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.
Contents Specifications.......................................................................................... 3 Save This Manual................................................................................................ 3 Safety Warnings and Precautions................................................. 3 Unpacking.................................................................................................. 5 Mounting...............................................................................
Specifications Power Output Displacement / Stroke Ignition Type Cooling System Idling Carburetor Adjust Valve clearance Maximum Power Output Maximum Torque Distributor Timing Bore and Stroke Spark Plug Type Gasoline Type Gasoline Tank Capacity Drive Shaft Type Start Type Speed Oil Capacity and Type Engine Shaft Mounting Base Mounting Pattern Weight Overall Dimensions Recommended Applications Features 6.5 HP OHV Gas Engine, EPA 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. 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 children. 5.
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 Monoxide poisoning resemble the flu, with headaches, dizziness, or nausea.
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 bearings.
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. Check that all mounting nuts and bolts are tight. 2. Check oil level (See illustration below, left.) If needed, add oil.
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 it back slightly. , then move 4. Turn the Engine Switch (6K) to the On position. 5. Gently pull the Pull Cord Handle (16K) until it engages.
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. On/Off Switch in Off position. Gas 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.
Engine Excessively Hot Symptom Engine runs excessively hot. Probable Cause Possible Remedy 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. 1. Adjust ignition advance angle. 2. Fill with oil. 3. Clean out exhaust pipe and muffler. 4.
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.
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.
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 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.
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.
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 Cover Assembly Diagram Note: When ordering parts from this list, specify: Parts List B, CRANKCASE COVER ASSEMBLY and the ITEM No.
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.
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.
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.
Carburetor Assembly Diagram Note: When ordering parts from this list, specify: Parts List F, CARBURETOR ASSEMBLY and the ITEM No.
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 SKU 96549 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.
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 SKU 96549 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.
Muffler Assembly Diagram Note: When ordering parts from this list, specify: Parts List J, MUFFLER ASSEMBLY and the ITEM No. Muffler Parts List Part SKU 96549 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.
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 Part Description Qty 1K Bolt, M6x22 1 11K Spring, Friction 1 2K Crankcase Side Plate Assy 1 12K Spring Lid 1 3K Bolt, M6x18 3 13K Screw, Set 1 4K Fan Hood Assy.
Regulator Control Assembly Diagram Note: When ordering parts from this list, specify: Parts List L, REGULATOR CONTROL ASSEMBLY and the ITEM No.
Flywheel Assembly Diagram Note: When ordering parts from this list, specify: Parts List M, FLYWHEEL ASSEMBLY and the ITEM No. Flywheel Parts List Part SKU 96549 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.
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 SKU 96549 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.
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.
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).
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 (if so equipped). 5) Miscellaneous Items Used in Above Systems i) Vacuum, temperature and time sensitive valves and switches.