Harbor Freight Tools Lawn Mower 96156 User Guide

5.5 HP Lawn Mower enGIne  
96156  
InstaLLatIon, oPeratInG, and servIcInG  
InstructIons  
using an engine indoors can KILL You In  
MInutes.  
engine exhaust contains carbon monoxide.  
this is a poison you cannot see or smell.  
only use outsIde  
never use inside  
and far away from  
a home or garage,  
windows, doors, and  
vents.  
even IF doors and  
windows are open.  
®
distributed exclusively by Harbor Freight tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
visit our website at: http://www.harborfreight.com  
read this material before using this product.  
Failure to do so can result in serious injury.  
save tHIs ManuaL.  
©
®
Copyright 2008 by Harbor Freight Tools . All rights reserved. No portion of this manual or any artwork  
contained herein may be reproduced in any shape or form without the express written consent of  
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing  
improvements, actual product may differ slightly from the product described herein. Tools required for  
installation and service may not be included.  
For technical questions or replacement parts, please call 1-800-444-3353.  
Manual revised 08d, 09h  
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cautIon, without the  
safety alert symbol, is  
used to address practices not  
related to personal injury.  
save tHIs ManuaL  
Keep this manual for the safety warnings  
and precautions, installation, operating,  
inspection, maintenance and cleaning  
procedures. Write the product’s serial number  
in the back of the manual near the assembly  
diagram (or month and year of purchase if  
product has no number). Keep this manual  
and the receipt in a safe and dry place for  
future reference.  
warnInG! read all instructions.  
Failure to follow all instructions  
listed below may result in fire,  
serious injury and/or deatH. The  
warnings and precautions discussed  
in this manual cannot cover all  
possible conditions and situations that  
may occur. It must be understood  
by the operator that common sense  
and caution are factors which cannot  
be built into this product, but must be  
supplied by the operator.  
IMPortant saFetY  
InForMatIon  
In this manual, on the labeling, and  
all other information provided with  
this product:  
save tHese InstructIons  
this is the safety alert  
symbol. It is used to alert  
you to potential personal  
injury hazards. obey all  
safety messages that follow  
this symbol to avoid possible  
injury or death.  
InstaLLatIon PrecautIons  
1. Gasoline fuel and fumes are flammable,  
and potentially explosive. Use proper  
fuel storage and handling procedures.  
Do not store fuel or other flammable  
materials nearby.  
2. Have multiple ABC class fire  
danGer indicates a  
hazardous situation  
which, if not avoided, will result  
in death or serious injury.  
extinguishers nearby.  
3. Operation of this engine may create  
sparks that can start fires around dry  
vegetation.  
warnInG indicates a  
hazardous situation  
which, if not avoided, could  
result in death or serious injury.  
A spark arrestor may be required.  
The operator should contact local fire  
agencies for laws or regulations relating  
to fire prevention requirements.  
4. Install only to a lawn mower and only in  
an upright position.  
cautIon, used with  
the safety alert  
symbol, indicates a hazardous  
situation which, if not avoided,  
could result in minor or moderate  
injury.  
5. Wear ANSI-approved safety goggles,  
heavy-duty work gloves, and dust mask/  
respirator during installation.  
6. Use only oil and fuel recommended  
in the “Specifications” section of this  
manual.  
notIce is used to  
address practices not  
related to personal injury.  
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7. Follow lawn mower manufacturer’s  
installation procedures for attaching the  
engine to the mower and connecting the  
output shaft.  
6. Use only accessories that are  
recommended by Harbor Freight Tools  
for your model. Accessories that may  
be suitable for one engine may become  
hazardous when used on another  
engine.  
oPeratInG PrecautIons  
7. Do not operate in explosive  
atmospheres, such as in the presence  
of flammable liquids, gases, or dust.  
Gasoline-powered engines may ignite  
the dust or fumes.  
1.  
carBon MonoxIde  
Hazard  
using an engine indoors  
can KILL You In MInutes.  
Engine exhaust contains  
carbon monoxide. This is a poison you  
cannot see or smell.  
8. Stay alert, watch what you are doing and  
use common sense when operating this  
engine. Do not use this engine while  
tired or under the influence of drugs,  
alcohol or medication.  
9. Do not overreach. Keep proper  
footing and balance at all times. This  
enables better control of the engine in  
unexpected situations.  
NEVER use inside a home or garage,  
EVEN IF doors and windows are open.  
10. Dress properly. Do not wear loose  
clothing or jewelry. Keep hair, clothing  
and gloves away from moving parts.  
Loose clothes, jewelry or long hair can  
be caught in moving parts.  
Only use OUTSIDE and far away from  
windows, doors, and vents.  
11. Parts, especially exhaust system  
components, get very hot during use.  
Stay clear of hot parts.  
2. Keep children away from the engine,  
especially while it is operating.  
12. Do not cover the engine during  
operation.  
