Harbor Freight Tools 96156 User's Manual
Contents
1. 8 STARTING THE ENGINE 8 CHECKING AND FILLING ENGINE ONL 8 CHECKING AND FILLING FUEL 9 START PROCEDURE 9 BREAK IN PERIOD 10 SERVIGING orti oiii E etes 11 MAINTENANCE PROCEDURES 11 ENGINE OIL CHANGE 11 AIR FILTER ELEMENT MAINTENANCE 11 SPARK PLUG MAINTENANCE 12 CLEANING MAINTENANCE AND LUBRICATION SCHEDULE 12 AFTER INITIAL 20 OPERATION HOUR PERIOD sissicsnssiviascasonnsaannan 12 EVERY 25 OPERATION HOURS THEREAFTER 12 EVERY 50 OPERATION HOURS 12 EVERY 100 OPERATION HOURS 12 EVERY 300 OPERATION HOURS 12 13 TROUBLESHOOTING 14 Page 2 For technical questions please call 1 800 444 3353 PARIS 16 ASSEMBLY 17 LIMITED 90 DAY WARRANTY 18 EMISSION CONTROL SYSTEM 2 22 18 SKU 96156 SAVE THIS MANUAL CAUTION CAUTION without the safety alert symbol is Keep this manual for the safety warnings used to address practices not and precautions installation operating related to personal injury inspection maintenance and cleaning procedures Write the product s serial number WARNING Read all instructions in the back of the2. minutes to circulate the treated gasoline through the carburetor Wait for engine to cool before proceeding c Clean out area around spark plug Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole d Reinstall spark plug but leave spark plug wire disconnected e Pull recoil starter to distribute oil in cylinder Stop after one or two revolutions when you feel the piston start the compression stroke when you start to feel resistance Apply a thin coat of rust preventive oil to all uncoated metal parts Cover and store in a dry well ventilated area out of reach of children Before starting the engine after storage keep in mind that untreated gasoline will deteriorate quickly Drain the fuel tank and filter and change to fresh fuel if untreated gasoline has been sitting for a month if treated gasoline has been sitting beyond the fuel stabilizer s recommended time period or if the engine does not start properly SKU 96156 For technical questions please call 1 800 444 3353 Page 13 start Page 14 Troubleshooting Engine will not MOWER ENGINE SPECIFIC 1 Brake Handle not held or brake cable not connected properly 2 Mower on top of grass FUEL RELATED No fuel in tank or fuel valve closed Choke not in start position especially with cold engine Low quality or deteriorated old gasoline Carburetor not primed Dirty fuel passageways blocking
3. slowly release the choke cable allowing it to return to its open run position 2 After each start up run the engine for five minutes with no load to allow it to stabilize 3 Operate the lawn mower according to the manufacturer s instructions After use release the brake handle to stop the mower WARNING Ifthe engine does not stop promptly when the brake handle is released carefully close the fuel valve DO NOT USE THE ENGINE AGAIN UNTIL THE BRAKE ASSEMBLY HAS BEEN REPAIRED BY A QUALIFIED TECHNICIAN To prevent accidents turn off the engine and disconnect its spark plug wire after use Wait for the engine to cool clean external parts with clean cloth then store the equipment out of children s reach according to the Storage instructions in this manual Page 10 For technical questions please call 1 800 444 3353 Break in Period 1 Breaking in the engine will help to ensure proper equipment and engine operation and will extend the engine s lifespan The warranty is void if the engine is not broken in properly The first 20 hours of operation is the break in period During the first 3 hours of use Do not apply a heavy load to the mower After the first 20 hours of use Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the SERVICING section SKU 96156 SERVICING TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL STARTIN
4. their physician s before use Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure Caution is necessary when near the engine s magneto or recoil starter Page 4 CAN KILL YOU IN MINUTES 15 For technical questions please call 1 800 444 3353 Use only accessories that are recommended by Harbor Freight Tools for your model Accessories that may be suitable for one engine may become hazardous when used on another engine Do not operate in explosive atmospheres such as in the presence of flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes Stay alert watch what you are doing and use common sense when operating this engine Do not use this engine while tired or under the influence of drugs alcohol or medication Do not overreach Keep proper footing and balance at all times This enables better control of the engine in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Parts especially exhaust system components get very hot during use Stay clear of hot parts Do not cover the engine during operation Keep the engine and surrounding area clean at all times Use the engine accessories etc in accordance with these instructions and in the manner intended
