Harbor Freight Tools Lawn Mower 96154 11HP User Guide

OHV GAS ENGINE - HORIZONTAL  
MOdEL 99856 - 13 HP  
MOdEL 96154 - 11 HP  
ASSEMbLy ANd OPERATION INSTRucTIONS  
IMPORTANT!  
your Warranty is  
voided if:  
You do not put  
Engine oil in the  
Engine’s crankcase  
prior to its first use.  
Never run the Engine  
with low or no oil.  
Running the Engine  
with low or no oil will  
permanently damage  
the Engine.  
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  
Visit our website at: http://www.harborfreight.com  
TO PREVENT SERIOuS INjuRy, REAd ANd uNdERSTANd  
ALL WARNINGS ANd INSTRucTIONS bEfORE uSE.  
©
®
Copyright 2007 by Harbor Freight Tools . All rights reserved. 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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GENERAL SAfETy RuLES  
WARNING!  
REAd ANd uNdERSTANd ALL INSTRucTIONS  
failure to follow all instructions listed below may result in  
electric shock, fire, and/or serious injury.  
SAVE THESE INSTRucTIONS  
WORk AREA  
1.  
2.  
Keep your work area clean and well lit. Cluttered and dark areas invite acci-  
dents.  
Do not operate the Engine in explosive atmospheres, such as in the presence of  
flammable liquids, gases, or dust. Gasoline engines create sparks which may ignite  
the dust or fumes.  
3.  
Keep bystanders, children, and visitors away while operating a power tool. Distrac-  
tions can cause you to lose control. Protect others in the work area from debris  
such as chips and sparks. Provide barriers or shields as needed. Children should  
never be allowed in the work area.  
PERSONAL SAfETy  
1.  
2.  
Stay alert. Watch what you are doing, and use common sense when operating 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 the Engine may  
result in serious personal injury.  
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.  
4.  
Do not overreach. Keep proper footing and balance at all times. Proper footing  
and balance enables better control of the Engine in unexpected situations.  
Use safety equipment. Always wear eye protection. Dust mask, nonskid  
safety shoes, hard hat, or hearing protection must be used for appropri-  
ate conditions. Always wearANSI-approved safety goggles when using  
or performing maintenance on this Engine.  
TOOL uSE ANd cARE  
1.  
Do not force the Engine. Use the correct Engine for your application. The correct  
Engine will do the job better and safer at the rate for which it is designed. Do not force  
the Engine and do not use the Engine for a purpose for which it is not intended.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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2.  
3.  
Do not use the Engine if the Engine’s Ignition Switch does not turn it on or off. Any  
tool that cannot be controlled with the Ignition Switch is dangerous and must be  
replaced.  
Disconnect the Spark Plug Wire from the Engine before making any adjustments,  
changing accessories, or storing the tool. Such preventive safety measures reduce  
the risk of starting the tool accidentally. Always disconnect the Spark Plug Wire  
before performing any inspection, maintenance, or cleaning procedures. Maintain  
tools with care. Keep the Engine clean. Properly maintained engines are less  
likely to malfunction and are easier to control. Do not use a damaged Engine. Tag  
damaged engines “Do not use” until repaired.  
4.  
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 Engine serviced  
before using. Many accidents are caused by poorly maintained equipment.  
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.  
SERVIcE  
1.  
2.  
Engine service must be performed only by qualified repair personnel. Service or  
maintenance performed by unqualified personnel could result in a risk of injury.  
When servicing the Engine, 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 injury and void applicable warranties.  
SPEcIfIc SAfETy RuLES  
1.  
IMPORTANT! Your Warranty is voided if:  
You do not put engine oil in the Engine’s crankcase prior to its first use. Before  
each use, check the oil level. Never run the Engine with low or no engine oil. Run-  
ning the Engine with low or no Engine oil will permanently damage the Engine.  
2.  
3.  
4.  
Maintain labels and nameplates on the Engine. These carry important information.  
If unreadable or missing, contact Harbor Freight Tools for a replacement.  
Maintain a safe working environment. Make sure there is adequate surrounding  
workspace.  