3. Do not leave the engine unattended  
when it is running. Turn off the engine  
before leaving the work area.  
13. Keep the engine and surrounding area  
clean at all times.  
4. Wear ANSI-approved safety goggles and  
hearing protection during use.  
14. Use the engine, accessories, etc., in  
accordance with these instructions and  
in the manner intended for the particular  
engine, taking into account the working  
conditions and the work to be performed.  
Use of the engine for operations different  
from those intended could result in a  
hazardous situation.  
5. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close proximity  
to a heart pacemaker could cause  
pacemaker interference or pacemaker  
failure. Caution is necessary when near  
the engine’s magneto or recoil starter.  
15. Do not operate the engine with known  
leaks in the fuel system.  
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16. This product contains or, when used,  
produces a chemical known to the State  
of California to cause cancer and birth  
defects or other reproductive harm.  
(California Health & Safety Code §  
25249.5, et seq.)  
guards, and heat shields, among other  
guards.  
3. do not alter or adjust any part of  
the engine that is sealed by the  
manufacturer or distributor.  
4. Wear ANSI-approved safety goggles,  
heavy-duty work gloves, and dust mask/  
respirator during service.  
17. When spills of fuel or oil occur, they must  
be cleaned up immediately. Dispose  
of fluids and cleaning materials as per  
any local, state, or federal codes and  
regulations. Store oil rags in a bottom-  
ventilated, covered, metal container.  
5. Maintain labels and nameplates on  
the engine. These carry important  
information. If unreadable or missing,  
contact Harbor Freight Tools for a  
replacement.  
18. Keep hands and feet away from moving  
parts. Do not reach over or across  
engine while operating.  
6. Have the engine serviced by a qualified  
repair person using only identical  
replacement parts. This will ensure that  
the safety of the engine is maintained.  
Do not attempt any service or  
19. Before use, check for misalignment  
or binding of moving parts, breakage  
of parts, and any other condition that  
may affect the engine’s operation. If  
damaged, have the engine serviced  
before using. Many accidents are  
caused by poorly maintained engines.  
maintenance procedures not explained  
in this manual or any procedures that  
you are uncertain about your ability to  
perform safely or correctly.  
20. Use the correct engine for the  
application. Do not modify the engine  
and do not use the engine for a purpose  
for which it is not intended. Install on  
Lawn mower only.  
tHe enGIne BraKe Is For  
eMerGencY sHutoFF; do not  
rePLace tHe BraKe sPrInG wItH  
a weaKer sPrInG.  
7. Store engine out of the reach of children.  
8. Follow scheduled maintenance.  
9. Refueling Precautions:  
21. Follow lawn mower manufacturer’s  
operation precautions.  
a. Do not smoke, or allow sparks, flames,  
or other sources of ignition around the  
engine, especially when refuelling.  
servIce PrecautIons  
1. Before service, maintenance, or  
cleaning:  
b. Do not refill the fuel tank while the  
engine is running or hot.  
a. close the engines fuel valve.  
c. Do not fill fuel tank to the top. Leave  
a little room for the fuel to expand as  
needed.  
b. allow the engine to completely cool.  
c. then, remove the spark plug wire(s)  
from the spark plug(s).  
d. Refuel in a well-ventilated area only.  
2. Keep all safety guards in place and in  
proper working order. Safety guards  
include muffler, air cleaner, mechanical  
save tHese  
InstructIons.  
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sPecIFIcatIons  
InstaLLatIon  
read the entIre IMPortant  
saFetY InForMatIon  
section at the beginning of this  
manual including all text under  
subheadings therein before  
installation or use of this product.  
Engine Rating  
5.5 Horsepower  
89+ octane unleaded gasoline  
0.45 Gallons  
Type  
Fuel  
Capacity  
10W-30  
(Detergent or non-detergent)  
Type  
Engine Oil  
Capacity  
18.6 oz.  
Run Time @ 50% Load 3.5 Hours with full tank  
to Prevent  
serIous InjurY  
Sound Level  
77 dB  
4 Stroke, OHV  
(1P68FV / 7CLGS.16368V)  
Engine Type  
FroM accIdentaL startInG:  
close the engines fuel valve,  
wait for the engine to cool, and  
disconnect the spark plug wire(s)  
before installing or making any  
adjustments to the engine.  
Bore x Stroke  
68 mm x 45 mm  
Compression Ratio  
Displacement  
8:1  
163cc  
Rotation viewed from PTO  
Counterclockwise  
(power takeoff - the output shaft)  
7/8” x 3-1/8”, 3/16” keyway,  
end tapped 3/8”-24  
Shaft Size/Type  
to Prevent  
serIous InjurY:  
operate only with proper spark  
arrestor installed.  
operation of this engine may  
create sparks that can start fires  
around dry vegetation.  
a spark arrestor may be required.  
the operator should contact  
local fire agencies for laws or  
regulations relating to fire  
prevention requirements.  
