Harbor Freight Tools Saw 98089 User Manual

14” PORTaBle GaS  
CuT-OFF SaW  
98089  
SeT uP anD OPeRaTinG inSTRuCTiOnS  
Diagrams within this manual may not be drawn proportionally.  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
Distributed exclusively by Harbor Freight Tools®.  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
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.  
For technical questions or replacement parts, please call 1-800-444-3353.  
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PeRSOnal SaFeTY  
1. Stay alert. Watch what you are doing, and use common sense when operat-  
ing a power tool. Do not use a power tool while tired or under the influence  
of drugs, alcohol, or medication. A moment of inattention while operating power  
tools may result in serious personal injury.  
2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.  
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,  
jewelry, or long hair can be caught in moving parts.  
3. Remove adjusting keys or wrenches before turning the Cut Off Saw on. A  
wrench or a key that is left attached to a rotating part of the machine may result in  
personal injury.  
4. Do not overreach. Keep proper footing and balance at all times. Proper foot-  
ing and balance enables better control of the power tool in unexpected situations.  
5. use safety equipment. Always wear ANSI-approved safety impact goggles when  
using this product. Proper hearing and breathing protection must also be used.  
TOOl uSe anD CaRe  
1. Do not force the tool. use the correct tool for your application. The correct  
tool will do the job better and safer at the rate for which it is designed.  
2. Do not use the Cut Off Saw if the engine’s Kill Switch (5D) does not immedi-  
ately turn it off. Any tool that cannot be controlled with its Kill Switch is danger-  
ous and must be replaced.  
3. Store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
4. maintain tools with care. Properly maintained tools are less likely to malfunction  
and are easier to control. Do not use a damaged tool. Tag damaged tools “Do  
not use” until repaired.  
5. Check for misalignment or binding of moving parts, breakage of parts, and  
any other condition that may affect the tool’s operation. if damaged, have  
the tool serviced before using. Many accidents are caused by poorly maintained  
tools.  
6. use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one tool may become hazardous  
when used on another tool.  
SKU 98089  
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SeRViCe  
1. Tool service must be performed only by qualified repair personnel. Service or  
maintenance performed by unqualified personnel could result in a risk of injury.  
2. When servicing a tool, use only identical replacement parts. Follow instruc-  
tions in the “Inspection, Maintenance, And Cleaning” section of this manual.  
Use of unauthorized parts or failure to follow maintenance instructions may create  
a risk of electric shock or injury.  
SPeCiFiC SaFeTY GeneRal RuleS anD PReCauTiOnS  
1. maintain labels and nameplates on the Cut Off Saw. These carry important  
information. If unreadable or missing, contact Harbor Freight Tools for a replace-  
ment.  
2. industrial applications must follow OSHa guidelines.  
3. never stand on the Cut Off Saw. Serious injury could result if the Saw is tipped.  
4. never leave the Cut Off Saw unattended when it is running. Turn off the Saw  
before leaving.  
5. Do not allow children and other unauthorized people to handle or play with  
the Cut Off Saw. Keep children and other bystanders away from the working  
area.  
6. This Cut Off Saw is designed for outdoor use only. Do not operate the Cut  
Off Saw in a closed area or in a poorly ventilated area. When running, the en-  
gine of this Cut Off Saw produces carbon monoxide, a colorless, odorless,  
toxic fume that, when inhaled, can cause serious personal injury or death.  
Whenever possible, use a carbon monoxide detector (not included) to detect  
excessive carbon monoxide fumes in the work area and in the surrounding  
area.  
7. Do not force the Cut Off Saw. This tool will do the work better and safer at the  
speed and capacity for which it was designed.  
FiRe anD eXPlOSiOn PReCauTiOnS  
1. Gasoline fuel and fumes are flammable, and potentially explosive. Use  
proper fuel storage and handling procedures. Always have multiple ABC class fire  
extinguishers nearby.  
2. Keep the Cut Off Saw and surrounding areas clean at all times.  
3. When spills of fuel or oil occur, they must be cleaned up immediately. Dis-  
pose of fluids and cleaning materials as per any local, state, or federal codes and  
regulations. Store oil rags in a covered metal container.  
SKU 98089  
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4. Never store fuel or other flammable materials near the Cut Off Saw.  
5. Do not smoke, or allow sparks, flames, or other sources of ignition around  
the Cut Off Saw.  
6. Keep grounded conductive objects, such as tools, away from exposed, live  
electrical parts and connections to avoid sparking or arcing. These events  
could ignite fumes or vapors.  
7. Do not refill the Fuel Tank while the Engine is running or while the Engine is  
still hot. Do not operate the Cut Off Saw with known leaks in the fuel system.  
meCHaniCal PReCauTiOnS  
1. Prior to performing service, maintenance, or cleaning procedures, always  
make sure the engine is off. allow the engine and Cut Off Saw to  
completely cool. Then, remove the spark plug from the engine.  