Avoid unintentional starting. Make sure you are prepared to begin work before  
turning on the Engine. Learn and memorize how to shut off the Engine prior to  
starting it.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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5.  
6.  
People with pacemakers should consult their physician(s) before use. Electro-  
magnetic 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.  
Never leave the Engine unattended when it is running. Turn off the Engine before  
leaving the work area.  
7.  
8.  
9.  
Always use the Engine on a flat, level, dry ground surface.  
Make sure to keep hands and fingers away from all moving parts of the Engine.  
Prior to installing the Engine onto a power equipment unit, make sure to read and  
understand all instructions and safety precautions as outlined in the owner’s manual  
for the power equipment.  
TOXIc fuMES, fIRE, ANd EXPLOSION PREcAuTIONS  
1.  
This Engine is designed for outdoor use only. Do not operate the Engine in a closed  
area or in a poorly ventilated area. When running, the Engine produces carbon  
monoxide, a colorless, odorless, toxic gas 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.  
2.  
Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel  
storage and handling procedures. Always have multiple ABC class fire extinguish-  
ers nearby.  
3.  
4.  
Keep the Engine and surrounding areas clean at all times.  
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 regula-  
tions. Store oil rags in a covered metal container.  
5.  
6.  
Never store fuel or other flammable materials near the Engine.  
Do not smoke, or allow sparks, flames, or other sources of ignition around the  
Engine.  
7.  
Keep grounded conductive objects, such as tools, away from exposed, live electri-  
cal parts and connections to avoid sparking or arcing. These events could ignite  
fumes or vapors.  
8.  
Do not refill the Fuel Tank while the Engine is running or hot.  
Do not operate the Engine with known leaks in the Engine’s fuel system.  
Use only Engine manufacturer recommended oil and fuel.  
9.  
10.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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MEcHANIcAL PREcAuTIONS  
1.  
Prior to performing service, maintenance, or cleaning procedures, always make sure  
the Engine’s Ignition Switch is in its “OFF” position. Allow the Engine to completely  
cool. Then, remove the Spark Plug Wire from the Spark Plug.  
2.  
3.  
Do not alter or adjust any part of the Engine that is assembled and supplied by the  
manufacturer or distributor.  
Always follow and complete scheduled Engine maintenance.  
cHEMIcAL PREcAuTIONS  
1.  
2.  
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.  
Avoid body contact with fuels, oils, and lubricants used in the Engine. If swallowed,  
seek immediate medical treatment. 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 Engine  
when it is running.  
MISc. PREcAuTION  
WARNING! 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.  
uNPAckING  
When unpacking, check to make sure all of the parts shown on the Parts  
List in this manual are included. If any parts are missing or broken, please call Harbor  
Freight Tools at the number shown on the cover (and at the bottom of each page) of this  
manual as soon as possible.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 6  
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ASSEMbLy INSTRucTIONS  
TO MOuNT THE ENGINE  
1.  
IMPORTANT: If you have any doubts about your ability to perform the following  
assembly procedures, you should have a qualified service technician perform the  
assembly for you.  
Mounting  
Mounting  
Holes  
Holes  
figure A  
2.  
3.  
Located near the Crankshaft (16 - page 16) are different-sized mounting holes with  
which to mount the Engine to your power equipment unit. (See figure A.)  
Set the Engine side-by-side to the power equipment unit, and align the mounting  
holes of the Engine with the mounting holes in the power equipment unit. NOTE:  
There are different patterns of mounting holes available. Use the mounting holes  
that best match the ones on the power equipment unit. (See figure A.)  
4.  
5.  
6.  
Use hardened steel Bolts, Washers, Lock Washers, and Nuts (not included) of the  
appropriate diameter and length to secure the Engine to the power equipment unit.  
(See figure A.)  
cAuTION! check to make sure the bolts, Washers, Lock Washers, and the  
Nuts used dO NOT come in contact with any moving part of the Engine and  
power equipment unit.  