F6TC resistive  
Type  
®
®
(NGK BP-6HS,Champion RL86C)  
0.028”-0.031”  
0.1 mm  
Spark Plug  
Gap  
Intake  
Exhaust  
Idle  
Valve  
Clearance  
0.15 mm  
2000 RPM  
Speed  
Maximum 3250 RPM  
The emission control system for this  
engine is warranted for standards set by the  
U.S. Environmental Protection Agency. For  
warranty information, refer to the last pages of  
this manual.  
1. IMPortant: If you have any doubts  
about your ability to perform the following  
procedures, have a qualified service  
technician perform the installation.  
At high altitudes, the engine’s carburetor  
and any other parts that control the fuel-air  
ratio will need to be adjusted by a qualified  
mechanic to allow efficient high-altitude use  
and to prevent damage to the engine and any  
other devices used with this product.  
2. Install this engine on a lawn mower only.  
unPacKInG  
When unpacking, make sure that the  
item is intact and undamaged. If any parts  
are missing or broken, please call Harbor  
Freight Tools at 1-800-444-3353 as soon as  
possible.  
Figure a - Mounting Hole Locations (Bottom view)  
3. Set the Engine upright on the mower,  
and align the four 3/8” diameter coarse  
threaded engine mounting holes with  
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four mower mounting holes.  
Brake  
bracket  
mower brake  
cable  
(see Figure a.)  
note: Depending on the mower, it may  
be necessary to drill mounting holes or  
make a mounting plate to align with the  
engine mounting holes.  
4. Use four 3/8” diameter, coarse threaded,  
hardened, stainless steel Bolts, Lock  
Washers, and Washers (not included) of  
appropriate length to secure the Engine  
to the mower.  
mower brake  
cable sheath  
Brake  
arm  
Make sure the hardware does not  
contact moving parts.  
FIGure c  
choke  
control  
choke mower choke  
bracket cable sheath  
6. Insert the mower’s brake cable sheath  
through the hole in the Brake bracket.  
Secure the mower brake cable to the  
brake arm. Adjust the brake cable  
sheath to remove all slack and secure it  
in place using the adjusting nuts on the  
cable sheath. (see Figure c.)  
mower  
choke  
cable  
tHe enGIne BraKe Is For  
eMerGencY sHutoFF; do not  
rePLace tHe BraKe sPrInG wItH  
a weaKer sPrInG. If operating  
the engine brake is too difficult, a  
qualified technician must install a  
different brake handle on the mower.  
automatic  
throttle control  
(not adjustaBLe)  
FIGure B  
note: The brake/choke cables on some  
mowers may need to be adjusted in a  
different manner. Install according to  
mower manufacturer’s instructions.  
5. Insert the mower’s choke cable sheath  
through the hole in the Choke bracket.  
Secure the mower choke cable to the  
choke control. Adjust the choke cable  
sheath to remove all slack and secure it  
in place using the adjusting nuts on the  
cable sheath. (see Figure B.)  
7. throttle control - The throttle control on  
this engine is controlled automatically.  
Only a qualified technician should  
adjust the throttle controlling  
mechanism.  
8. Refer to the mower’s service manual for  
instructions on how to properly attach a  
belt drive pulley, chain drive gear, etc.  
onto the output shaft of the Engine.  
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Fuel  
valve  
oPeratInG InstructIons  
read the entIre IMPortant  
saFetY InForMatIon  
section at the beginning of this  
manual including all text under  
subheadings therein before  
installation or use of this product.  
engine controls  
automatic  
throttle control  
(not adjustaBLe)  
Fuel tank  
starter  
Handle  
choke control  
cap  
Fuel valve - This controls the fuel supply to  
the engine.  
The horizontal position is closed (off).  
The vertical position is open (on).  
choke control - This controls the air-fuel  
ratio for starting the engine.  
The released position is open (run).  
The engaged position is closed (start).  
oil Fill  
automatic throttle control - This is  
not adjustable except by a qualified  
technician.  
Brake  
arm  
starting the engine  
oil Fill - The oil fill cap has a dipstick  
attached. The crosshatch pattern at the  
bottom of the dipstick is the proper oil  
range. Before each use, check that the  
oil level is at the top of the cross hatched  
pattern, but not above that level.  
Inspect engine looking for  
damaged, loose, and missing parts  
before installation and starting. If  
any problems are found, do not  
use engine until fixed properly.  
Brake arm - This must be held back to allow  
the engine to operate. It will force the  
engine to stop when released.  
checking and Filling engine oil  
cautIon! Your Warranty is VOID if the  
engine’s crankcase is not properly  
filled with oil before each use. Before  
each use, check the oil level. Do not  
run the engine with low or no engine  
oil. Running the engine with no or low  
engine oil WILL permanently damage the  
engine.  
starter Handle - This is pulled to start the  
engine.  
