Harbor Freight Tools 96500 User's Manual
Contents
1. QI 12 Cleaning Alr Fite Mt TRE 12 Cleaning and Replacing Spark Plug Lunae irit ndo b oa beste Gabe aoa ncs 12 Changing IM c C eerie E 13 Cleaning the Deposit Cup M K 13 Torque Value for Major Engine Botts otii iaok debetur aiataaiaet exta va diaeta reca 14 Transporting the ENING M 14 SUOMI AU ENN sesasine e aNs EE EEN E Ae Aa TE EREE NERA 14 PARTS LISTS AND ASSEMBLY DIAGRAMS 15 up 2B Or 15 Assembly Diagram isisao apua o VE VEMM MM PUD M UH anana 17 WARRAN IY eee 18 Emission Control System Warranty cccccccsscccceeeeeeeeeseeeeeeeeeeeeseceeeeeeeessaaaees 19 SKU 96500 For technical questions please call 1 800 444 3353 Page 2 SPECIFICATIONS Power Output 6 5 HP OHV Gas Engine EPA and CARB approved Displacement Stroke 196 cc 4 stroke Ignition Type Electronic ignition T C l Start Type Recoil Cooling System Forced air cooling Maximum Power Output 4 8 KW Q 3600 RPM Maximum Torque 11 N M 2500 RPM Idling Carburetor Adjust 1700 150 RPM Valve clearance Cold engine Intake 0 15 0 02mm Exhaust 0 20 0 02 mm 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 Capac2. 7a Carburetor Assembly 1 Es je Ci Ee Monat 2 Er Pipe Camp a Us oware i Es Mexe2 Bot t so comete 2 Page 15 Part Description Qty a C es mwrc ho p Packngring o as Fem t 26 Fuel Cap with Assembly er Fem ho as exhaust mutter t Cd s EmastGake 1 so mwen 2 m mrm t os Crankcase Side Plate Assomby 1 s meen id p Fan Hood Assemby i s ReoiSmer 1 be wena i s engine Switch T Cd os Recoi Starter Assembly 1 e Pisec i AT ou Patt __Oeseriptien a o pde toi Regulating Frame Assemby 1 Hos Back Spring os Regulating Spring i Hor Pumas t Hos tek t os Regulating arm i hor wma t Hos mes Screw 2 os waxrsma h mo Staring Flange t mr FiywheetFan t mz fewe t rs ignition Coirassemoy t r4 Outer Pipe 85x4 5x050 1 ms CharcoalTane o ne Outer Pipe 12x60 t mr PeeGam e ns Outer Pipe nexa 1 Le ee ee i j jnmi j j l Record Product s Serial Number Here Note Note replacement parts SKU 96500 For technical questions please call 1 800 444 3353 If product has no serial number record month and year of
3. governor between cylinder and crankcase 8 Replace main bearing 7 Engine speed maximum set too high 8 Crankshaft main bearing burnt Abnormal Engine Noise Symptom Probable Cause Possible Remedy Noise of piston banging or other metal on metal 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 Replace worn parts Replace worn parts Replace main bearing Replace piston ring Clean combustion chamber Adjust electrode clearance Empty gas tank and refill with proper gasoline 8 See Troubleshooting Excessively Hot Engine 9 Readjust valve clearance 10 Retighten flywheel NOOR WD SKU 96500 For technical questions please call 1 800 444 3353 Page 11 MAINTENANCE Before performing maintenance procedures it may be helpful to locate the items to be serviced in the photos on page 6 Many Engine maintenance adjustments and repairs must be completed by a qualified small engine mechanic Scheduled Maintenance Frequency Each First Each Every 6 Each year or Item Use month or 50 months or 300 hours 20 hours hours 10
4. off during distributor adjustment SKU 96500 For technical questions please call 1 800 444 3353 Page 4 16 17 18 19 20 21 22 23 24 25 A Fire Hazard Do not fill Fuel tank when the engine is running Do not operate if gasoline has been spilled Clean spilled gasoline before starting the Engine and dis pose of cleaning materials in a ventilated metal container Do not operate near a pilot light or open flame Operate the Engine in well ventilated areas only Carbon Monoxide is produced dur ing operation and is deadly in a closed environment Early signs of Carbon Monoxide poisoning resemble the flu with headaches dizziness or nausea If you have these symptoms the engine may not be working properly or it is being utilized with too little ventilation in the work area 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 completely Install this product on a proper surface Locate on a flat level and solid surface that is capable of supporting the weight of the Engine and the connected machinery Do not operate the Engine with safety guards removed While the Engine is run ning 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 sil