5. ATING INSTRUCTIONS Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before installation or use of this product A Engine Controls Starter Handle Fuel Tank Cap Oil Fill Oil Fill The oil fill cap has a dipstick attached The crosshatch pattern at the bottom of the dipstick is the proper oil range Before each use check that the oil level is at the top of the cross hatched pattern but not above that level Brake Arm This must be held back to allow the engine to operate It will force the engine to stop when released Starter Handle This is pulled to start the engine Page 8 For technical questions please call 1 800 444 3353 Choke Control ls Throttle Control NOT ADJUSTABLE Fuel Valve This controls the fuel supply to the engine The horizontal position is closed off The vertical position is open on Choke Control This controls the air fuel ratio for starting the engine The released position is open run The engaged position is closed start Automatic Throttle Control This is not adjustable except by a qualified technician A Checking and Filling Engine Oil CAUTION Your Warranty is VOID if the engine s crankcase is not properly filled with oil before each use Before each use check the oil level Do not run the engine with low or no engine oil Running the engine with no o
6. G Close the engine s fuel valve wait for the engine to cool and disconnect the spark plug wire s before performing any inspection maintenance or cleaning procedures TO PREVENT AWARNING SERIOUS INJURY FROM ENGINE FAILURE Do not use damaged engine If abnormal noise vibration or excess smoking occurs have the problem corrected before further use Maintenance Procedures Many maintenance procedures A including those not detailed in this manual will need to be performed by a qualified technician for safety If you have any doubts about your ability to safely service the engine have a qualified technician service the engine instead Note Warranty is void if proper maintenance and servicing procedures are not followed Engine Oil Change ACAUTION Oil is very hot during operation and can cause burns Wait for engine to cool before changing oil 1 Place a drain pan not included underneath the crankcase s drain plug 2 Remove the drain plug and if possible tilt the crankcase slightly to help drain the oil out Recycle used oil 3 Replace the drain plug and gasket if supplied and tighten it 4 Refill the oil to the proper level following the instructions under the Starting the Engine section Air Filter Element Maintenance 1 Wipe off the air cleaner cover 2 air cleaner cover is held in place by two knobs Remove them 3 Remove the air filter element 4 Wash the el
7. Greyhound 5 5 HP LAWN MOWER ENGINE INSTALLATION OPERATING AND SERVICING INSTRUCTIONS DANGER Using an engine indoors CAN KILL YOU IN MINUTES Engine exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside Only use OUTSIDE a home or garage and far away from EVEN IF doors and windows doors and windows are open vents Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Tools required for installation and service may not be included For technical questions or replacement parts please call 1 800 444 3353 Manual Revised 08d 09h CONTENTS IMPORTANT SAFETY INFORMATION 3 6 UNPACKING 6 20 6 OPERATING INSTRUCTIONS 8 ENGINE CONTROLS
8. a only SAVE THESE INSTRUCTIONS SKU 96156 For technical questions please call 1 800 444 3353 Page 5 SPECIFICATIONS Engine Rating 5 5 Horsepower Fuel 89 octane unleaded gasoline Capacity 0 45 Gallons 10W 30 Type Detergent or non detergent Capacity 18 6 oz Run Time 50 Load 3 5 Hours with full tank Sound Level dB 4 Stroke OHV Bore x Stroke 68 mm x 45 mm Compression Ratio Engine Oil Displacement cd viewed from PTO 7 8 x 3 1 8 3 16 keyway shareetesrTyDe end tapped 3 8 24 we F6TC resistive Spark Plug 6HS Champlon EROR mm em Valve Clearance ide 2000RPM 22 The emission control system for this engine is warranted for standards set by the U S Environmental Protection Agency For warranty information refer to the last pages of this manual Speed At high altitudes the engine s carburetor and any other parts that control the fuel air ratio will need to be adjusted by a qualified mechanic to allow efficient high altitude use and to prevent damage to the engine and any other devices used with this product UNPACKING When unpacking make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at 1 800 444 3353 as soon as possible Page 6 For technical questions please call 1 800 444 3353 INSTALLATION Read the ENTIRE IMPORTANT A SAFETY INFORMATION section at the beginning of this manual in