2. Do not alter or adjust any part of the Cut Off Saw or engine that is assembled  
and supplied by the manufacturer.  
3. always follow scheduled Cut Off Saw and engine maintenance.  
CHemiCal PReCauTiOnS  
1. avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.  
2. avoid body contact with fuels, oils, and lubricants used in the Cut Off Saw  
and engine. If swallowed, seek medical treatment immediately. Do not induce  
vomiting if fuel is swallowed. For skin contact, immediately wash with soap and  
water. For eye contact, immediately flush eyes with clean water.  
nOiSe PReCauTiOn  
Prolonged exposure to high noise levels is hazardous to hearing. Always  
wear ANSI-approved hearing protection when operating or working around the Cut  
Off Saw when it is running.  
SaW BlaDe PReCauTiOnS  
1. Only use Saw Blades with the following specifications:  
a. 14” Diameter.  
b. From 7/64” to 1/4” thickness.  
c. 1” Diameter spindle mounting hole.  
d. Only composite abrasive or diamond abrasive Saw Blades rated at a mini-  
mum of 4,700 RPm.  
SKU 98089  
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2. never use carbide-tipped, woodcutting, or circular machine Saw Blades.  
They can cause severe personal injury from reactive forces, blade contact, or  
thrown objects.  
3. Only cut asphalt, concrete, stone, brick, and plastics with this Cut Off Saw.  
4. inspect the Saw Blade frequently, and replace immediately if the Blade is  
cracked, or warped. Cracked or warped Saw Blades may shatter or break and  
cause serious personal injury.  
5. always install the Saw Blade so that the arrow on the Blade points in the  
direction of the rotation of the spindle.  
6. Keep hands and fingers away from the cutting area and Saw Blade.  
7. never attempt to cut more than one workpiece at a time.  
8. When cutting a large workpiece, make sure its entire length is properly sup-  
ported. If necessary, use a roller stand (not included).  
9. allow the Saw Blade to spin up to full speed before feeding it into a work-  
piece. When turning off the Cut Off Saw, allow the Saw Blade to spin down and  
stop on its own. Do not press against the Saw Blade to stop it.  
10. Do not force the Saw Blade into the workpiece when cutting. Apply moderate  
pressure, allowing the Saw Blade to cut without being forced.  
11. To avoid accidental injury, always wear heavy duty work gloves when chang-  
ing the Saw Blade.  
12. The Saw Blade will become hot while cutting. Allow the Saw Blade to com-  
pletely cool before handling.  
13. Turn off the Cut Off Saw and allow the Saw Blade to completely stop if the  
Saw Blade is to be backed out of an uncompleted cut.  
14. never attempt to remove material stuck in the Cut Off Saw while it is operat-  
ing.  
KiCKBaCK PReCauTiOnS  
1. make sure the workpiece is free from nails, metal rebar, and any other for-  
eign objects that could damage the Saw Blade or cause “kickback”.  
2. Causes and operator prevention of “kickback”: Kickback is a sudden reac-  
tion to a pinched, bound, or misaligned Saw Blade, causing an uncontrolled Cut  
Off Saw to lift up and out from the workpiece toward the operator. When the Saw  
Blade is pinched or bound tightly by the kerf closing down, the Saw Blade stalls  
and the engine reaction drives the Cut Off Saw rapidly back toward the operator.  
If the Saw Blade becomes twisted or misaligned in the cut, the teeth at the back  
SKU 98089  
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edge of the Saw Blade can raise the Cut Off Saw (walk up) toward the operator.  
Kickback is a result of tool misuse and/or incorrect operating procedures or condi-  
tions and can be avoided by taking proper precautions as given below:  
maintain control of the Cut Off Saw at all times. Never allow the rotating Saw  
Blade to rest on the workpiece without holding on to the Saw with both hands.  
When the Saw Blade is binding, or when interrupting a cut for any reason,  
turn off the Cut Off Saw and hold the Saw motionless until the Saw Blade  
comes to a complete stop. Never attempt to remove the Saw Blade from the  
workpiece or pull the Saw backward while the Saw Blade is in motion or kickback  
may occur. Investigate and take corrective actions to eliminate the cause of Saw  
Blade binding.  
When restarting the Cut Off Saw on a workpiece, center the Saw Blade in  
the pre-cut kerf and check that the Saw Teeth are not engaged into the work-  
piece. If the Saw Blade is binding, the Cut Off Saw may walk up or kickback as  
the Saw is restarted.  
Support large panels with roller stands (not included) to minimize the risk of  
Saw Blade pinching and kickback. Large panels tend to sag under their own  
weight. Supports must be placed under the panel and near the outer edge of the  
panel.  
Do not use a dull or damaged Saw Blade. Unsharpened or improperly set Saw  
Blades produce a narrow kerf causing excessive friction, Saw Blade binding and  
kickback.  
