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GAS ENGINE - 6.5 HP
Model 96500
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 repr
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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 and CARB approved Displacement / Stroke 196 cc; 4-stroke Ignition Type Electronic ignition (T.C.I.) Start Type Recoil Cooling System Forced air cooling Maximum Power Output 4.8 KW @ 3600 RPM Maximum Torque 11-N.M./2500-RPM Idling Carburetor Adjust 1700 +/- 150 RPM Valve clearance Cold engine – Intake: 0.15 +/- 0.02mm; Exhaust: 0.20 +/- 0.02 mm Distributor Timing Intake valve opening: BTDC10°; Intake valve closing: ABDC20° Bore and Stroke
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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. 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. When not in use, t
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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 dis- pose 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 dur- ing operation and is deadly in a closed environment. Early signs of Carbon Monoxide poisoning resemble the flu, with headach
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unp Acking When unpacking, check to make sure the all parts are included. If any parts are miss- ing 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.
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OperA tiOn controls and indicators spark plug (25) Air cleaner (75) Muffler (88) Muffler (88) fuel t ank (87) drive shaft Oil dipstick Oil plug (30) (36) 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: f ailure 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 additi
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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). c aution: To avoid damaging the Engine, never run it without the Air Filter assembly at- tached. 4. Remove the debris filter, clean, and replace it before filling. Remove the Fuel
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tr OubleshOO ting general/basic t roubleshooting symptom probable cause possible remedy Engine will not start. 1. Engine Switch in Off position. 1. Turn to On position. 2. Fuel 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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symptom probable cause possible remedy Engine stops suddenly. 1. Gas tank empty. 1. Fill gas tank. 2. Carburetor clogged 2. Clean carburetor and check 3. Floater is leaking. fuel line. 4. Needle valve sticks. 3. Repair or replace. 5. Spark plug dirty or damaged. 4. Disassemble floater chamber 6. Spark plug connector wire and clean. damaged or disconnected. 5. Replace spark plug. 7. Low oil auto-shutdown. 6. Check and repair spark plug 8. Ignition coil damaged. wire. 9. Cylinder
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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 6. 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 or item use month or 50 months or 300 hours. 20 hours hours 100 hours. Engine oil Check Replace Replace Air Filter Check Clean Clean Replace Spark Plug Clean & Adjust Replace Spark Eliminator
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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. Pour the used oil into a con
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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 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.
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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 Washer 1 52 Connecting Rod Assembly 1 13 Regulator Gear Assemb
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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 M14x1.5 Nut 1 91 M6x22 Bolt 1 110 Starting Flange 1 92 Crankcase Side Plate Assembly 1 111 Flywheel Fan 1 93
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AsseMbly diA grAM reV 07i SKU 96500 for technical questions, please call 1-800-444-3353. Page 17
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liMited 90 d Ay 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. 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 installati
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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. E
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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. Any replacement part, provided it is equivalent in durability and performance, may