5. risk of personal injury and damage to equipment READ ALL INSTRUCTIONS BEFORE USING THIS ENGINE 1 Keep work area clean Dark and cluttered areas invite injuries SKU 96500 For technical questions please call 1 800 444 3353 Page 3 10 1i 12 13 14 15 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 Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords Children must never be allowed to operate the Engine or be in the work area when the Engine is in operation Store idle equipment When not in use the Engine must be stored in a dry location to inhibit rust Always lock it up 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 or use it 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 using the Engi
6. the Choke SKU 96500 For technical questions please call 1 800 444 3353 Page 8 TROUBLESHOOTING General Basic Troubleshooting Symptom Probable Cause Possible Remedy Engine difficult to start Cylinder compression OK Spark OK Fuel supply blocked 1 Air vent in Gas Cap clogged 2 Gas Valve plugged up 3 Main jet clogged or misadjusted 4 Needle valve improperly closed or start hole is clogged 5 Floater in fuel tank is damaged or sticking Engine will not start 1 Engine Switch in Off position 1 Turn to On position 2 Fuel Valve in closed position 2 Push to open position 3 Choke set to open position 3 Set to closed position 4 Gas Tank empty 4 Fill Gas Tank 5 Spark plug dirty 5 Remove spark plug and clean 6 Technical problem 6 Service by qualified mechanic Engine runs rough 1 Gasoline wrong type 1 Replace with 89 octane gas pinging noises 2 Gasoline has water 2 Empty tank and replace gas Engine stops by itself 1 Low oil level auto shut off 1 Check oil level Add if needed but has gas 2 Technical problem 2 Service by qualified mechanic Engine does not reach 1 Choke closed 1 Open Choke full speed 2 Air filters clogged 2 Clean air filter elements 3 Technical problem 3 Service by qualified mechanic Engine Difficult to Start Symptom Probable Cause Possible Remedy 1 Clean Gas Cap air vent 2 Unclog Gas Valve 3 Clean and
7. 0 hours Engine oil Check Replace Replace Air Filter Check Clean Clean Replace Spark Plug Clean amp Adjust Replace Spark Eliminator Clean Idling Check amp Adjust Valve Clearance Check amp Adjust Fuel Tank amp Filter Clean Fuel Line Check Deposit Cup Clean Proper Idle 1700 150 Valve Clearance Intake 0 15 0 02mm RPM cold engine Exhaust 0 20 x 0 02mm Cleaning Air Filter __ Nut Air Filter Using compressed air blow the dust from both elements and the Housing Filter Base on the Engine If the Filter Elements cannot be cleaned wash the foam element with mild soap and water and allow to dry thor Filter oughly Purchase a new paper Filter Element if necessary Reinstall SISUTEINS Filter Elements Air Filter Housing and Nut Cleaning and Replacing Spark Plu 1 Remove the Spark Plug with a socket wrench not supplied Wait for the Engine to cool to avoid burning hands a Due 027 to 031 2 Clean Spark Plug with a steel brush If the insulator is damaged replace Spark Plug Caution Using other than the recommended Spark Plug replacement type can damage the Engine see Specifications on page 2 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 SKU 96500 For technical questions please call 1 800 444 33
8. 53 Page 12 4 Replace Spark Plug by hand for the first few turns then tighten securely with the socket wrench A Spark Plug with a new Gasket requires 1 2 more turn to tighten than the used Gasket which requires 1 8 to 1 4 turns to tighten Changing Oil 1 Run the Engine for five minutes to warm up the oil then shut off the Engine 2 Place a drain pan under the Drain Plug 3 Remove the Dip Stick and unscrew the Drain Plug IUT UC Dip Stick Drain Plug Drain Pan 4 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 in a manner approved by state local and federal regulations 5 Replace Drain Plug and securely tighten 6 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 7 Replace the Dip Stick carefully Cleaning the Deposit Cup 1 Push the Fuel Valve to the closed left position 2 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 3 Remove the Deposit Cup and O ring and wash them in cleaning solvent 4 Reinstall the Deposit Cup and O ring 5 Push the Fuel Valve to the open right position and check for gas leaks from the Deposit Cup Reinstall th