Push the Saw Blade past the workpiece prior to release.  
make sure to check the Blade Guard for proper operation. Never disable the  
Guard. Do not use the Cut Off Saw if the Guard assembly does not operate prop-  
erly. Before each use, make sure the Blade Guard does not touch the Saw Blade.  
miSC. PReCauTiOnS  
1. WARNING! Some dust created by power sanding, sawing, grinding, drilling, and  
other construction activities, contain chemicals known (to the State of California) to  
cause cancer, birth defects or other reproductive harm. Some examples of these  
chemicals are: lead from lead-based paints, crystalline silica from bricks and ce-  
ment or other masonry products, arsenic and chromium from chemically treated  
lumber. Your risk from these exposures varies, depending on how often you do  
this type of work. To reduce your exposure to these chemicals: work in a well ven-  
tilated area, and work with approved safety equipment, such as those dust masks  
that are specially designed to filter out microscopic particles.  
(California Health & Safety Code § 25249.5, et seq.)  
2. WaRninG! People with pacemakers should consult their physician(s) before us-  
ing this product. Electromagnetic fields in close proximity to a heart pacemaker  
could cause interference to or failure of the pacemaker.  
SKU 98089  
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3. WaRninG! The warnings and precautions discussed in this manual cannot cover  
all possible conditions and situations that may occur. It must be under stood by the  
operator that common sense and caution are factors which cannot be built into this  
product, but must be supplied by the operator.  
SaVe THeSe inSTRuCTiOnS  
CauTiOn! Your Warranty is voided if:  
You do not operate the Cut Off Saw with the proper 50:1 fuel mix in its Fuel  
Tank. Never run the Engine with an improper fuel mix, low or no fuel mix. Running  
the Engine with an improper fuel mix, low or no fuel mix will permanently damage  
the unit.  
See PaGeS 12 anD 13 OF THiS manual FOR Fuel miX inSTRuCTiOnS.  
unPaCKinG  
When unpacking, check to make sure all the parts shown on the Parts lists on  
pages 19 through 26 are included. If any parts are missing or broken, please call Har-  
bor Freight Tools at the number shown on the cover of this manual as soon as possible.  
PRODuCT FeaTuReS  
(See Figure a, page 11, for details.)  
1. Saw Blade (23F): Use only composite abrasive or diamond abrasive Blades (not  
included). Depending on the material to be cut, these Blades are made of differ-  
ent materials. Make sure to choose the right Blade for the material being cut. The  
Saw Blade should be 14” in diameter. From 7/64” to 1/4” thickness, and with a 1”  
diameter spindle mounting hole. The Saw Blade should be rated at a minimum of  
4,700 RPM.  
2. Flanges (22F): Clamp and support the composite or diamond Saw Blade (23F).  
3. Hex Bolt (25F): Tightens the Flange (22F).  
4. Blade Guard (19F): Safety guard. Directs sparks and dust away from the opera-  
tor.  
5. Front Handle (3G): Use to securely hold the Cut Off Saw when operating.  
6. Spark Plug Cover (4D): A removable cover for access to the Spark Plug (2B).  
7. On/OFF (5D): Engine stops when this switch is in Off position.  
8. Full Throttle lock Button (9D): To lock the Throttle Trigger (10D) in wide open  
position, press this button while the Throttle Trigger is fully depressed. Pressing  
and releasing the Throttle Trigger will return the Throttle Trigger to its idle position.  
SKU 98089  
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9. Throttle Trigger (10D): Controls the Engine speed. Pulling back on the Throttle  
Trigger opens the throttle and the Engine accelerates. Releasing the Throttle Trig-  
ger slows down the Engine.  
10. Rear Handle (7D): Use to securely hold the Cut Off Saw when operating.  
11. Filter Cover lock lever (13e): Locks the Air Filter Cover (1E). Pull back on the  
Filter Cover Lock Lever to open the Air Filter Cover.  
12. Pre-Filter 1 (2e), Pre-Filter 2 (3e), Filter Housing (4e), Paper air Filter (5e),  
Secondary Filter (6e): Filters the air, preventing dirt and debris from entering the  
Carburetor (7C).  
13. Choke lever (5C): Turning this Lever counterclockwise closes the Carburetor.  
Use the Choke Lever to prime the Engine (cold starting). Turn clockwise for nor-  
mal operation.  
14. Starter Grip (3a): Pull to start Engine.  
15. Fuel Tank Cap (16C): Open this Cap for filling the Fuel Tank (2C, 10C). Close the  
Fuel Tank Cap prior to for starting and operation.  
16. Decompression Valve (7B): Press down on this Valve to make starting easier.  
When air pressure in the Engine reaches a preset value, the Valve automatically  
closes.  
17. Belt Tensioner with Tensioning nut (35F): For V-Belt tension adjustment. Turn  
the Nut clockwise to loosen the V-Belt. Turn the Nut counterclockwise to add more  
tension to the V-Belt.  
18. Muffler (9B): Reduces both noise and emissions.  
19. Blade Guard Positioning Knob (38F): Loosen the Knob to adjust the Blade  
Guard (19F) position.  
