Instruction/ maintenance manual of the product 96549 Harbor Freight Tools
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GAS ENGINE - 6.5 HP Model 96549 ASSEMBL Y AND OPERA TION INSTR UCTIONS Due to continuing impro vements , actual product may diff er slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo , CA 93011 Visit our website at: http://www .
P age 2 SKU 96549 For technical questions, please call 1-800-444-3353. Contents SPECIFICA TIONS ......................................................................................... 3 Sav e This Manual .............................................
P age 3 SKU 96549 For technical questions, please call 1-800-444-3353. SPECIFICA TIONS P ower Output 6.5 HP OHV Gas Engine, EP A appro ved Displacement / Stroke 196 cc; 4-stroke Ignition T ype Electronic ignition (T .C .I.) Cooling System F orced air cooling Idling Carburetor Adjust 1700 +/- 150 RPM V alve clearance Cold engine – Intak e: 0.
P age 4 SKU 96549 For technical questions, please call 1-800-444-3353. Observe work area conditions. Do not use the Engine in damp or wet locations. Do not e xpose to rain. K eep w ork area w ell lit. Do not use powered tools in the presence of flammable gases or liquids .
P age 5 SKU 96549 For technical questions, please call 1-800-444-3353. Fire Hazard! Do not fill gas tank when the Engine is running. Do not operate if gasoline has been spilled. Clean spilled gasoline before star ting the Engine . Do not operate near a pilot light or open flame .
P age 6 SKU 96549 For technical questions, please call 1-800-444-3353. MOUNTING Mount the Engine using the f our mounting holes at the base (hardware not supplied). Select a flat, le vel location ab le to withstand the weight, vibr ation, and the load de vice connected to the Engine.
P age 7 SKU 96549 For technical questions, please call 1-800-444-3353. Pre-Operation Chec ks Caution: Failure to ad d oil to the Engine bef ore use will dama ge the Engine and void the factory warranty . Engine oil is the k ey f actor in engine perf or mance .
P age 8 SKU 96549 For technical questions, please call 1-800-444-3353. Starting the Engine During this procedure, it ma y be helpful to ref er to the photos of the Engine Controls on page 6. Push the Gas V alve to the open (right) position. Close the Choke (15F) b y pulling it to the left.
P age 9 SKU 96549 For technical questions, please call 1-800-444-3353. TR OUBLESHOO TING General/Basic T r oubleshooting Symptom Probab le Cause P ossible Remedy Engine will not star t. 1. On/Off Switch in Off position. 2. Gas V alve in closed position.
P age 10 SKU 96549 For technical questions, please call 1-800-444-3353. Low Engine P ower Symptom Probab le Cause P ossible Remedy When pressing Throttle f or higher speed, engine responds slowly; speed is decreased; or engine stops. Incorrect Ignition timing.
P age 11 SKU 96549 For technical questions, please call 1-800-444-3353. Engine Excessively Hot Symptom Probab le Cause P ossible Remedy Engine runs excessiv ely hot. 1. Ignition timing off . 2. Engine oil low . 3. Exhaust pipe or muffler clogged. 4. Flow guard is leaking.
P age 12 SKU 96549 For technical questions, please call 1-800-444-3353. MAINTENANCE Bef ore performing maintenance procedures, it ma y be helpful to locate the items to be ser viced in the photos on page 5. Man y Engine maintenance , adjustments , and repairs m ust be completed by a qualified, small engine mechanic.
P age 13 SKU 96549 For technical questions, please call 1-800-444-3353. Measure the Spar k Plug electrode gap with a feeler gauge (not supplied). It should be between 0.7 to 0.8 mm. If adjustment is necessar y , bend the side electrode carefully , then re-measure.
P age 14 SKU 96549 For technical questions, please call 1-800-444-3353. T orque V alue f or Major Engine Bolts Item T orque V alue (ft-lb) Cylinder Head Bolts 18 Flywheel Bolt 52~59 Crankcase Co ver Bolts 18 Connecting Rod 9 T ranspor ting the Engine Press the Gas V alve to the left (closed) position.
P age 15 SKU 96549 For technical questions, please call 1-800-444-3353. PLEASE READ THE FOLLO WING CAREFULL Y THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THESE P AR TS LISTS AND ASSEMBL Y DIAGRAMS IN THIS MANU AL AS A REFERENCE T OOL ONL Y .