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1. Clean the top of the dipstick and the area start Procedure  
around it. Remove the dipstick and wipe  
it off with a clean rag.  
Before starting the engine:  
a. Follow the Installation  
Instructions to prepare the  
equipment.  
2. Reinsert the dipstick without threading  
it in and remove it to check the oil level.  
The oil level should be between the high  
and low marks on the dipstick.  
b. read and follow the instructions  
provided with the lawn mower.  
c. Inspect the equipment and  
engine.  
3. If the oil level is below the low mark  
add SAE 10W-30 (detergent or non-  
detergent) oil until the oil level is between  
the high and the low marks.  
d. Fill the engine with the proper  
amount and type of fuel and oil.  
e. connect the spark plug wire if it  
is disconnected.  
4. Replace the Oil Dipstick.  
cautIon! Do not run the engine with too  
little or too much oil. The engine will be  
permanently damaged.  
warnInG! to prevent injury:  
do not tie down the brake  
handle or otherwise override the  
engine brake.  
checking and Filling Fuel  
to sHut oFF tHe enGIne,  
reLease tHe Mower’s  
BraKe HandLe.  
warnInG! to Prevent  
serIous InjurY FroM FIre:  
Fill the fuel tank in a well-ventilated  
area away from ignition sources.  
Do not smoke.  
1. Move the lawn mower to a flat location  
free of loose rocks, tall grass, sand, or  
loose ground that may be thrown by the  
lawnmower, or slow down the engine  
while starting.  
1. To ll the Fuel Tank, first wipe off the  
Fuel Tank Cap and the surrounding area.  
2. Unscrew, and remove the Fuel Tank  
Cap.  
2. If the lawn mower is equipped with a  
transmission, put it in neutral and set the  
parking brake.  
3. Mix fuel stabilizer (not included) with 89  
octane (or better) unleaded gasoline  
according to fuel stabilizer directions.  
3. Open the fuel valve by turning it so it is  
vertical.  
4. Fill the Fuel Tank to about 1 inch under  
the fill neck of the gasoline tank with the  
stabilized unleaded gasoline mixture.  
4. Then, pull and hold the choke control  
cable (the closed, start position). Do not  
pull the choke control if restarting a warm  
engine.  
5. Then replace the Fuel Tank Cap.  
5. Squeeze the mower’s brake handle to  
disengage the engine brake.  
6. Grasp the starter handle, and pull slowly  
until resistance is felt. While holding the  
handle, allow the starter rope to rewind  
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slowly. Then, pull the starter handle  
with a rapid, full arm stroke. Once again  
while holding the handle, allow the rope  
to rewind slowly. Repeat as necessary,  
until the engine starts.  
Break-in Period  
1. Breaking-in the engine will help to ensure  
proper equipment and engine operation,  
and will extend the engine’s lifespan.  
The warranty is void if the engine is not  
broken in properly. The first 20 hours of  
operation is the break-in period.  
7. After the engine starts and warms up,  
slowly release the choke cable, allowing  
it to return to its open (run) position.  
2. During the first 3 hours of use:  
8. After each start-up, run the engine for  
five minutes with no load to allow it to  
stabilize.  
Do not apply a heavy load to the mower.  
3. After the first 20 hours of use:  
Change the engine oil.  
9. Operate the lawn mower according to  
the manufacturer’s instructions.  
Under normal operating conditions  
subsequent maintenance follows the  
schedule explained in the SERVICING  
section.  
10. After use, release the brake handle to  
stop the mower.  
warnInG! If the engine does not stop  
promptly when the brake handle is  
released, carefully close the fuel  
valve. do not use tHe enGIne  
aGaIn untIL tHe BraKe asseMBLY  
Has Been rePaIred BY a  
quaLIFIed tecHnIcIan.  
11. To prevent accidents, turn off the engine  
and disconnect its spark plug wire after  
use. Wait for the engine to cool, clean  
external parts with clean cloth, then store  
the equipment out of children’s reach  
according to the Storage instructions in  
this manual.  
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engine oil change  
servIcInG  
cautIon! Oil is very hot during operation  
and can cause burns. Wait for engine to  
cool before changing oil.  
to Prevent  
serIous InjurY  
FroM accIdentaL startInG:  
close the engines fuel valve,  
wait for the engine to cool, and  
disconnect the spark plug wire(s)  
before performing any  
inspection, maintenance, or  
cleaning procedures.  
drain  
Plug  
to Prevent  
serIous InjurY  
1. Place a drain pan (not included)  
underneath the crankcase’s drain plug.  
FroM enGIne FaILure:  
do not use damaged engine. If  
abnormal noise, vibration, or  
excess smoking occurs, have the  
problem corrected before further  
use.  
2. Remove the drain plug and, if possible,  
tilt the crankcase slightly to help drain  
the oil out. Recycle used oil.  
3. Replace the drain plug (and gasket, if  
supplied) and tighten it.  