20. Shaft lock (34F): Press and hold the Shaft Lock to facilitate Saw Blade (23F)  
changing and installation.  
21. Trigger Safety lever (16D): This lever must be depressed in order for the engine  
to start.  
22. Foot Plate (26C): Place foot on plate while starting engine.  
SKU 98089  
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3G  
19F  
5D  
9D  
16D  
7D  
10D  
5C  
3a  
24F  
26C  
38F  
16C  
34F  
7B  
13e  
35F  
2E  
4e  
5e  
6e  
FiGuRe a  
SKU 98089  
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aSSemBlY inSTRuCTiOnS  
CauTiOn! Make sure to wear ANSI-approved safety impact eyeglasses when  
performing any assembly of the Cut Off Saw. Also, when installing or replacing the  
Saw Blade (23F) (not included) wear heavy duty work gloves to avoid accidental  
cuts to the hands and fingers.  
To install a Saw Blade:  
1. Make sure to refer to the “SAW BLADE PRECAUTIONS” section on page 6 of  
this manual to select the correct size and type of Saw Blade to install in the Cut Off  
Saw.  
2. Press down on the Shaft Lock (34F) to hold the Blade Shaft (16F) in position.  
(See Figure a.)  
3. Loosen and remove the Hex Bolt (25F). Then, remove the Washer (24F) and outer  
Flange (22F). (See Figure a.)  
4. Mount the new Saw Blade (not included) on the Blade Shaft (16F). imPORTanT:  
Make sure the arrow shown on the Saw Blade points in the same direction as the  
arrow shown on the Blade Guard (19F). (See Figure a.)  
5. Once the Saw Blade (not included) is mounted on the Blade Shaft (16F), replace  
the outer Flange (22F) and Washer (24F). Then, firmly tighten the Hex Bolt (25F)  
to secure the Saw Blade in place. (See Figure a.)  
6. Make sure to check the Blade Guard (19F) for proper operation. If necessary,  
loosen the Blade Guard Positioning Knob (38F) to adjust the Blade Guard (19F)  
position. Never disable the Guard. Do not use the Cut Off Saw if the Guard as-  
sembly does not operate properly. Before each use, make sure the Blade Guard  
does not touch the Saw Blade. (See Figure a.)  
PRe-STaRT inSTRuCTiOnS  
To Fill The Fuel Tank:  
1. WaRninG! Your Warranty is voided if: You do not operate the Cut Off Saw  
with the proper 50:1 fuel mix in its Fuel Tank. Never run the Engine with an im-  
proper fuel mix, low or no fuel mix. Running the Engine with an improper fuel mix,  
low or no fuel mix will permanently damage the unit.  
2. To obtain the proper 50:1 fuel mix, combine two cycle oil with unleaded gasoline  
(minimum 91 octane rating) in a clean, approved container. Cover and shake to  
thoroughly mix before each fueling. Refer to the Chart below for proper mix quan-  
tities. nOTe: Mix only enough fuel for a few days work. The maximum storage  
time of mixed fuel is 3 months. (See Table a.)  
SKU 98089  
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3. Once the proper fuel mix is obtained, remove the Fuel Tank Cap (16C). Fill the  
Fuel Tank (2C, 10C) approximately 3/4 full with the fuel mix (the Fuel Tank capacity  
is 0.4 gallons). Then, replace the Fuel Tank Cap. (See Figure a.)  
Fuel miX QuanTiTieS  
Ratio  
50:1  
50:1  
50:1  
Two Cycle Oil  
4 Fl. Oz.  
Unleaded Gasoline (91 Octane)  
1.5 Gal.  
3 Gal.  
8 Fl. Oz.  
16 Fl. Oz.  
6 Gal.  
Table a  
OPeRaTinG inSTRuCTiOnS  
note: Please read and familiarize yourself with the How To Stop The Cut Off Saw  
instructions on page 13 before operating.  
To Start The Cut Off Saw:  
1. WaRninG! Wear ANSI-approved safety impact goggles, hearing protection, and  
NIOSH-approved dust mask/respirator during use.  
2. Place the Cut Off Saw on flat, level ground, so that the Saw Blade (not included)  
does not contact any objects or the ground. Orient the saw away from your body.  
3G  
BLADE NOT  
INCLUDED  
5D  
9D  
10D  
3C  
5C  
7B  
26D  
FiGuRe B  
3. Move the ON/OFF Button (5D) to the on position. Place your hand on the Rear  
Handle (7D). Hold the Trigger Safety Lever (16D) down with your palm while  
squeezing the Trigger (10D) and then using your thumb, press down on the Full  
Throttle Lock Button (9D). (See Figure B.)  
REV 08f  
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4. Release the Trigger (10D). The Trigger should remain locked in the engaged posi-  
tion. (See Figure B.)  