9. CENTRAL MACHINERY GAS ENGINE 6 5 HP j eTe 96500 ASSEMBLY AND OPERATION INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 9301 1 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 ize eye lm 3 rijs Me cc TN 3 SAFETY WARNINGS AND PRECAUTIONS eene 3 Ul ec P 5 egg Gases pc 6 OPERATION pe C 6 Controls and MIGICANONS MP 6 Pre Operati n GMCS T POS T 7 THOUBLESHOOTIN QG cii ceccscetcccercccecccneeeratenceatidnenestndcnneenidemeuenneencueeeas 9 teneraliBasi Troubleshooting isisisi qs ace datar eei en eta udtundaxs sm a 9 Engine Difficult to Stari eacus cotto amanda petamus asap iet aat ti uh aetas 9 Low Engine POWE usui bei ead notra wav sores ia ami oodd a Ce deae 10 Engine nob Running SImIDOBI sasssa a dpa unu enini opas 10 Engine Excessively POE uat tx taba o babita Ge cota a EAEN 11 Abnormal Engine NOIS sser 11 MAINTENANCE sais 12 Sched led INIA MAIN CG X
10. arranty 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 t
11. cal questions please call 1 800 444 3353 Page 18 Emission Control System Warranty California and United States Emission Control Defects Warranty Statement The California Air Resources Board herein CARB the United States Environmental Protection Agency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 1995 and later Small Off Road Engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti smog standards Elsewhere within the United States new off road spark ignition engines certified for model year 1997 and later must meet similar standards set forth by the EPA HFT must warrant the emission control system on your engine for the periods of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor or fuel injection system and the ignition system Also included may be hoses belts connectors and other 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 1995 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by HFT Harbor Freight Tools Emission Control Defects W
12. e Deposit Cup and tighten hardware SKU 96500 For technical questions please call 1 800 444 3353 Page 13 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 ie Press the Fuel Valve to the left closed position 2 Wait until the engine is cool before lifting and moving 3 Keep the Engine level while carrying with another person Storing the Engine il Replace the Engine oil with new oil before storing as described on page 13 2 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 Align arrow of starting sleeve with the hole in the Cup starter 3 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 Fuel Tank The Fuel Valve must be open When drained replace the Drain Plug See illustration above left 4 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 step ensures that the inlet and outlet valves are closed preventing a buildup of moisture and rust within th
13. e 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 SKU 96500 For technical questions please call 1 800 444 3353 Page 19 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 replacement part provided it is equivalent in durability and performance may be used in performance of maintenance or repairs The owner is responsible for commissioning a qualified technician mechanic to perform all required maintenance as outlined in the Inspection Cleaning and Maintenance section on page 14 and 15 of this manual 6 Warranted Parts 1 Fuel Metering System i Carburetor and its internal parts ii Fuel pump if so equipped iii Cold start enrichment system 2 Air Induction System i Intake pipe manifold ii Air cleaner 3 Ignition System i Spark plug ii Magneto ignition system 4 Catalyst System if so equipped i Exhaust pipe stud ii Muffler iii Catalytic converter
14. e engine 5 Cover the Engine with a waterproof cover SKU 96500 For technical questions please call 1 800 444 3353 Page 14 PARTS LIST Part Description Qty i foroan e p Washer 2 Sd s Bearing Ft 1 orankshat onse o s omeme Cd s Reguiating Sway er 1 C Sid s spen t a Ss SS S ININ as ores o so meses o o Piston Ring o 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3 3 34 35 _ T EN SKU 96500 For technical questions please call 1 800 444 3353 Part Description Qty Ln Ponang o s eean t La Scraper angsa ho a5 Piston Ring Assembly L5 Piston Pin ip eo ar Psn Ls Piston Pn t Hs Sek so Connecting Rod Gover 1 s gr 2 sz Connecting Rod Assembly t ss Woocrutkey Sd sa Crankshaft Assembly 1 ss foana ooo 2 ss sew 2 s Valve Rocker e ss Adjusting BotforVave Gap 2 ss Valve Rocker Assembly 2 oo Pusher Guided fer meer e ma e ss Camshaft Assemby t ea Exhaustvave 1 s maeva t ss veweSping s Intake Valve Spring Seat t ss Exnaust vaie Spring Sea 1 e om o Ho meri 1 Ei Connecting Block M Ua Carburetor Gasket 1 73 Air Cleaner Gasket h
