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GAS ENGINE - 6.5 HP
Model 96549
AsseMbly And OperA tiOn 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 underst And
All w Arnings 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 repro
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contents specificA tiOns ......................................................................................... 3 Save This Manual ...............................................................................................3 sAfety wArnings And precA utiOns ................................................ 3 unp Acking ................................................................................................. 5 MOunting .................................................................
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specificA tiOns 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
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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. k eep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, or extension cords. 4. 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 child
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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. 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 Monox- ide poisoning resemble the flu, with headaches, dizziness, or nausea. If you develop these symptoms, there may
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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 load device connected to the Engine. If installed indoors, proper exhaust ventilation tubing must be installed. If installed outdoors, a weatherproof housing is recommended. 2. Install the Engine load. The Engine load must be perfectly aligned with the Engine drive shaft to prevent undue wear on the shaft and bearing
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pre-Operation checks caution: f ailure 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. Check that all mounting nuts and bolts are tight. 2. Check oil level (See illustration below, left.) If needed, add oil. Unscrew the
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starting the engine During this procedure, it may be helpful to refer to the photos of the Engine Controls on page 6. 1. Push the Gas Valve to the open (right) position. 2. Close the Choke (15F) by pulling it to the left. note: If the Engine is already hot, it is not necessary to close the Choke. 3. Push the Throttle Lever (18F) to the slow (right) position , then move it back slightly. 4. Turn the Engine Switch (6K) to the On position. 5. Gently pull the Pull Cord Handle (16K) until it
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tr OubleshOO ting general/basic t roubleshooting symptom probable cause possible remedy Engine will not start. 1. On/Off Switch in Off position. 1. Turn to On position. 2. Gas 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
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low engine p ower symptom probable cause possible remedy When pressing Throttle Incorrect Ignition timing. Re-adjust ignition advance angle. for higher speed, engine Fuel supply problem: 1. Clean line. Bleed line of air. responds slowly; speed is 1. Fuel line is clogged or has air 2. Readjust jet. decreased; or engine stops. 2. Main jet not adjusted properly 3. Clean needle valve hole and 3. Carburetor needle valve hole main jet and main jet clogged 4. Clean or replace gas valve. 4. Gas
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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 result
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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 each first each every 6 each year item use month or 50 months or or 300 20 hours hours 100 hours. hours. Engine oil Check Replace Replace Air Filter Check Clean Clean Replace Spark Plug Clean & Adjust Replace Spark Eliminator
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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. 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 1. Run t
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t orque Value for Major engine bolts item t orque Value (ft-lb) Cylinder Head Bolts 18 Flywheel Bolt 52~59 Crankcase Cover Bolts 18 Connecting Rod 9 t ransporting the engine 1. Press the Gas 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 1. Replace the Engine oil with new oil before storing as described on page 13. 2. Remove the Spark Plug as described on page 12. A
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pleAse reAd the fOllO wing 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 REPRE- SENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS q UALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS q UALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MAN- UFACTURER AND/OR DISTRIBUTOR ExPRESSLY STATES THAT ALL REPAIRS AND PAR
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pArts lists And AsseMbly diA grAMs crankcase Assembly diagram note: When ordering parts from this list, specify: parts list A , CRANKCASE ASSEMBLY and the ITEM No. crankcase p arts list part description Qty part description Qty 1A Drain Plug 2 11A Bolt, M6x14 2 2A Washer 2 12A Regulating Shaft 1 3A Bearing, 6205 1 13A Washer, Drive Gear 1 4A Seal, Oil, Crankshaft 1 14A Pin 2 5A Crankcase 1 15A Drive Gear, Regulator 1 6A Sway Bar, Regulator 1 16A Fly Block 2 7A Washer 2 17A Drive Gear Assembly R
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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 p arts list part description Qty part description Qty 1B Oil Plug with Seal 1 7B Pin, Set 2 2B Oil Plug 1 8B Dipstick 1 3B Seal 2 9B Dipstick with seal 1 4B Crankcase Cover 1 10B Oil Seal, Crankshaft 1 5B Bearing, 6250 1 11B Bolt, M8x32 7 6B Gasket, Crankcase 1 SKU 96549 for technical questions, please call 1-800-444-3353. Page 17
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cylinder head and cover Assembly diagram note: When ordering parts from this list, specify: parts l ist c , CYLINDER HEAD AND COVER ASSEMBLY and the ITEM No. cylinder head and cover p arts list part description Qty part description Qty 1C Bolt, M6x12 6 9C Stud, M8x34 2 2C Air duct 1 10C Spark Plug, F6TC 1 3C Intake Valve Guide 1 11C Exhaust Valve Guide 1 4C Lead Wind Cover 1 12C Circle Clip 1 5C Stud, M6x109 2 13C Bolt 4 6C Pin, Set 10x16 2 14C Gasket, Cylinder Head Cover 1 7C Gasket, Cylinder
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crankshaft, piston, and connecting rod Assembly diagram note: When ordering parts from this list, specify: parts l ist d, CRANKSHAFT, PISTON, AND CONNECTING ROD ASSEMBLY and the ITEM No. crankshaft, piston, and connecting rod p arts list part description Qty part description Qty 1D Piston Ring (I) 1 10D Connecting Rod 1 2D Piston Ring (II) 1 11D Connecting Rod Cover 1 3D Side Rail 2 12D Bolt 2 4D Expander 1 13D Connecting Rod Assembly 1 5D Scraper Ring Set 1 14D Woodruff Key 1 6D Piston Ring As
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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 p arts list part description Qty part description Qty 1E Lock Nut 2 9E Spring, Extension 1 2E Sleeve 2 10E Camshaft Assembly 1 3E Valve, Rocker 2 11E Valve, Exhaust 1 4E Bolt, Adjusting, Valve Gap 2 12E Valve, Intake 1 5E Valve, Rocker, Assembly 2 13E Spring, Valve 2 6E Pusher Guide 1 14E Spring Seat, Intake Va