5. Press the Decompression Valve Button (7B) in. (See Figure B.)  
6. Set the Choke Lever (5C) to the START position. (See Figure B.)  
7. Place your right foot on the Foot Pad (26C) while you firmly hold the Front Handle  
(3G) with your left hand. (See Figure B.)  
8. Pull the Starter Grip (3A) several times until the engine fires, (or turns over, tries to  
start but doesn’t). (See Figure B.)  
9. Set the Choke Switch (5C) to the Run position, press the Decompression Valve  
Button (7B) in and pull the rope again.  
10. As soon as the Engine starts, squeeze the Throttle Trigger (10D) briefly and let up.  
The Full Throttle Lock Button (9D) will revert to its original position, causing the  
Engine to idle. (See Figure B.)  
11. NOTE: If the weather is very cold (20 degrees F or colder), follow the normal  
starting instructions except for this one change. Set the Choke Switch (5C) to the  
middle position initially instead of the start position as instructed in step 6.  
12. If the engine does not start, press the Decompression Valve Button (7B) in and at-  
tempt to start it again.  
To Operate The Cut Off Saw:  
1. NOTE: During the break-in phase, which takes about eight hours of use, the Cut  
Off Saw must not be operated at high speeds without a load (do not pull the Throt-  
tle Trigger (10D) beyond 3/4 of full throttle). Following this procedure will lengthen  
the service life of the Saw.  
2. NOTE: After running the Cut Off Saw for an extended period of time, allow the En-  
gine to idle for several minutes to dissipate the heat. This will prevent some engine  
parts (ignition system, carburetor, etc.) from being damaged by overheating.  
3. IMPORTANT: The Saw Blade (not included) will not rotate when the Engine idles.  
(See Figure A.)  
4. When the Cut Off Saw is ready to operate, gently pull the Throttle Trigger (10D)  
backward to accelerate the Engine. Once the Engine accelerates, the Saw Blade  
will begin to rotate and speed up. When the blade speed is up and stable, you can  
begin to move the Saw slowly toward the object to be cut.  
5. While holding the Cut Off Saw firmly, approach the object to be cut with the Saw  
Blade and increase pressure on the Cut Off Saw slowly until the Saw Blade is at  
the desired depth of cut. Move forward along a straight line to complete the cut.  
To Turn Off The Cut Off Saw:  
To turn off the saw after a cut is completed, lift the Saw Blade out of the cut then  
release the Throttle Trigger (10D). Wait until the Engine slows down to idle speed  
and the Saw Blade stops rotating, then move the On/OFF Switch (5D) located at  
the front of the Rear Handle (7D) to its OFF position. (See Fig. B.)  
REV 08f  
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inSPeCTiOn, mainTenanCe, anD CleaninG  
1. WaRninG! Always make sure the Cut Off Saw is in the “OFF” position prior to  
performing any service, maintenance, or cleaning of the Saw or the Engine.  
2. Before each use, inspect the general condition of the Cut Off Saw. Check for  
loose screws, misalignment or binding of moving parts, cracked or broken Saw  
Blade, loose connections, and any other condition that may affect the safe opera-  
tion of the Cut Off Saw. If abnormal noise or vibration occurs, have the problem  
corrected before further use.  
Do not use damaged equipment.  
3. To adjust the V-Belt (3F) tension:  
V-BelT  
(3F)  
HeX BOlT  
(11F)  
SCReW  
(1F)  
BOlT  
(14F)  
HeX BOlT  
(11F)  
TRanSmiSSiOn BOX COVeR  
(2F)  
TenSiOninG nuT  
(35F)  
FiGuRe C  
a. Loosen and remove the Screws (1F) on the Transmission Box Cover (2F). Then,  
remove the Transmission Box Cover. (See Figure C.)  
b. Loosen the three Hex Bolts (11F) on the Bearing Plate (12F). (See Figure C.)  
c. Turn the Tensioning Nut (35F) clockwise to increase tension on the V-Belt (3F).  
Turn the Tensioning Nut counterclockwise to decrease tension on the V-Belt (or  
turn the Bolt (14F) clockwise or counterclockwise). (See Figure C.)  
d. Tighten the three Hex Bolts (11F) on the Bearing Plate (12F). (See Figure C.)  
e. Replace the Transmission Box Cover (2F), and secure it with the Screws (1F).  
(See Figure C.)  
4. To clean the Pre-Filter 1 (2e), Pre-Filter 2 (3e), Filter Housing (4e), Paper air  
Filter (5e), and Secondary Filter (6e).  
a. It is recommended to clean the Pre-Filter 1, Pre-Filter 2, Filter Housing, Paper Air  
Filter, and Secondary Filter daily. To do so, pull the Filter Cover Lock Lever (13E)  
backward to allow the Air Filter Cover (1E) swing open. Remove the Pre-Filter 1,  
Pre Filter 2, Filter Housing, and Paper Air Filter in succession. Clean and dry the  
parts or replace if necessary. Once cleaned or replaced, install the parts in re-  
verse order of removal and close the Air Filter Cover. (See Figure D.)  