NOTE: Refer to the power equipment unit’s owner manual for instructions on how  
to properly install a belt drive pulley, chain drive gear, etc. onto the Crankshaft  
(16 - page 16) of the Engine.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 7  
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TO PROVIdE bATTERy POWER TO THE STARTER MOTOR  
1.  
The Engine’s Starter Motor (4 - page 26) unit can be powered by a typical 12 VDC  
battery (not included).  
fIGuRE b  
STARTER MOTOR (4 - PAGE 26)  
bLAck WIRE  
fROM THIS bOLT  
TO NEGATIVE (-)  
bATTERy POST  
REd STARTER WIRE  
TO  
POSITIVE (+)  
bATTERy POST  
2.  
To provide battery power to the Starter Motor (4 - page 26), connect the bLAck  
(negative -) wire from the negative (-) post on the battery to the Bolt designated on  
the base of the engine. Then connect the REd (positive +) wire from the Starter  
Motor to the positive (+) post on the battery. (See figure b.)  
PRE-OPERATING INSTRucTIONS  
1.  
2.  
3.  
Make sure the Engine’s Crankcase is filled with approximately 37 ounces of  
10-30W automotive oil. Also, make sure the Engine’s Fuel Tank is filled with  
approximately 1-1/2 gallon of unleaded gasoline before attempting to start the  
Engine. Failure to do so WILL damage the Engine and void the Warranty.  
Before adding oil check to make sure the Drain Plug (2 - page 13) is tight. Unscrew  
and remove the Dipstick (15 - page 14). Pour the required amount of oil into the  
Crankcase Cover (4 - page 14). Then screw the Dipstick back into the Crankcase  
Cover. (See figure c, next page.)  
Unscrew and remove the Fuel Filler Cap (11 - page 19) from the Fuel Tank  
(9 - page 19). Pour the required amount of unleaded gasoline (mid to high oc-  
tane) into the Fuel Tank. Then screw the Fuel Filler Cap back onto the Fuel Tank.  
(See figure c.)  
REV 07k  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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fuEL fILLER cAP (11 - PAGE 19)  
fuEL TANk (8 - PAGE 19)  
fIGuRE c  
dIPSTIck (15 - PAGE 14)  
dRAIN PLuG (2 - PAGE 13)  
OPERATING INSTRucTIONS  
1.  
Make sure the power equipment unit’s transmission (if applicable) is in its  
“NEuTRAL” or “PARk” position before attempting to start the Engine.  
THROTTLE (7 - PAGE 23)  
cHOkE  
fIGuRE d  
fuEL LEVER  
2.  
To start the Engine, turn the Fuel Lever to its “OPEN” position. Turn the Choke  
to its “START” position. Then turn the Throttle to the RIGHT to its “SLOW”  
position. (See fig. d.) Note: If the Engine is already hot, keep the Choke in the  
“RuN” position.  
REV 07g  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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fIGuRE E  
IGNITION SWITcH (8 - PAGE 27)  
3.  
4.  
To start the Engine, using the battery for cranking power, insert the Ignition Key  
(19 - page 27) and turn the Engine Ignition (8 - page 27) to its “START” position. If  
necessary, repeat this procedure until the Engine starts. NOTE: To prolong Starter  
Motor (4 - page 26) life, use short starting cycles (5 seconds maximum, then wait  
one minute before attempting restart. (See figure E.)  
To start the Engine manually, using the Starter Recoil Handle (17 - page 22), in-  
sert the Ignition Key (19 - page 27) and turn the Engine Ignition (8 - page 27) to its  
“RuN” position. Grasp the Starter Recoil Handle and pull slowly until resistance  
is felt. Allow the Handle to retract slowly. Then pull the Handle with a rapid, full  
arm stroke. Allow the Handle to retract slowly. If necessary, repeat this procedure  
until the Engine starts.  
5.  
Once the Engine starts, turn the Choke to its “RuN” position. Then adjust the  
Throttle to the RIGHT (7 - page 23) to the the speed (RPM) you desire. (See fig-  
ure d.)  
6.  
7.  
8.  
IMPORTANT: Allow the Engine to run at no load for five minutes after each start-  
up so that the Engine can stabilize.  