P age 16 SKU 96549 For technical questions, please call 1-800-444-3353. P AR TS LISTS AND ASSEMBL Y DIA GRAMS Crankcase Assembl y Diagram Note: When ordering par ts from this list, specify: P ar ts List A , CRANKCASE ASSEMBL Y and the ITEM No .
P age 17 SKU 96549 For technical questions, please call 1-800-444-3353. Crankcase Co ver Assembl y Diagram Note: When order ing par ts from this list, specify: Parts List B , CRANKCASE CO VER AS- SEMBL Y and the ITEM No .
P age 18 SKU 96549 For technical questions, please call 1-800-444-3353. Cylinder Head and Co ver Assembl y Diagram Note: Whe n orde ring pa r ts fro m thi s list , spe cif y: P arts List C , CYLI NDE R HEA D AND CO VER ASSEMBL Y and the ITEM No .
P age 19 SKU 96549 For technical questions, please call 1-800-444-3353. Crankshaft, Piston, and Connecting Rod Assembly Dia gram Note: When ordering par ts from this list, specify: Parts List D , CRANKSHAFT , PIST ON, AND CONNECTING ROD ASSEMBL Y and the ITEM No.
P age 20 SKU 96549 For technical questions, please call 1-800-444-3353. Camshaft and Roc ker V alve Assembly Diagram Note: When ordering par ts from this list, specify: P ar ts List E , CAMSHAFT AND ROCKER V AL VE ASSEMBL Y and the ITEM No .
P age 21 SKU 96549 For technical questions, please call 1-800-444-3353. Carb uretor Assembl y Diagram Note: When ordering par ts from this list, specify: P ar ts List F , CARB URET OR ASSEMBL Y and the ITEM No .
P age 22 SKU 96549 For technical questions, please call 1-800-444-3353. Fuel T ank Assembl y Diagram Note: When order ing par ts from this list, specify: P ar ts List G , FUEL T ANK ASSEMBL Y and the ITEM No .
P age 23 SKU 96549 For technical questions, please call 1-800-444-3353. Air Cleaner Assembl y Diagram Note: When ordering par ts from this list, specify: Parts List H , AIR CLEANER ASSEMBL Y and the ITEM No .
P age 24 SKU 96549 For technical questions, please call 1-800-444-3353. Muffler Assembl y Diagram Note: When order ing par ts from this list, specify: Parts List J , MUFFLER ASSEMBL Y and the ITEM No .
P age 25 SKU 96549 For technical questions, please call 1-800-444-3353. Recoil Star ter Assembl y Diagram Note: Whe n or derin g pa r ts from thi s li st, spe cify : P arts Li st K , RE COIL ST AR TER ASS EMB L Y and the ITEM No .
P age 26 SKU 96549 For technical questions, please call 1-800-444-3353. Regulator Contr ol Assembl y Diagram Note: When ordering par ts from this list, specify: P ar ts List L , REGULA T OR CONTROL ASSEMBL Y and the ITEM No .
P age 27 SKU 96549 For technical questions, please call 1-800-444-3353. Flywheel Assemb ly Dia gram Note: When order ing par ts from this list, specify: P ar ts List M , FL YWHEEL ASSEMBL Y and the ITEM No . Flywheel P ar ts List P art Description Qty 1M Nut, M14x1.
P age 28 SKU 96549 For technical questions, please call 1-800-444-3353. Ignition Coil Assembl y Diagram Note: When order ing par ts from this list, specify: P ar ts List N , IGNITION COIL ASSEMBL Y and the ITEM No .
P age 29 SKU 96549 For technical questions, please call 1-800-444-3353. Wiring Diagram LIMITED 90 D A Y W ARRANTY Harbor F reight T ools Co . make s e v er y eff or t to assure that its products meet .
P age 30 SKU 96549 For technical questions, please call 1-800-444-3353. Emission Contr ol systEm W arranty United States Emission Control Def ects Warranty Statement The United States En vironmental P.
P age 31 SKU 96549 For technical questions, please call 1-800-444-3353. 6. W arranted P ar ts 1) Fuel Metering System Carburetor and its internal par ts. Fuel pump (if so equipped). Cold star t enrichment system. 2) Air Induction System Intake pipe/manif old.
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