9. age 15 PARTS LIST Crankcase 7 Gasket crankcase Starting flange 1 oo 0 5 5 gt 1515 Ry o Slo alo 5 gt o amp o F linder 11 12 1 1 3 Fuel filler cap asm 27 rake _ _ 4 5 7 8 9 0 1 2 1 1 1 2 2 2 2 N Ko wo Crankshaft Filter cover 35 36 37 Crankshaft Filter Gasket Crankshaft Filter Gasket 4 Gasket carburetor 4 Ek 5 ala NIS I e x i seal 22554057 45a BrakeSpring su Ti Record Product s Serial Number Here UJ RS m c o 3 P Heat insulator B AB 28 30 31 32 33 35 36 37 39 40 1 2 43 44 45 47 Description 2 Stud Dipstick 2 Gasket air cleaner 4 4 1 O c o ct gt ea 7 Regulating sway bar Oil seal 26 11 5 7 y D Ignition coil 2 c Upper oil seal 25x38x7 Choke link a 63 64 65 66 67 68 69 70 8 9 50 51 52 53 55 56 57 58 59 61 63 64 65 67 70 74 76 77 79 82 83 84 85 88 91 92 93 94 95 Pp M M Spring seat exhaust valve 4 Lock bolt Spark plug F6TC Spring seat intake valve O S Bolt M6x20 UJ o o x N e Bolt x Bolt M8x50 Nut M6 Nut M6 Nut M6 Starterhood Cid Pipe clamp with thr
10. cluding all text under subheadings therein before installation or use of this product TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL STARTING Close the engine s fuel valve wait for the engine to cool and disconnect the spark plug wire s before installing or making any adjustments to the engine TO PREVENT AWARNING serious INJURY Operate only with proper spark arrestor installed Operation of this engine may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 1 IMPORTANT If you have any doubts about your ability to perform the following procedures have a qualified service technician perform the installation 2 Install this engine on a lawn mower only Figure A Mounting Hole Locations Bottom View 3 Set the Engine upright on the mower and align the four 3 8 diameter coarse threaded engine mounting holes with SKU 96156 four mower mounting holes BEV AN mower brake See Figure A f bracket a NOTE Depending on the mower it may be necessary to drill mounting holes or make a mounting plate to align with the engine mounting holes P a A 4 Use four 3 8 diameter coarse threaded LL hardened stainless steel Bolts Lock 4 Washers and Washers not included of to secure the Engine aer rete na
11. ct local fire which if not avoided could agencies for laws or regulations relating result in death or serious injury to fire prevention requirements CAUTION used with 4 Install only to a lawn mower and only in A CAUTION the safety alert an upright position symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during installation Use only oil and fuel recommended 6 NOTICE is used to in the Specifications section of this address practices not manual related to personal injury SKU 96156 For technical questions please call 1 800 444 3353 Page 3 Follow lawn mower manufacturer s installation procedures for attaching the engine to the mower and connecting the output shaft OPERATING PRECAUTIONS CARBON MONOXIDE HAZARD Using an engine indoors Engine exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open S wo Only use OUTSIDE and far away from windows doors and vents Keep children away from the engine especially while it is operating Do not leave the engine unattended when it is running Turn off the engine before leaving the work area Wear ANSI approved safety goggles and hearing protection during use People with pacemakers should consult
12. cts 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 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 carbu retor 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 Th
13. e 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 SKU 96156 If any emission related part on your engine is defective the part will be repaired or replaced by HFT Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual HFT recommends that you retain all receipts covering 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 unap proved 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 arrange ments 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 Harbo
14. ead Self locking nut M6 2 CD c 0 A D y 2 o o 6205 It M6x12 It M6x32 It M clamp gt t 2 D o y D 2 Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Page 16 For technical questions please call 1 800 444 3353 REV 08b SKU 96156 ASSEMBLY DIAGRAM REV 08b SKU 96156 For technical questions please call 1 800 444 3353 Page 17 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO LIMITED 90 DAY WARRANTY Harbor Freight Tools Co makes every
15. 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 Page 18 For technical questions please call 1 800 444 3353 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 produ
16. ement in warm water and mild detergent several times Rinse Squeeze out excess water and allow it to dry completely Soak the filter in lightweight oil briefly then squeeze out the excess oil 5 Install the new filter or the cleaned filter Secure the Air Cleaner Cover before use SKU 96156 For technical questions please call 1 800 444 3353 Page 11 Spark Plug Maintenance qe Page 12 Disconnect spark plug wire from end of plug Clean out debris from around spark plug Using a spark plug wrench remove the spark plug Inspect the spark plug If the electrode is oily clean it using a clean dry rag If the electrode has deposits on it polish it using emery paper If the white insulator is cracked or chipped the spark plug needs to be replaced When installing a new spark plug adjust the plug s gap to the specification on the Specification chart Do not pry against the electrode or the insulator the spark plug can be damaged Install the new spark plug or the cleaned spark plug into the engine Gasket style Finger tighten until the gasket contacts the cylinder head then about 1 2 2 3 turn more Non gasket style Finger tighten until the plug contacts the head then about 1 16 turn more Apply a small amount of dielectric grease not included to the insulator of the spark plug and attach the wire securely to the spark plug For technical questions please call 1 800 444 3353 Cleaning Main