Maintenance Procedures  
Many maintenance procedures,  
including those not detailed in this  
manual, will need to be performed  
by a qualified technician for safety.  
4. Refill the oil to the proper level following  
the instructions under the Starting the  
Engine section.  
If you have any doubts about your air Filter element Maintenance  
ability to safely service the engine,  
1. Wipe off the air cleaner cover.  
have a qualified technician service  
the engine instead.  
2. The air cleaner cover is held in place by  
two knobs. Remove them.  
note: Warranty is void if proper maintenance  
and servicing procedures are not  
followed.  
3. Remove the air filter element.  
4. Wash the element in warm water and  
mild detergent several times. Rinse.  
Squeeze out excess water and allow  
it to dry completely. Soak the filter in  
lightweight oil briefly, then squeeze out  
the excess oil.  
5. Install the new filter or the cleaned filter.  
Secure the Air Cleaner Cover before  
use.  
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spark Plug Maintenance  
cleaning, Maintenance, and  
Lubrication schedule  
1. Disconnect spark plug wire from end  
of plug. Clean out debris from around  
spark plug.  
note: This maintenance schedule is  
intended solely as a general guide. If  
performance decreases or if engine  
operates unusually, check systems  
immediately. The maintenance needs  
of each engine will differ depending on  
factors such as duty cycle, temperature,  
air quality, fuel quality, and other factors.  
2. Using a spark plug wrench, remove the  
spark plug.  
3. Inspect the spark plug:  
If the electrode is oily, clean it using a  
clean, dry rag.  
If the electrode has deposits on it, polish  
it using emery paper.  
If the white insulator is cracked or  
chipped, the spark plug needs to be  
replaced.  
note: These procedures are in addition to  
the regular checks and maintenance  
explained as part of the regular operation  
of the engine.  
4. When installing a new spark plug, adjust  
the plug’s gap to the specification on the  
Specification chart. Do not pry against  
the electrode or the insulator, the spark  
plug can be damaged.  
after Initial 20 operation Hour Period:  
a. Change engine oil.  
every 25 operation Hours thereafter:  
a. Clean/replace air filter element.  
b. Inspect/clean spark plug.  
5. Install the new spark plug or the cleaned  
spark plug into the engine. Gasket-style:  
Finger-tighten until the gasket contacts  
the cylinder head, then about 1/2-2/3  
turn more.  
every 50 operation Hours:  
a. Change engine oil.  
Non-gasket-style: Finger-tighten until the  
plug contacts the head, then about 1/16  
turn more.  
every 100 operation Hours:  
a. Replace spark plug.  
b. Replace air filter element.  
6. Apply a small amount of dielectric grease  
(not included) to the insulator of the  
spark plug and attach the wire securely  
to the spark plug.  
note: All maintenance procedures scheduled  
for 25, 50, and 100 operation hours  
should be performed at least yearly.  
every 300 operation Hours:  
a. Clean fuel tank and carburetor.  
b. Clean carbon build-up from combustion  
chamber.  
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storage  
1. Wait for engine to cool, then clean  
engine with clean cloth.  
2. When the engine is to remain idle for  
longer than 20 days, prepare the engine  
for storage as follows:  
a. Change engine oil and empty fuel tank.  
b. Either leave fuel tank empty or refill  
fuel tank with fresh unleaded gasoline  
mixed with a fuel stabilizer intended for  
long term engine storage (not included).  
After filling, run engine for about 5-10  
minutes to circulate the treated gasoline  
through the carburetor. Wait for engine  
to cool before proceeding.  
c. Clean out area around spark plug.  
Remove spark plug and pour one  
tablespoon of engine oil into cylinder  
through spark plug hole.  
d. Reinstall spark plug, but leave spark  
plug wire disconnected.  
e. Pull recoil starter to distribute oil  
in cylinder. Stop after one or two  
revolutions when you feel the piston  
start the compression stroke (when you  
start to feel resistance).  
3. Apply a thin coat of rust preventive oil to  
all uncoated metal parts.  
4. Cover and store in a dry, well-ventilated  
area out of reach of children.  
5. Before starting the engine after storage,  
keep in mind that untreated gasoline  
will deteriorate quickly. Drain the fuel  
tank and filter, and change to fresh fuel  
if untreated gasoline has been sitting  
for a month, if treated gasoline has  
been sitting beyond the fuel stabilizer’s  
recommended time period, or if the  
engine does not start properly.  
SKU 96156  
For technical questions, please call 1-800-444-3353.  
Page 13  
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troubleshooting  
MOWER ENGINE SPECIFIC:  
MOWER ENGINE SPECIFIC:  
engine will not  
1. Brake Handle not held or brake  
cable not connected properly.  
1. Make sure brake handle is held down and  
brake cable is properly adjusted.  
start  
2. Mower on top of grass.  
2. Start mower atop clear area free of loose  
objects and grass.  