When finished using the Engine, turn the Engine’s Ignition (8 - page 27) to its “Off”  
position. Then close the Engine’s Fuel Lever. (See figures d and E.)  
NOTE: In an emergency, the Engine can be turned off by either:  
a. Turning the Engine Ignition (8 - page 27) to its “Offposition.  
b. Turning the Fuel Lever to its “cLOSEd” position.  
c. Removing the Spark Plug Cap (4 - page 25).  
REV 07g  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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INSPEcTION, MAINTENANcE, ANd cLEANING  
1.  
2.  
WARNING! Never perform any services or maintenance on the Engine while  
it is running. Before performing any inspection, maintenance, and cleaning, turn  
off the Engine and disconnect the Spark Plug Wire from the Spark Plug to prevent  
accidental starting. Then, allow the Engine to completely cool.  
Before each use, inspect the general condition of the Engine. Check for loose bolts  
and nuts, misalignment, binding of moving parts, loose or broken parts, damaged  
fuel lines, and any other condition that may affect the safe operation of the Engine.  
If abnormal noise or vibration occurs, turn off the Engine immediately and have the  
problem corrected before further use. do not use damaged equipment.  
3.  
4.  
Follow all maintenance procedures as outlined in the Engine Maintenance  
Schedule below at the specified intervals. (See figure G.)  
After each use, remove all debris from the Engine with a soft brush, cloth, vacuum,  
or with compressed air. Do not use solvents. Do not allow water to enter the inter-  
nal workings of the Engine.  
5.  
6.  
When storing, drain all fuel out of the Engine’s Fuel Tank. If this is not done, old fuel  
in the Engine’s Fuel Tank and Carburetor may become contaminated and prevent the  
Engine from starting until cleaned out. Do not drain oil. Always store the Engine in  
a clean, dry, safe location out of reach of children and other unauthorized people.  
cAuTION! All maintenance, service, and repairs not mentioned in this  
manual must only be performed by a qualified service technician.  
Engine Maintenance Schedule  
electrodes  
^
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
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TROubLESHOOTING  
Problem  
Engine will not start.  
Possible cause  
1. Low on fuel or oil.  
Possible Solution  
1. Add fuel or oil.  
2. Ignition switch is in “OFF”  
position.  
2. Turn ignition switch to “ON”  
position.  
3. Faulty spark plug.  
3. Clean or replace spark plug.  
4. Properly adjust choke.  
4. Choke in wrong position.  
5. Fuel lever in “CLOSED”  
position.  
5. Turn fuel lever to “OPEN”  
position.  
6. Engine under load during start- 6. Remove load from Engine.  
up.  
7. Spark plug wire loose.  
8. Fuel line clogged.  
9. Air filter clogged.  
7. Attach wire to spark plug.  
8. Clean fuel line and filter.  
9. Clean air filter.  
10. Fuel contaminated.  
10. Drain fuel tank and carburetor  
bowl. Refill with fresh fuel.  
11. Faulty ignition system.  
12. Battery low or defective.  
11. Have a qualified service  
technician check out ignition  
system.  
