F Inlet Gasket 1
2F Connecting Block 1
3F Carburetor Gasket 1
4F Screw, Idle Adjustment 1
5F Chamber Bode, Mixture 1
6F Nozzle, Main 1
7F Jet, Main 1
8F Float 1
9F Float Chamber Gasket 1
10F Float Chamber 1
11F Washer 2
12F Float Chamber Drain Screw 1
13F Screw 1
14F Air Cleaner Gasket 1
15F Choke 1
Part Description Qty
16F Choke Stem 1
17F Washer, Air-proof 1
18F Throttle Lever 1
19F Washer 1
20F Screw, M4 2
21F Cover 1
22F Choke Switch 1
23F Throttle Unit 1
24F Spring, Mixture Adjustment
Screw
25F Screw, Mixture Adjustment 1
26F Choke Unit 1
27F Float Chamber 1
28F Carburetor Assembly 1
29F Float Needle 1
1
For technical questions, please call 1-800-444-3353.
Page 21SKU 96549
Fuel Tank Assembly Diagram
Note: When ordering parts from this list, specify: Parts List G, FUEL TANK ASSEMBLY and
the ITEM No.
Fuel Tank Parts List
Part Description Qty
1G Pipe Clamp 2
2G Pipe, Outlet 1
3G Bolt, M6x22 1
4G Connector 1
5G Packing Ring 1
6G Nut, M6 2
7G Filter Cup 1
8G Packing Ring 1
9G Fuel Filler Cap 1
10G Fuel Filler Cap with Packing Ring 1
11G Fuel Tank 1
For technical questions, please call 1-800-444-3353.
Page 22SKU 96549
Air Cleaner Assembly Diagram
Note: When ordering parts from this list, specify: Parts List H, AIR CLEANER ASSEMBLY
and the ITEM No.
Air Cleaner Parts List
Part Description Qty
1H Wing Nut 2
2H Air Cleaner Cover 1
3H Filter Element 1
4H Washer 1
5H Sleeve A 2
6H Air Cleaner Housing 1
7H Screw, M5x12 2
8H Air Cleaner Base 1
9H Gasket 1
10H Sleeve B 1
11H Air Cleaner Assembly 1
For technical questions, please call 1-800-444-3353.
Page 23SKU 96549
Muffler Assembly Diagram
Note: When ordering parts from this list, specify: Parts List J, MUFFLER ASSEMBLY and
the ITEM No.
Muffler Parts List
Part Description Qty
1J Screw, M5x8 4
2J Muffler Hood 1
3J Nut, M8 2
4J Muffler 1
5J Exhaust Muffler 1
6J Exhaust Gasket 1
For technical questions, please call 1-800-444-3353.
Page 24SKU 96549
Recoil Starter Assembly Diagram
Note: When ordering parts from this list, specify: Parts List K, RECOIL STARTER ASSEMBLY
and the ITEM No.
Recoil Starter Parts List
Part Description Qty
1K Bolt, M6x22 1
2K Crankcase Side Plate Assy 1
3K Bolt, M6x18 3
4K Fan Hood Assy. 1
5K Bolt, M6x12 5
6K Engine Switch 1
7K Casing 1
8K Spring, Spiral 1
9K Spring, Ratchet 2
10K Ratchet 2
Part Description Qty
11K Spring, Friction 1
12K Spring Lid 1
13K Screw, Set 1
14K Starter Wheel 1
15K Rope, Starter 1
16K Pull Cord Handle 1
17K Recoil Starter 1
18K Recoil Starter Assembly 1
19K Clip, Plastic 1
20K Diode 1
For technical questions, please call 1-800-444-3353.
Page 25SKU 96549
Regulator Control Assembly Diagram
Note: When ordering parts from this list, specify: Parts List L, REGULATOR CONTROL
ASSEMBLY and the ITEM No.
Regulator Control Parts List
Part Description Qty
1L Nut, M6 1
2L Panel, Setting 1
3L Spring Patch 1
4L Hand Grip 1
5L Washer 1
6L Bolt, M5x25 1
7L Spring, Regulating 1
8L Support Panel Assembly 1
Part Description Qty
9L Spring 1
10L Spring, Back 1
11L Spring, Fine Regulating 1
12L Rod, Pull 1
13L Bolt, Lock 1
14L Arm, Regulating 1
15L Nut, M6 1
16L Regulating Frame Assembly 1
For technical questions, please call 1-800-444-3353.
Page 26SKU 96549
Flywheel Assembly Diagram
Note: When ordering parts from this list, specify: Parts List M, FLYWHEEL ASSEMBLY and
the ITEM No.
Flywheel Parts List
Part Description Qty
1M Nut, M14x1.5 1
2M Starting Flange 1
3M Flywheel Fan 1
4M Flywheel 1
For technical questions, please call 1-800-444-3353.
Page 27SKU 96549
Ignition Coil Assembly Diagram
Note: When ordering parts from this list, specify: Parts List N, IGNITION COIL ASSEMBLY
and the ITEM No.
Ignition Coil Parts List
Part Description Qty
1N Screw, M6x22 2
2N Engine Stop Cable 1
3N Ignition Coil 1
4N Spark Plug Cap 1
5N Ignition Coil Assembly 1
For technical questions, please call 1-800-444-3353.
Page 28SKU 96549
Wiring Diagram
LIMITED 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 this product is free from
defects in materials and workmanship for the period of 90 days from the date of purchase. This
warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or
accidents, repairs or alterations outside our facilities, criminal activity, improper installation,
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 verifies 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 specific legal rights and you may also have other rights which
vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
For technical questions, please call 1-800-444-3353.
Page 29SKU 96549
Emission Control systEm Warranty
United States Emission Control Defects Warranty Statement
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 1997 and later Small Off-Road Engine (herein engine). Within the United States, new off-road,
spark-ignition engines certified for model year 1997 and later, must be designed, built and equipped to meet the stringent anti-smog 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 emission-related 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 1997 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 recom-
mends that you retain all receipts covering maintenance on your engine, but HFT cannot deny warranty solely for the lack of receipts
or for your failure to ensure the performance of all scheduled maintenance.
•
As the engine owner, you should, however, be aware that HFT may deny you warranty coverage if your engine or a part has failed due
to abuse, neglect, improper maintenance, or unapproved modifications.
•
You are responsible for shipping your engine to a HFT warranty 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 first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workman-
ship that cause the failure of warranted parts for a period of two (2) years after the date of delivery to the first 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 warranted part
while it is still covered under this warranty.
4. Coverage Exclusions
Warranty claims shall be filed in accordance with the provisions of the HFT warranty policy explained in the box at the top of the previ-
ous 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 including, but not limited to:
a)
Use of parts which are not authorized by HFT
b)
Improper installation, adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty
center
c)
Failure to follow recommendations on fuel use contained in the Owner’s Manual
d)
Improper or inadequate maintenance of any warranted parts
e)
Repairs performed outside of the authorized warranty service dealers
f)
Alterations by changing, adding to or removing parts 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 first scheduled replacement point for that part. Any replace-
ment 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 qualified technician/mechanic to perform all required maintenance, as outlined in the Inspection,
Cleaning, and Maintenance section in this manual.
For technical questions, please call 1-800-444-3353.
Page 30SKU 96549
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)
Muffler.
ii)
Catalytic converter (if so equipped).
iii)
5) Miscellaneous Items Used in Above Systems
Vacuum, temperature and time sensitive valves and switches.
i)
Hoses, belts, connectors, and assemblies.
ii)
For technical questions, please call 1-800-444-3353.
Page 31SKU 96549
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