15. encer 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 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 ear protection when operating or working around the Engine when it is running Warning The warnings cautions and instructions discussed in this instruction manual can 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 SKU 96500 For technical questions please call 1 800 444 3353 Page 5 UNPACKING When unpacking check to make sure the all parts are included If any parts are miss ing or broken please call Harbor Freight Tools at the number on the cover of this
16. evel Full is indicated by oil on the Upper Level SKU 96500 For technical questions please call 1 800 444 3353 Page 7 mark Use a siphon to avoid spilling the oil Carefully screw the Dip Stick back into the Engine crankcase ae Nut Air Filter Dip Stick Housing Filter Elements Upper Level Mark Full 3 Check Air Filter 75 See illustration above right Unscrew Air Filter Housing Nut and remove the Air Filter Housing 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 at tached 4 Remove the debris filter clean and replace it before filling Remove the Fuel Cap 85 and fill the Fuel Tank 87 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 Clean up any spilled gas with a dry cloth A Fire Hazard Do not fill Fuel Tank when the Engine is running or near a pilot light or open flame Do not smoke Do not operate the Engine if gasoline has been spilled Clean spilled gasoline before starting the engine GAS Debris Filter Starting the Engine During this procedure it may be helpful to refer to the photos of the Engine Controls on page 6 i ie Push the Fuel Valve to the open right position D 2 Close the Choke by pulling it to the left Note If the Engine is already hot it is not necessary to close
17. he engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two 2 years after the date of delivery to the 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 us
18. if so equipped 5 Miscellaneous items Used in Above Systems i Vacuum temperature and time sensitive valves and switches ii Hoses belts connectors and assemblies SKU 96500 For technical questions please call 1 800 444 3353 Page 20
19. ity 0 95 gallon 3 6 liters Drive Shaft Type Horizontal 34 straight keyed shaft with ball bearings Direction counterclockwise facing shaft Length 2 1 4 Central thread 5 16 24 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 Mounting Pattern 3 x 6 3 8 Weight 33 8 Ibs 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 2007 EPA Phase Il CA Emission Regs Fuel shutoff valve The Emission Control System for this generator s engine is warranted for standards set by the U S Environmental Protection Agency and by the California Air Resources Board also known as CARB For warranty information refer to the back two pages of this manual Save This Manual You will need the manual for the safety warnings and precautions assembly instruc tions 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 Gas Engine basic safety precautions should always be followed to reduce the
20. manual as soon as possible MOUNTING 1 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 equipment connected to the Engine If installed indoors proper exhaust ventilation tubing must be installed If installed outdoors weatherproof housing is recommended 2 Install the Engine load The Engine load must be perfectly aligned with the Engine drive shaft to prevent un due wear on the shaft and bearings Contact a qualified technician to connect the Engine SKU 96500 For technical questions please call 1 800 444 3353 Page 6 OPERATION Controls and Indicators Spark Plug 25 Fuel Tank 87 Muffler 88 Muffler 88 Air Cleaner 75 Oil Dipstic 36 Fuel Valve Recoil Starter 95 Pre Operation Checks Caution Failure to add oil to the Engine before first 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 3 for recommended oil type T Check that all mounting nuts and bolts are tight 2 Check oil level See illustration below left If needed add oil Unscrew the oil Dip Stick 36 and wipe clean Insert the Dip Stick back into the hole without screwing it in Remove it again and check the oil l
21. ne Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines Maintain the Engine with care Follow instructions for lubricating and changing ac cessories Remove adjusting keys and wrenches Check that all keys and adjusting wrenches are removed from the Engine before starting Avoid unintentional starting Be sure the power switch and Fuel 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 operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not use the Gas 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 Engine 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