FUEL RELATED:  
FUEL RELATED:  
1. No fuel in tank or fuel valve closed. 1. Fill fuel tank and open fuel valve.  
2. Choke not in start position,  
especially with cold engine.  
2. Move choke to start position if engine is  
cold.  
3. Low quality or deteriorated, old  
gasoline.  
3. Use only fresh 89+ octane unleaded  
gasoline.  
4. Carburetor not primed.  
4. Prime carburetor by pressing priming bulb  
specified number of times (if equipped).  
5. Dirty fuel passageways blocking fuel 5. Clean out passageways using fuel additive.  
flow.  
Heavy deposits may require further  
cleaning.  
6. Carburetor needle stuck. Fuel can  
be smelled in the air.  
6. Gently tap side of carburetor float chamber  
with screwdriver handle.  
7. Too much fuel in chamber. This can 7. Turn choke to run position. Remove spark  
be caused by the carburetor needle  
sticking.  
plug and pull the start handle several times  
to air out the chamber. Reinstall spark plug  
and set choke to start position.  
IGNITION (SPARK) RELATED:  
IGNITION (SPARK) RELATED:  
1. Spark plug wire not connected  
securely.  
1. Connect spark plug wire properly.  
2. Spark plug electrode wet or dirty.  
3. Incorrect spark plug gap.  
2. Clean spark plug.  
3. Correct spark plug gap.  
4. Spark plug wire or spark plug  
broken.  
4. Replace spark plug wire and/or spark plug.  
5. Incorrect spark timing or faulty  
ignition system.  
5. Have qualified technician diagnose/repair  
ignition system.  
COMPRESSION RELATED:  
COMPRESSION RELATED:  
1. Cylinder not lubricated. Problem  
after long storage periods.  
1. Pour tablespoon of oil into spark plug hole.  
Crank engine a few times and try to start  
again.  
2. Loose or broken spark plug.  
(Hissing noise will occur when trying  
to start.)  
2. Tighten spark plug. If that does not work,  
replace spark plug. If problem persists, may  
have head gasket problem, see #3.  
3. Loose cylinder head or damaged  
head gasket. (Hissing noise will  
occur when trying to start.)  
3. Tighten head. If that does not remedy  
problem, replace head gasket.  
4. Engine valves or tappets  
misadjusted or stuck.  
4. Adjust valve clearance. If that does not  
work, clean or replace valves/tappets.  
Follow all safety precautions whenever diagnosing or  
servicing the engine.  
Page 14  
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SKU 96156  
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Problem  
Possible causes  
Probable solutions  
1. Spark plug wire loose.  
1. Check wire connections.  
Engine misfires  
2. Incorrect spark plug gap or  
damaged spark plug.  
2. Re-gap or replace spark plug.  
3. Defective spark plug wire.  
4. Old or low quality gasoline.  
3. Replace spark plug wire.  
4. Use only fresh 89+ octane unleaded  
gasoline.  
5. Incorrect compression.  
1. Low oil shutdown.  
5. Diagnose and repair compression. (Use  
engine will not start: coMPressIon  
reLated section.)  
1. Fill engine oil to proper level. Check engine  
oil before EVERY use.  
engine stops  
suddenly  
2. Fuel tank empty or full of impure or 2. Fill fuel tank with fresh 89+ octane unleaded  
low quality gasoline.  
gasoline.  
3. Defective fuel tank cap creating  
3. Test/replace fuel tank cap.  
vacuum, preventing proper fuel flow.  
4. Improper idle speed.  
5. Brake cable broken.  
4. Properly adjust idle speed.  
5. Repair brake cable as needed.  
6. Faulty magneto, incorrect timing, or 6. Have qualified technician diagnose and  
clogged carburetor.  
service engine.  
1. Old or low quality gasoline.  
1. Fill fuel tank with fresh 89+ octane unleaded  
gasoline.  
engine knocks  
2. Engine overloaded.  
2. Do not exceed engine’s load rating.  
3. Incorrect spark timing, deposit  
buildup, worn engine, or other  
mechanical problems.  
3. Have qualified technician diagnose and  
service engine.  
1. Impure or low quality gasoline.  
1. Fill fuel tank with fresh 89+ octane unleaded  
gasoline.  
Engine backfires  
2. Engine too cold.  
2. Use cold weather fuel and oil additives to  
prevent backfiring.  
3. Choke not open after engine warm. 3. Move choke to run position after engine  
warms up.  
4. Engine not properly adjusted for  
high altitude operation.  
4. Qualified technician must adjust engine at  
altitudes greater than 5,000 feet above sea  
level.  
5. Intake valve stuck, choke stuck,  
incorrect timing, clogged carburetor,  
or overheated engine.  
5. Have qualified technician diagnose and  
service engine.  
Follow all safety precautions whenever diagnosing or  
servicing the engine.  
SKU 96156  
For technical questions, please call 1-800-444-3353.  