17. f cableysheath Make sure the hardware does not contact moving parts Choke FIGURE C 6 Insert the mower s brake cable sheath through the hole in the Brake bracket Secure the mower brake cable to the brake arm Adjust the brake cable sheath to remove all slack and secure it in place using the adjusting nuts on the cable sheath See Figure C THE ENGINE BRAKE IS FOR EMERGENCY SHUTOFF DO NOT REPLACE THE BRAKE SPRING WITH A WEAKER SPRING If operating the engine brake is too difficult a u fihrottle Control qualified technician must install a AS TABES different brake handle on the mower FIGURE B 5 Insert the mower s choke cable sheath through the hole in the Choke bracket Secure the mower choke cable to the choke control Adjust the choke cable sheath to remove all slack and secureit 7 Throttle Control The throttle control on Note The brake choke cables on some mowers may need to be adjusted in a different manner Install according to mower manufacturer s instructions in place using the adjusting nuts on the this engine is controlled automatically cable sheath See Figure B Only a qualified technician should adjust the throttle controlling mechanism 8 Refer to the mower s service manual for instructions on how to properly attach a belt drive pulley chain drive gear etc onto the output shaft of the Engine SKU 96156 For technical questions please call 1 800 444 3353 Page 7 OPER
18. for the particular engine taking into account the working conditions and the work to be performed Use of the engine for operations different from those intended could result in a hazardous situation Do not operate the engine with known leaks in the fuel system SKU 96156 20 21 This product contains or when used produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq When spills of fuel or oil occur they must be cleaned up immediately Dispose of fluids and cleaning materials as per any local state or federal codes and regulations Store oil rags in a bottom ventilated covered metal container Keep hands and feet away from moving parts Do not reach over or across engine while operating Before use check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the engine s operation If damaged have the engine serviced before using Many accidents are caused by poorly maintained engines Use the correct engine for the application Do not modify the engine and do not use the engine for a purpose for which it is not intended Install on Lawn mower only Follow lawn mower manufacturer s operation precautions SERVICE PRECAUTIONS Before service maintenance or cleaning a Close the engine s fuel valve b Allow the engine to c
19. fuel flow Carburetor needle stuck Fuel can be smelled in the air Too much fuel in chamber This can be caused by the carburetor needle sticking MOWER ENGINE SPECIFIC 1 Make sure brake handle is held down and brake cable is properly adjusted 2 Start mower atop clear area free of loose objects and grass FUEL RELATED Fill fuel tank and open fuel valve Move choke to start position if engine is cold Use only fresh 89 octane unleaded gasoline Prime carburetor by pressing priming bulb specified number of times if equipped Clean out passageways using fuel additive Heavy deposits may require further cleaning Gently tap side of carburetor float chamber with screwdriver handle Turn choke to run position Remove spark plug and pull the start handle several times to air out the chamber Reinstall spark plug and set choke to start position IGNITION SPARK RELATED 1 Spark plug wire not connected securely 2 Spark plug electrode wet or dirty Incorrect spark plug gap Spark plug wire or spark plug broken Incorrect spark timing or faulty ignition system IGNITION SPARK RELATED Connect spark plug wire properly Clean spark plug Correct spark plug gap Replace spark plug wire and or spark plug Have qualified technician diagnose repair ignition system COMPRESSION RELATED 1 Cylinder not lubricated Problem after long storage periods Lo
20. ipe 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 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 Page 19