22. ngle Fuel supply problem 1 Fuel line is clogged or has air 2 Main jet not adjusted properly 3 Carburetor needle valve hole 1 Clean line Bleed line of air 2 Readjust jet 3 Clean needle valve hole and main jet and main jet clogged 4 Clean or replace gas valve 4 Gas valve clogged 5 Clean combustion chamber 5 Carbon buildup in combustion 6 Clean filter elements chamber 7 Repair or replace 6 Air filter is clogged 7 Intake pipe leaking Low compression 1 Replace damaged part 1 Piston piston ring or cylinder 2 Replace cylinder gaskets worn 3 Adjust valve 2 Air leakage from surface where 4 Repair or replace valve cylinder block contacts cylinder head 3 Valve clearance incorrect 4 Valve tightness poor 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 Replace worn part Replace piston and or pin Replace tie rod Replace roller bearing RON Abnormal combustion 1 Engine too hot 2 Carbon fouling in combustion chamber 3 Wrong gasoline type 1 See Troubleshooting page 11 Engine Excessively Hot 2 Clean chamber 3 Drain gas from system and replace with correct type Spark plug not firing 1 Water in carbure
23. or readjust 4 Take apart needle valve and repair clean and blow out 5 Repair floater Engine difficult to start Cylinder compression OK Fuel system problem 1 Gas dirty has water or is old 1 Drain gas and replace 2 Drain extra gas dry spark plug 5 Air leakage between cylinder block and cylinder 6 Air leakage in valve Spark OK 2 Engine cylinder flooded electrodes Gas supply OK 3 Gas wrong type 3 Drain gas and replace Engine difficult to start 1 Spark plug has carbon buildup 1 Remove spark plug and clean Cylinder Compression OK or dirt on and around electrodes 2 Replace spark plug Gas supply OK 2 Electrodes are burned 3 Adjust spark plug electrodes Ignition coil spark OK 3 Improper spark gap Engine difficult to start 1 Piston ring worn 1 Replace piston rings Gas supply OK 2 Piston ring is sticking 2 Clean out carbon fouling Ignition system OK 3 Piston ring broken 3 Replace piston ring 4 Spark plug loose or without a 4 Tighten with a gasket gasket 5 Check oylinder gasket and bolts 6 Check valve clearance and thickness repair if required SKU 96500 For technical questions please call 1 800 444 3353 Page 9 Low Engine Power Symptom Probable Cause Possible Remedy When pressing Throttle for higher speed engine responds slowly speed is decreased or engine stops Incorrect Ignition timing Re adjust ignition advance a
24. plaint 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 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM BLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 96500 For techni
25. purchase instead Some parts are listed and shown for illustration purposes only and are not available individually as Page 16 ASSEMBLY DIAGRAM 6 DENN 9E t 6f b E LE REV 07i SKU 96500 For technical questions please call 1 800 444 3353 Page 17 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 in juries 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 com
26. tor float 1 Clean Carburetor correctly chamber 2 Adjust spark plug gap 2 Spark plug electrode gap 3 Re adjust wrong 4 Repair or replace coil 3 Incorrect ignition timing 4 Ignition coil malfunction SKU 96500 For technical questions please call 1 800 444 3353 Page 10 Symptom Probable Cause Possible Remedy Engine stops suddenly Gas tank empty Carburetor clogged Floater is leaking Needle valve sticks Spark plug dirty or damaged Spark plug connector wire damaged or disconnected 7 Low oil auto shutdown 8 Ignition coil damaged 9 Oylinder or valve damaged oOaRWND 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 Engine Excessively Hot Symptom Probable Cause Possible Remedy Engine runs excessively 1 Ignition timing off 1 Adjust ignition advance angle hot 2 Engine oil low 2 Fill with oil 3 Exhaust pipe or muffler 3 Clean out exhaust pipe and clogged muffler 4 Flow guard is leaking 4 Repair leakage 5 Cooling fan loose damaged 5 Clean repair or replace fan or clogged 6 Replace damaged parts 6 Cylinder piston or piston 7 Re adjust engine speed ring is worn resulting in air flow
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