REV 08h  
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aiR COVeR  
lOCK leVeR  
(13e)  
SeCOnDaRY  
FilTeR  
FilTeR HOuSinG  
(4e)  
(6e)  
PRe-FilTeR 1  
PaPeR aiR  
FilTeR  
(5e)  
aiR FilTeR COVeR  
(2e)  
(1e)  
PRe-FilTeR 2  
(3e)  
FiGuRe D  
5. To service the Spark Plug (2B): If the Engine loses power, is difficult to start, or  
runs poorly at idling speed, first check the condition of the Spark Plug. To check  
the Spark Plug:  
a. Remove the Spark Plug Cover (4D) located at the front of the Rear Handle (7D).  
(See Figure e.)  
b. Remove the Spark Plug Wire (18). Then, unscrew and remove the Spark Plug  
(2B). (See Figure e.)  
c. Clean off the carbon build-up on the Spark Plug (2B). (See Figure e.)  
d. Check the electrode gap to see if it is 0.020”. If necessary, readjust.  
(See Figure e.)  
e. Replace the Spark Plug (2B) after every 100 operating hours, or earlier if the elec-  
trodes are badly eroded (a Bosch WSR 6 F or NGK BPMR 7A is recommended  
for replacement). (See Figure e.)  
f. Replace the Spark Plug (2B), Spark Plug Wire (18), and Spark Plug Cover (4D).  
(See Figure e.)  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 15  
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SPaRK PluG WiRe  
SPaRK PluG  
COVeR  
(18)  
(4D)  
SPaRK PluG  
(2B)  
0.020”  
FiGuRe e  
6. When storing the Saw, make sure to store the unit in a clean, dry, safe location  
out of reach of children and other unauthorized people. For long periods of stor-  
age, drain and clean the Fuel Tank (2C, 10C).  
7. CauTiOn! all maintenance, service, or repairs not mentioned in this manual  
must only be performed by a qualified service technician.  
TROuBleSHOOTinG  
Problem  
Possible Solution  
1. Check for amount of fuel.  
2. Make sure Choke Lever is in proper position.  
3. Make sure Spark Plug Wire is not loose.  
4. Check condition of Spark Plug. Wipe off any access fuel with  
a clean, dry cloth. Prior to reinstalling the spark plug, vent the  
combustion chamber by pulling the start grip several times.  
Engine will not start or runs  
poorly.  
5. Make sure Air Filter assembly is clean.  
6. Make sure to press Decompression Valve before starting. Clean/  
replace valve if it pops up without being pulled when unit is off.  
7. Have a qualified service technician check the ignition system.  
8. Have a qualified technician check/adjust the carburetor. The  
carburetor is not set to run satisfactorily at altitudes above 5,000  
ft.  
Engine smokes excessive- 1. Check for proper mix of fuel.  
ly when running.  
2. Check Air Filter condition.  
1. Check for proper mix and amount of fuel.  
2. Check condition of Spark Plug.  
3. Adjust tension on V-Belt.  
Saw Blade not rotating up  
to full speed.  
4. Check Air Filter.  
1. Make sure Blade is undamaged.  
2. Make sure Saw Blade is properly installed.  
Poor quality of cut.  
Kill Switch does not turn off Immediately discontinue use of Cut Off Saw. Have a  
Engine.  
qualified service technician check the Kill Switch.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 16  
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PleaSe ReaD THe FOllOWinG CaReFullY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND AS-  
SEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANU-  
FACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY  
KIND TO THE BUYER 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 CERTI-  
FIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL  
RISKS AND LIABILITYARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT  
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF  
REPLACEMENT PARTS THERETO.  
PaRTS liST/aSSemBlY DiaGRam  
CRanKSHaFT HOuSinG aSSemBlY  
Part  
1
Description  
Screw (M5 x 20)  
Q’ty  
10  
1
Part  
Description  
Q’ty  
1
10 Gasket  
2
Plug  
11 Positioning Sleeve  
12 Crankshaft Housing (Right)  
13 Oil Seal (15 x 24 x 7)  
14 Oil Needle  
2
3
Cover  
1
1
4
Screw (M5 x 20)  
Washer (5)  
3
1
5
3
1
6
Coil  
1
15 Ball Bearing (6202)  
16 Cover  
1
7
Oil Seal (17 x 28 x 7)  
Crankshaft Housing (Left)  
Ball Bearing (6203)  
1
1
8
1
17 Plug  
1
9
1
18 Spark Plug Wire  
1
18  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 17  
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PaRTS liST/aSSemBlY DiaGRam  
CRanKSHaFT & PiSTOn aSSemBlY  
Part Description  
1A Flywheel/Starter Cover  
2A Screw Plug  
3A Starter Grip  
4A Starter Rope  
5A Rewind Spring  
6A Spring Cover  
7A Rope Rotor  
8A Pawl  
Q’ty.  