Page 15  
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Parts LIst  
Part  
1
2
3
4
5
6
7
8
description  
qty  
Part  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
88  
89  
90  
91  
92  
93  
94  
95  
96  
description  
qty  
2
2
4
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
2
1
2
1
1
2
2
2
2
2
1
1
1
2
1
1
1
1
1
9
2
4
6
2
1
3
1
4
1
2
Starting flange  
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Stud  
Stud  
Bolt  
Gauze  
Dipstick  
Filler  
Fuel pipe  
Air duck  
Fuel cock  
Crankcase  
Set pin Ø9×14  
Gasket, crankcase  
Sump, crankcase B  
Cylinder head asm  
Gasket, cylinder head  
Exhaust gasket  
Cylinder head cover  
Gasket, cylinder head cover  
Piston  
Gasket, air cleaner  
Regulating sway bar  
Split pin  
Oil seal Ø6×11×5  
Washer  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
Nut  
Ignition coil  
Sleeve  
Piston ring set  
Carburetor C  
Upper oil seal Ø25×38×7  
Choke link  
Drain plug  
Stud  
Muffler  
Washer  
Muffler hood  
Set pin Ø10×16  
Piston pin  
Piston pin circlip  
Camshaft  
Pusher guide  
Adjusting bolt for valve gap  
Valve rocker  
Sleeve  
Driven gear, regulator  
Clamp, regulating shaft  
Regulating arm asm  
Back spring  
Flywheel  
Regulating mount C  
Fuel filler cap asm  
Fuel filler cap  
Air cleaner housing  
Foam ,air cleaner  
Air cleaner cover  
Air cleaner bolt  
Gasket, inlet  
Lock nut  
Tappet  
Intake valve  
Exhaust valve  
Spring seat, intake valve  
Valve spring  
Spring seat, exhaust valve  
Cap  
Crankshaft set  
Connecting rod  
Pusher  
Lock bolt  
Valve piece  
Spark plug F6TC  
Bearing 6205  
Bolt M6×12  
Bolt M6×20  
Bolt M6×32  
Crankshaft Filter-cover  
Crankshaft Filter-Gasket  
Crankshaft Filter-Gasket  
Heat insulator  
Gasket, carburetor  
Stud  
Pulling rod  
Oil seal Ø25×40×7  
Brake asm.  
Bolt M8×50  
Nut M6  
Nut M6  
Nut M6  
Starter hood  
Pipe clamp with thread  
Adjusting washer  
Self-locking nut M6  
45a Brake Spring  
46  
47  
Fine regulating spring  
Stud  
record Products serial number Here:  
note: If product has no serial number, record month and year of purchase instead.  
note: Some parts are listed and shown for illustration purposes only, and are not available  
individually as replacement parts.  
rev 08b  
Page 16  
For technical questions, please call 1-800-444-3353.  
SKU 96156  
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asseMBLY dIaGraM  
45a  
rev 08b  
SKU 96156  
For technical questions, please call 1-800-444-3353.  
Page 17  
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To take advantage of this warranty,  
the product or part must be returned to us  
with transportation charges prepaid. Proof  
of purchase date and an explanation of the  
complaint must accompany the merchandise.  
If our inspection verifies the defect, we  
will either repair or replace the product at  
our election or we may elect to refund the  
purchase price if we cannot readily and  
quickly provide you with a replacement. We  
will return repaired products at our expense,  
but if we determine there is no defect, or that  
the defect resulted from causes not within the  
scope of our warranty, then you must bear the  
cost of returning the product.  
PLease read tHe FoLLowInG  
careFuLLY  
THE MANUFACTURER AND/OR DISTRIBUTOR  
HAS PROVIDED THE PARTS LIST AND ASSEMBLY  
DIAGRAM 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. IN FACT, THE MANUFACTURER AND/  
OR DISTRIBUTOR ExPRESSLY STATES THAT ALL  
REPAIRS AND PARTS REPLACEMENTS SHOULD  
BE UNDERTAKEN BY CERTIFIED AND LICENSED  
TECHNICIANS, AND NOT BY THE BUYER. THE  
BUYER ASSUMES ALL RISK AND LIABILITY ARISING  
OUT OF HIS OR HER REPAIRS TO THE ORIGINAL  
PRODUCT OR REPLACEMENT PARTS THERETO,  
OR ARISING OUT OF HIS OR HER INSTALLATION  
This warranty gives you specific legal  
rights and you may also have other rights  
which vary from state to state.  
OF REPLACEMENT PARTS THERETO.  
