GAS ENGINE - 6.5 HP Model 96500 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.
Contents Specifications.......................................................................................... 3 Save This Manual................................................................................................ 3 Safety Warnings and Precautions................................................. 3 Unpacking.................................................................................................. 5 Mounting...............................................................................
Specifications Power Output Displacement / Stroke Ignition Type Start Type Cooling System Maximum Power Output Maximum Torque Idling Carburetor Adjust Valve clearance Distributor Timing Bore and Stroke Spark Plug Type Gasoline Type Gasoline Tank Capacity Drive Shaft Type Speed Oil Capacity and Type Engine Shaft Mounting Mounting Pattern Weight Overall Dimensions Recommended Applications Features 6.5 HP OHV Gas Engine, EPA and CARB approved 196 cc; 4-stroke Electronic ignition (T.C.I.
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. 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. 4. Store idle equipment.
16. 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 dispose of cleaning materials in a ventilated metal container. 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.
Unpacking When unpacking, check to make sure the all parts are included. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this 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.
Operation Controls and Indicators Fuel Tank (87) Spark Plug (25) Air Cleaner (75) Muffler (88) Muffler (88) Drive Shaft Oil Dipstick (36) Oil Plug (30) Oil Plug (30) Deposit Cup Drain Plug (1) Drain Plug (1) Engine Switch (97) Throttle Choke 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.
mark. Use a siphon to avoid spilling the oil. Carefully screw the Dip Stick back into the Engine crankcase. 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 attached. 4. Remove the debris filter, clean, and replace it before filling.
Troubleshooting General/Basic Troubleshooting Symptom Probable Cause Engine will not start. Engine runs rough, pinging noises. Engine stops by itself, but has gas. Engine does not reach full speed. 1. 2. 3. 4. 5. 6. 1. 2. 1. 2. 1. 2. 3. Engine Switch in Off position. Fuel Valve in closed position. Choke set to open position. Gas Tank empty. Spark plug dirty. Technical problem. Gasoline wrong type. Gasoline has water. Low oil level auto shut off. Technical problem. Choke closed. Air filters clogged.
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. 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.
Symptom Engine stops suddenly. Probable Cause 1. Gas tank empty. 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. Possible Remedy 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.
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.
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. 4. Allow all the oil to drain out into the pan.
Torque Value for Major Engine Bolts Item Cylinder Head Bolts Flywheel Bolt Crankcase Cover Bolts Connecting Rod Torque Value (ft-lb) 18 52~59 18 9 Transporting the Engine 1. 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 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.
Parts list Part Description Qty Part Description Qty 1 Oil Drain Plug 2 41 Piston Ring (II) 1 2 Washer 2 42 Side Rail 2 3 Bearing 6205 1 43 Expander 1 4 Crankshaft Oil Seal 1 44 Scraper Ring Set 1 5 Crankcase 1 45 Piston Ring Assembly 1 6 Regulating Sway Bar 1 46 Piston Pin Clip 2 7 Washer 1 47 Piston 1 8 Split Pin 1 48 Piston Pin 1 9 Oil Sensor 1 49 Shank 1 10 M6x14 Bolt 2 50 Connecting Rod Cover 1 11 Regulating Shaft 1 51 Bolt 2 12 W
Part Description Qty Part Description Qty 81 Packing Ring 2 100 Diode 1 82 M6 Nut 2 101 Regulating Frame Assembly 1 83 Filter Cup 1 102 Back Spring 1 84 Packing Ring 1 103 Regulating Spring 1 85 Fuel Cap 1 104 Pulling Rod 1 86 Fuel Cap with Assembly 1 105 Lock Bolt 1 87 Fuel Tank 1 106 Regulating Arm 1 88 Exhaust Muffler 1 107 M6 Nut 1 89 Exhaust Gasket 1 108 M6x25 Screw 2 90 M6 Nut 2 109 M14x1.
Assembly Diagram REV 07i SKU 96500 For technical questions, please call 1-800-444-3353.
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.
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.
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.