1
Part Description  
16A Piston  
Q’ty.  
1
1
17A Piston Ring  
18A Needle Cage  
19A Washer  
2
1
1
1
1
1
20A Clutch Shoe  
21A Retainer  
3
1
3
1
22A Clutch  
1
1
23A Tension Spring  
24A Ring  
3
9A Spring Clip  
10A Collar Nut  
11A Starter Cup  
12A Flywheel  
1
1
1
25A Retainer Ring (30)  
26A Bearing (6200)  
27A V-Belt Pulley  
28A Washer  
1
1
1
1
1
13A Crankshaft  
14A Locking Clip  
15A Piston Pin  
1
1
2
29A Collar Nut (M8 x 1)  
30A Rope Bushing  
1
1
1
29a  
28a  
27a  
26a  
25a  
24a  
17a  
16a  
15a  
14a  
18a  
23a  
31a  
12a  
21a  
20a  
13a  
22a  
2a  
19a  
11a  
3a  
4a  
10a  
9a  
7a  
8a  
1a  
6a  
30a  
5a  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 18  
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PaRTS liST/aSSemBlY DiaGRam  
CYlinDeR & muFFleR aSSemBlY  
Part  
Description  
Qty.  
1
Part  
Description  
Qty.  
1
1B Cylinder  
8B Exhaust Gasket  
9B Muffler Assembly  
10B Screw (M5 x 16)  
11B Muffler Guard  
2B Spark Plug  
1
1
3B Cylinder Cover  
4B Screw (M5 x 16)  
5B Screw (M5 x 20)  
6B Washer  
1
2
3
1
4
12B Screw M5 x 12  
13B Gasket, Cylinder Base  
1
1
1
7B Decompression Valve  
1
13B  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 19  
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PaRTS liST/aSSemBlY DiaGRam  
Fuel TanK & CaRBuReTOR  
Part  
Description  
Qty.  
8
Part  
Description  
Qty.  
1
1C Screw (M5 x 20)  
2C Fuel Tank (Left)  
3C Pin  
16C Fuel Tank Cap  
17C Washer  
1
1
2
18C Tank Vent  
1
4C Rubber Mount  
5C Choke Lever  
6C Air Hose  
2
19C Gasket  
1
1
20C Fuel Pick-Up Filter  
21C Hose  
1
1
1
7C Carburetor  
8C Screw (M5 x 55)  
9C Split Pin  
1
22C “U” Rubber Tube  
23C Screw Bracket  
24C Screw (M4x5)  
25C Lock Nut (M5)  
26C Foot Pad  
1
2
1
2
1
10C Fuel Tank (Right)  
11C Connecting Hose  
12C Sleeve  
1
2
1
1
1
27C Screw M5X20  
28C Foot Pad Support  
29C Pin  
2
13C Manifold  
1
1
14C Hose Clip  
15C O-Ring  
1
1
1
29  
28  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
REV 08f  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 20  
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PaRTS liST/aSSemBlY DiaGRam  
HanDle & main COVeR aSSemBlY  
Part  
Description  
Qty.  
1
Part  
Description  
Qty.  
1
1D Main Cover  
10D Throttle Trigger  
11D Trigger Pin  
2D Side Sealing Cover  
3D Front Sealing Cover  
4D Spark Plug Cover  
5D Kill Switch  
1
1
1
12D Torsion Spring  
13D Shaft  
1
1
1
1
14D Throttle Triggering Wire  
15D Flameout Wire  
16D Trigger Safety Lever  
17D Retainer Ring 4  
1
6D Screw (ST2.9 x 13)  
7D Rear Handle  
2
1
1
1
8D Torsion Spring  
9D Throttle Lock  
1
1
1
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
REV 08f  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 21  
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PaRTS liST/aSSemBlY DiaGRam  
aiR FilTeR aSSemBlY  
Part  
Description  
Qty.  
1
Part  
Description  
Qty.  
1
1E Filter Cover  
9E Filter Base  
2E Pre-Filter I  
1
10E Gasket  
1
3E Pre-Filter 2  
1
11E Screw (M5 x 16)  
12E Flat Spring  
2
4E Filter Housing  
5E Paper Air Filter  
6E Secondary Filter  
7E Screw (ST2.9 x 19)  
8E Half Round  
1
1
1
13E Filter Cover Lock Lever  
14E Torsion Spring  
15E Pin (B3 x 32)  
16E Screw (M5 x 12)  
1
1
1
2
1
1
1
15e  
13e  
14e  
12e  
10e  
9e  
8e  
7e  
6e  
5e  
4e  
3e  
2e  
1e  
16e  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 22  
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PaRTS liST/aSSemBlY DiaGRam  
TRanSmiSSiOn BOX & CuTTeR aSSemBlY  
Part  
Description  
Qty.  
9
Part  
Description  
Qty.  