3491 Mission Oaks Blvd. • PO Box 6009 •  
Camarillo, CA 93011 • (800) 444-3353  
LIMIted 90 daY warrantY  
Harbor Freight Tools Co. makes every  
effort to assure that its products meet  
eMIssIon controL sYsteM  
warrantY  
united states emission control defects warranty  
statement  
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 installation, normal  
wear and tear, or to lack of maintenance. We  
shall in no event be liable for death, injuries  
to persons or property, or for incidental,  
contingent, special or consequential damages  
arising from the use of our product. Some  
states do not allow the exclusion or limitation  
of incidental or consequential damages,  
so the above limitation of exclusion may  
not apply to you. THIS WARRANTY IS  
ExPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, ExPRESS OR IMPLIED,  
INCLUDING THE WARRANTIES OF  
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). Within the United States, new off-road,  
spark-ignition engines certified for model year 1997 and later, must be  
designed, built and equipped to meet the stringent anti-smog standards  
set forth by the EPA. HFT must warrant the emission control system on  
your engine for the periods of time described below, provided there has  
been no abuse, neglect or improper maintenance of your engine.  
Your emission control system may include parts such as the carbu-  
retor or fuel-injection system, and the ignition system.Also included may  
be hoses, belts, connectors and other emission-related assemblies.  
Where a warrantable condition exists, HFT will repair your engine  
at no cost to you including diagnosis, parts and labor.  
Manufacturers warranty coverage  
The 1997 and later engines are warranted for two (2) years. If  
any emission-related part on your engine is defective, the part will be  
repaired or replaced by HFT.  
Harbor Freight tools emission control defects  
warranty coverage  
Engines are warranted for a period of two (2) years relative to  
emission control parts defects, subject to the provisions set forth below.  
MERCHANTABILITY AND FITNESS.  
Page 18  
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SKU 96156  
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If any emission related part on your engine is defective, the part will be  
repaired or replaced by HFT.  
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 be used in performance of maintenance or  
repairs. The owner is responsible for commissioning a qualified  
technician/mechanic to perform all required maintenance, as  
outlined in the Inspection, Cleaning, and Maintenance section in  
this manual.  
owners warranty responsibilities  
As the engine owner, you are responsible for the performance  
of the required maintenance listed in your Owner’s Manual. HFT  
recommends that you retain all receipts covering maintenance  
on your engine, but HFT cannot deny warranty solely for the lack  
of receipts or for your failure to ensure the performance of all  
scheduled maintenance.  
As the engine owner, you should, however, be aware that HFT  
may deny you warranty coverage if your engine or a part has  
failed due to abuse, neglect, improper maintenance, or unap-  
proved modifications.  
6. warranted Parts  
You are responsible for shipping your engine to a HFT warranty  
station as soon as a problem exists. Contact the HFT Customer  
Service department at the number below to make shipping arrange-  
ments. The warranty repairs should be completed in a reasonable  
amount of time, not to exceed 30 days.  
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  
If you have any questions regarding your warranty rights and  
responsibilities, you should contact the Harbor Freight Tools Customer  
Service Department at 1-800-444-3353.  
i)  
Intake pipe/manifold.  
ii) Air cleaner.  
3) Ignition system  
Harbor Freight tools emission control defects  
warranty Provisions  
i)  
Spark plug.  
ii) Magneto ignition system.  
1. Length of coverage  
4) catalyst system (if so equipped)  
HFT warrants to a first retail purchaser and each subsequent  
purchaser that the engine is free from defects in materials and  
workmanship that cause the failure of warranted parts for a  
period of two (2) years after the date of delivery to the first retail  
purchaser.  
i)  
Exhaust pipe stud.  
ii) Muffler.  
iii) Catalytic converter (if so equipped).  
5) Miscellaneous Items used in above systems  
2. no charge repair or replacement  
i)  
Vacuum, temperature and time sensitive valves and  
switches.  
Repair or replacement of any warranted part will be performed at  
no charge to the owner if the work is performed through a warranty  
station authorized by HFT. For emissions warranty service, contact  
the HFT Customer Service Department at 1-800-444-3353.  
ii) Hoses, belts, connectors, and assemblies.  
3. consequential damages coverage  
Coverage under this warranty shall also extend to the failure of  
any engine components caused by the failure of any warranted  
part while it is still covered under this warranty.  
4. coverage exclusions  
Warranty claims shall be filed in accordance with the provisions  
of the HFT warranty policy explained in the box at the top of the  
previous page. HFT shall not be liable for any loss of use of the  
engine, for any alternative usage, for any damage to goods, loss of  
time, or inconvenience. Warranty coverage shall also be excluded  
for any part which fails, malfunctions, or is damaged due to failure  
to follow the maintenance and operating instructions set forth in  
the Owner’s Manual including, but not limited to:  
a) Use of parts which are not authorized by HFT  
b) Improper installation, adjustment or repair of the engine or  
of any warranted part unless performed by an authorized  
warranty center  
c) Failure to follow recommendations on fuel use contained in  
the Owner’s Manual  
d) Improper or inadequate maintenance of any warranted  
parts  
e) Repairs performed outside of the authorized warranty service  
dealers  
f)  
Alterations by changing, adding to or removing parts from  
the engine.  
SKU 96156  
For technical questions, please call 1-800-444-3353.  
Page 19  
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