12. Recharge or replace battery.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 1ꢀ  
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PARTS LIST/dIAGRAM - cRANkcASE  
Part  
description  
Q’ty  
Part  
8
description  
Q’ty  
1
3
4
5
6
7
Washer  
1
1
1
1
1
Washer  
Split Pin  
1
1
1
1
1
Drain Plug  
9
Oil Seal, Crankshaft  
10  
11  
Regulating Sway Bar  
Nut (M10)  
Seal  
Diode  
1ꢀ  
13  
14  
O-Ring  
Crankcase  
Bolt (M6x14)  
Oil Sensor  
Oil Seal, Regulating Sway Bar  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 13  
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PARTS LIST/dIAGRAM - cRANkcASE cOVER  
Part  
1
description  
Oil Plug with Seal  
Q’ty  
Part  
11  
description  
Q’ty  
1
1
1
1
1
1
1
1
Washer  
1
1
1
1
1
1
7
1
Oil Plug  
1ꢀ  
Sliding Sleeve  
3
Seal  
13  
Gasket, Crankcase  
Set Pin (8x12)  
4
Crankcase Cover  
Washer, Drive Gear  
Drive Gear, Regulator  
Pin  
14  
5
15  
Dipstick  
6
16  
Dipstick with Seal  
Bearing (6206)  
Oil Seal, Crankshaft  
Bolt (M8x40)  
7
17  
8
Regulating Shaft  
Flying Block  
Snap Ring  
18  
9
19  
10  
20  
Drive Gear, Regulator  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 14  
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PARTS LIST/dIAGRAM - cyLINdER HEAd/cyLINdER HEAd cOVER  
Part  
1
description  
Q’ty  
Part  
11  
description  
Lead Wind Cover  
Q’ty  
Bolt  
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
Washer  
1ꢀ  
Stud (M6x8x134.5)  
Gasket, Cylinder Head  
Set Pin  
3
Rubber Seal  
13  
4
Bolt  
14  
5
Cylinder Head Cover Assy.  
Gasket, Cylinder Head Cover  
Bolt  
15  
Cylinder Head Assy.  
Spark Plug (F7RTCU)  
Stud (M8x48.5)  
Air Duct  
6
16  
7
17  
8
Circlip  
18  
9
Exhaust Valve Guide  
Intake Valve Guide  
19  
Seal  
10  
20  
Bolt (M6x12)  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 15  
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PARTS LIST/dIAGRAM - cRANkSHAfT, PISTON, cONNEcTING ROd  
Part  
1
description  
Piston Ring (I)  
Q’ty  
Part  
1ꢀ  
description  
Bearing (6202)  
Q’ty  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Piston Ring (II)  
Side Rail  
13  
Balancing Shaft  
Bearing (6207)  
Woodruff Key  
3
14  
4
Expander  
15  
5
Scraper Ring Set  
Piston Pin Circlip  
Piston  
16  
Crankshaft  
6
17  
Drive Gear  
7
18  
Timing Gear  
8
Piston Pin  
Shank  
19  
Piston Ring Set Kit  
Connecting Rod Assy.  
Crankshaft Assy.  
9
20  
10  
11  
Bearing Cap  
Bolt  
ꢀ1  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 16  
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PARTS LIST/dIAGRAM - cAMSHAfT, VALVE ROckER  
Part  
description  
Q’ty  
Part  
10  
description  
Exhaust Valve  
Q’ty  
1
3
4
5
6
7
8
9
Lock Nut  
1
1
1
1
1
1
1
1
1
Sleeve  
11  
Intake Valve  
Valve Rocker  
1ꢀ  
Spring Retainer, Exhaust Valve  
Valve Spring  
Adjusting Bolt for Valve Gap  
Pusher Guide  
13  
14  
Spring Keeper  
Spring Keeper  
Seal  
Push Rods  
15  
Valve Tappets  
16  
Extension Spring  
Camshaft Assy.  
17  
Valve Rocker Assy.  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 17  
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PARTS LIST/dIAGRAM - cARbuRETOR  
Part  
1
description  
Inlet Gasket  
Q’ty  
Part  
16  
description  
Choke Stem  
Q’ty  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Connecting Block  
Carburetor Gasket  
Idle Adjustment Screw  
Mixture Chamber Body  
Main Nozzle  
17  
Airproof Washer  
Throttle Lever  
Washer  
3
18  
4
19  
5
20  
Screw (M4)  
6
ꢀ1  
Cover  
7
Main Jet  
ꢀꢀ  
Choke Switch  
Throttle Unit  
8
Float  
ꢀ3  
9
Float Chamber Gasket  
Float Chamber  
Washer  
ꢀ4  
Spring, Mixture Adjustment Screw  
Mixture Adjustment Screw  
Choke Unit  
10  
11  
1ꢀ  
13  
14  
15  
ꢀ5  
ꢀ6  
Float Chamber Drain Screw  
Screw  
27  
Float Chamber  
Carburetor Assy.  