21. l 1 800 444 3353 Start Procedure A Before starting the engine a Follow the Installation Instructions to prepare the equipment Read and follow the instructions provided with the lawn mower c Inspect the equipment and engine d Fill the engine with the proper amount and type of fuel and oil e Connect the spark plug wire if it is disconnected WARNING To prevent injury Do not tie down the brake handle or otherwise override the engine brake TO SHUT OFF THE ENGINE RELEASE THE MOWER S BRAKE HANDLE 1 Move the lawn mower to a flat location free of loose rocks tall grass sand or loose ground that may be thrown by the lawnmower or slow down the engine while starting 2 Ifthe lawn mower is equipped with a transmission put it in neutral and set the parking brake 3 Open the fuel valve by turning it so it is vertical 4 Then pull and hold the choke control cable the closed start position Do not pull the choke control if restarting a warm engine 5 Squeeze the mower s brake handle to disengage the engine brake 6 Grasp the starter handle and pull slowly until resistance is felt While holding the handle allow the starter rope to rewind Page 9 10 slowly Then pull the starter handle with a rapid full arm stroke Once again while holding the handle allow the rope to rewind slowly Repeat as necessary until the engine starts After the engine starts and warms up
22. manual near the assembly Failure to follow all instructions diagram or month and year of purchase if listed below may result in fire product has no number Keep this manual serious injury and or DEATH The and the receipt in a safe and dry place for warnings and precautions discussed future reference in this manual cannot cover all possible conditions and situations that may occur It must be understood IM PO RTANT SAF ETY by the operator that common sense and caution are factors which cannot _____ INFORMATION be built into this product but must be In this manual on the labeling and supplied by the operator all other information provided with SAVE THESE INSTRUCTIONS this product This is the safety alert INSTALLATION PRECAUTIONS symbol Itis used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 1 Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Do not store fuel or other flammable materials nearby 2 Have multiple ABC class fire A DANGER DANGER indicates a extinguishers nearby hazardous situation Operation of this engine may create which if not avoided will result f in death or serious injury sparks that can start fires around dry vegetation WARNING indicates a A spark arrestor may be required AWARNING hazardous situation The operator should conta
23. 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 Repairs performed outside of the authorized warranty service dealers f Alterations by changing adding to or removing parts from the engine SKU 96156 For technical questions please call 1 800 444 3353 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 in this manual 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 p
24. ompletely cool c Then remove the spark plug wire s from the spark plug s Keep all safety guards in place and in proper working order Safety guards include muffler air cleaner mechanical a C guards and heat shields among other guards Do not alter or adjust any part of the engine that is sealed by the manufacturer or distributor Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during service Maintain labels and nameplates on the engine These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Have the engine serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the engine is maintained Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly THE ENGINE BRAKE IS FOR EMERGENCY SHUTOFF DO NOT REPLACE THE BRAKE SPRING WITH A WEAKER SPRING Store engine out of the reach of children Follow scheduled maintenance Refueling Precautions Do not smoke or allow sparks flames or other sources of ignition around the engine especially when refuelling Do not refill the fuel tank while the engine is running or hot Do not fill fuel tank to the top Leave a little room for the fuel to expand as needed Refuel in a well ventilated are
25. ose or broken spark plug Hissing noise will occur when trying to start Loose oylinder head or damaged head gasket Hissing noise will occur when trying to start Engine valves or tappets misadjusted or stuck COMPRESSION RELATED 1 Pour tablespoon of oil into spark plug hole Crank engine a few times and try to start again Tighten spark plug If that does not work replace spark plug If problem persists may have head gasket problem see 3 Tighten head If that does not remedy problem replace head gasket Adjust valve clearance If that does not work clean or replace valves tappets Follow all safety precautions whenever diagnosing or servicing the engine For technical questions please call 1 800 444 3353 SKU 96156 Possible Causes Probable Solutions Engine misfires Engine stops suddenly Engine knocks Engine backfires A SKU 96156 Spark plug wire loose Incorrect spark plug gap or damaged spark plug Defective spark plug wire 4 Old or low quality gasoline Incorrect compression Low oil shutdown Fuel tank empty or full of impure or low quality gasoline Defective fuel tank cap creating vacuum preventing proper fuel flow Improper idle speed Brake cable broken Faulty magneto incorrect timing or clogged carburetor Old or low quality gasoline Engine overloaded Incorrect spark timing deposit buildup worn engine or