2
1F Screw (M5 x 20)  
2F Transmission Box Cover  
3F V-Belt (10X855 Li)  
4F Nut (M10 – Left)  
5F Washer (10)  
20F Lock Washer  
21F Round Lock Nut  
22F Flange  
1
1
1
2
1
23F SawBlade(14DiameterNotIncluded)  
24F Washer  
0
1
1
6F Belt Pulley Assy.  
7F Washer (12)  
1
25F Hex Bolt  
1
1
26F Flat Bolt (M8 x 35)  
27F Anchor Plate  
28F Screw (M6 x 12.5)  
29F Rod Sleeve  
1
8F Clip (35)  
2
1
9F Ball Bearing (6202)  
10F Ring  
2
2
1
1
11F Bolt (M8 x 30)  
12F Bearing Plate  
13F Transmission Box  
14F Bolt (M8 x 35)  
15F Woodruff Key (4 x 13)  
16F Blade Shaft  
2
30F Spring  
1
1
31F Rod  
1
1
32F End Cap  
1
1
33F Dust Shield  
1
2
34F Shaft Lock  
1
1
35F Belt Tensioner w/Tensioning Nut  
36F Clamping Lever  
37F Cover  
1
17F Washer  
2
1
18F Rubber Ring  
19F Blade Guard Assy.  
1
1
1
38F BladeGuardPositioningKnob  
1
22F  
24F  
25F  
34F  
33F  
32F  
31F  
26F  
23F  
nOT  
inCluDeD  
27F  
30F  
29F  
28F  
22F  
21F  
20F  
19F  
35F  
36F  
37F  
18F  
17F  
16F  
15F  
38F  
14F  
12F  
13F  
11F  
10F  
9F  
8F  
7F  
6F  
5F  
4F  
3F  
2F  
1F  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 23  
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PaRTS liST/aSSemBlY DiaGRam  
FROnT HanDle & SuPPORT aSSemBlY  
Part  
Description  
Qty.  
1
Part  
Description  
Qty.  
2
1G Handle Bracket  
2G Screw (M5 x 12)  
3G Front Handle  
6G Screw (M5 x 25)  
7G Washer (8)  
8G Wheel  
2
2
1
2
4G Screw (M5 x 24)  
5G Spring Lock (8)  
2
9G Support  
1
2
10G Wheel Shaft  
2
1G  
2G  
3G  
4G  
10G  
9G  
8G  
5G  
7G  
6G  
nOTe:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
REV 08f  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 24  
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later, must meet such 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.  
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. 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, im-  
proper 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 inciden-  
tal, 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 WAR-  
RANTIES, EXPRESS OR IMPLIED, INCLUDING  
THE WARRANTIES OF MERCHANTABILITY AND  
FITNESS.  
Your emission control system may include parts such as the  
carburetor 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.  
manufacturer’s Warranty Coverage  
The 1995 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. If any emission related part on your engine is defective, the  
part will be repaired or replaced by HFT.  
Owner’s 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 main-  
tenance 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.  
To take advantage of this warranty, the  
product or part must be returned to us with trans-  
portation charges prepaid. Proof of purchase date  
and an explanation of the complaint must accom-  
pany 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 prod-  
ucts 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.  
-
-
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  
unapproved modifications.  
You are responsible for shipping your engine to a HFT war-  
ranty station as soon as a problem exists. Contact the HFT  
Customer Service department at the number below to make  
shipping arrangements. The warranty repairs should be  
completed in a reasonable amount of time, not to exceed 30  
days.  
If you have any questions regarding your warranty rights and  
responsibilities, you should contact the Harbor Freight Tools Cus-  
tomer Service Department at 1-800-444-3353.  
This warranty gives you specific legal rights  
and you may also have other rights which vary from  
state to state.  
Harbor Freight Tools emission Control Defects  
Warranty Provisions  
1. length of Coverage  
3491 Mission Oaks Blvd. •  
PO Box 6009 • Camarillo, CA 93011 • (800)  
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  
444-3353  
emission Control System  
Warranty  
first retail purchaser.  
2. no Charge Repair or Replacement  
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  
united States emission Control Defects  
Warranty Statement  
1-800-444-3353.  
The 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). The engine must be designed,  
built and equipped to meet stringent anti-smog standards. New  
off-road, spark-ignition engines certified for model year 1997 and  
3. Consequential Damages Coverage  
Coverage under this warranty shall also extend to the failure  
of any engine components caused by the failure of any war-  
ranted part while it is still covered under this warranty.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 25  
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4. Coverage exclusions  
Warranty claims shall be filed in accordance with the provi-  
sions 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 includ-  
ing, 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 autho-  
rized 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.  
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, pro-  
vided 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/me-  
chanic to perform all required maintenance, as outlined in the  
inspection, Cleaning, and maintenance section on page  
14 of this manual.  
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.  
ii) Hoses, belts, connectors, and assemblies.  
SKU 98089  
For technical questions, please call 1-800-444-3353  
PAGE 26  
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