26. other mechanical problems Impure or low quality gasoline Engine too cold Choke not open after engine warm Engine not properly adjusted for high altitude operation Intake valve stuck choke stuck incorrect timing clogged carburetor or overheated engine Check wire connections Re gap or replace spark plug Replace spark plug wire Use only fresh 89 octane unleaded gasoline Diagnose and repair compression Use Engine will not start COMPRESSION RELATED section Fill engine oil to proper level Check engine oil before EVERY use Fill fuel tank with fresh 89 octane unleaded gasoline Test replace fuel tank cap Properly adjust idle speed Repair brake cable as needed Have qualified technician diagnose and service engine Fill fuel tank with fresh 89 octane unleaded gasoline Do not exceed engine s load rating Have qualified technician diagnose and service engine Fill fuel tank with fresh 89 octane unleaded gasoline Use cold weather fuel and oil additives to prevent backfiring Move choke to run position after engine warms up Qualified technician must adjust engine at altitudes greater than 5 000 feet above sea level Have qualified technician diagnose and service engine Follow all safety precautions whenever diagnosing or servicing the engine For technical questions please call 1 800 444 3353 P
27. r Freight Tools Customer Service Department at 1 800 444 3353 Harbor Freight Tools Emission Control Defects Warranty Provisions Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two 2 years after the date of delivery to the first retail purchaser 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 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 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 previous page HFT shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconvenience Warranty coverage shall also be excluded for any part which fails malfunctions or is damaged due to failure to follow the maintenance and operating instructions set forth in the Owner s Manual including but not limited to a Use
28. r low engine oil WILL permanently damage the engine Starting the Engine Inspect engine looking for damaged loose and missing parts before installation and starting If any problems are found do not use engine until fixed properly SKU 96156 1 Clean the top of the dipstick and the area around it Remove the dipstick and wipe it off with a clean rag 2 Reinsert the dipstick without threading itin and remove it to check the oil level The oil level should be between the high and low marks on the dipstick 3 Ifthe oil level is below the low mark add SAE 10W 30 detergent or non detergent oil until the oil level is between the high and the low marks 4 Replace the Oil Dipstick CAUTION Do not run the engine with too little or too much oil The engine will be permanently damaged Checking and Filling Fuel A WARNING TO PREVENT 55 SERIOUS INJURY FROM FIRE Fill the fuel tank in a well ventilated area away from ignition sources Do not smoke 1 To fill the Fuel Tank first wipe off the Fuel Tank Cap and the surrounding area 2 Unscrew and remove the Fuel Tank Cap 3 Mix fuel stabilizer not included with 89 octane or better unleaded gasoline according to fuel stabilizer directions 4 Fillthe Fuel Tank to about 1 inch under the fill neck of the gasoline tank with the stabilized unleaded gasoline mixture 5 Then replace the Fuel Tank Cap SKU 96156 For technical questions please cal
29. tenance and Lubrication Schedule Note This maintenance schedule is intended solely as a general guide If performance decreases or if engine operates unusually check systems immediately The maintenance needs of each engine will differ depending on factors such as duty cycle temperature air quality fuel quality and other factors Note These procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the engine After Initial 20 Operation Hour Period a Change engine oil Every 25 Operation Hours Thereafter a Clean replace air filter element b Inspect clean spark plug Every 50 Operation Hours a Change engine oil Every 100 Operation Hours a Replace spark plug b Replace air filter element Note All maintenance procedures scheduled for 25 50 and 100 operation hours should be performed at least yearly Every 300 Operation Hours a Clean fuel tank and carburetor b Clean carbon build up from combustion chamber SKU 96156 Storage Wait for engine to cool then clean engine with clean cloth When the engine is to remain idle for longer than 20 days prepare the engine for storage as follows a Change engine oil and empty fuel tank b Either leave fuel tank empty or refill fuel tank with fresh unleaded gasoline mixed with a fuel stabilizer intended for long term engine storage not included After filling run engine for about 5 10
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