Float Needle  
ꢀ8  
Air Cleaner Gasket  
Choke  
ꢀ9  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 18  
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PARTS LIST/dIAGRAM - fuEL TANk  
Part  
description  
Q’ty  
Part  
description  
Q’ty  
1
3
4
5
6
Pipe  
1
1
1
1
7
Nut (M8)  
Fuel Tank  
Filter Cup  
1
1
1
1
1
Outlet Pipe  
Pipe Clamp  
Connector  
8
9
10  
11  
1ꢀ  
Packing Ring  
Bolt (M8x25)  
Fuel Filler Cap  
Packing Ring  
Fuel Filler Cap w/Packing Ring  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 19  
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PARTS LIST/dIAGRAM - AIR cLEANER  
Part  
description  
Q’ty  
Part  
description  
Q’ty  
1
3
4
5
6
Wing Nut  
1
1
1
1
1
7
Sleeve B  
1
1
1
1
Air Cleaner Cover  
Filter Element  
8
Bolt (M6x22)  
Washer  
9
Air Cleaner Base  
Sleeve A  
10  
11  
Nut (M6)  
Air Cleaner Assy.  
Air Cleaner Housing  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 20  
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PARTS LIST/dIAGRAM - MuffLER  
Part  
description  
Q’ty  
Part  
description  
Q’ty  
1
3
4
Nut (M8)  
5
1
1
1
5
6
7
8
Muffler  
1
4
1
1
Exhaust Pipe Gasket  
Exhaust Pipe  
Screw (M5x8)  
Muffler Hood Assy.  
Muffler Assy.  
Muffler Gasket  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ1  
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PARTS LIST/dIAGRAM - REcOIL STARTER  
Part  
1
description  
Engine Switch  
Q’ty  
Part  
11  
description  
Ratchet Spring  
Q’ty  
1
1
1
1
5
1
3
1
1
1
1
1
1
1
1
1
1
Wire Grommet  
Clip  
1ꢀ  
Ratchet  
3
13  
Friction Spring  
Set Screw  
Spring Lid  
Rope  
4
Plastic Clip  
Bolt (M6x12)  
Fan Hood Assy.  
Bolt (M6x8)  
Casing  
14  
5
15  
6
16  
7
17  
Handle  
8
18  
Recoil Starter  
Recoil Starter Assy.  
9
Coil Leaf Spring  
Cord Spool  
19  
10  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀꢀ  
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PARTS LIST/dIAGRAM - REGuLATING cONTROL SySTEM  
Part  
description  
Bolt (M5x35)  
Q’ty  
Part  
10  
description  
Q’ty  
1
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
Nut (M6)  
Spring  
1
1
1
1
1
1
1
Regulating Spring  
Clamp  
11  
1ꢀ  
Back Spring  
Lock Bolt  
Bolt (M6x12)  
Support Panel  
Washer  
13  
14  
Regulating Arm  
15  
Regulating Arm Spring  
Pulling Rod  
Throttle  
16  
Spring Patch  
Setting Panel  
17  
Regulating Frame Assy.  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ3  
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PARTS LIST/dIAGRAM - fLyWHEEL  
Part  
description  
Q’ty  
Part  
description  
Q’ty  
1
Nut (M16x1.5)  
1
3
Flywheel Fan  
1
Starting Flange  
1
4
Flywheel  
1
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ4  
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PARTS LIST/dIAGRAM - IGNITION cOIL  
Part  
description  
Q’ty  
Part  
description  
Q’ty  
1
3
4
5
Screw (M6x30)  
1
1
1
1
6
7
8
9
Charge Coil  
1
1
1
Engine Stop Cable  
Ignition Coil  
Clamp, Cord  
Bolt (M6x35)  
Bolt (M6x12)  
Spark Plug Cap  
Ignition Coil Assy.  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ5  
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PARTS LIST/dIAGRAM - STARTER MOTOR  
Part  
1
description  
Relay, Start-Up  
Q’ty  
Part  
13  
description  
Cable, Starter Motor  
Q’ty  
1
1
1
1
1
1
1
4
1
4
1
1
1
1
1
1
4
3
Rotor Comp.  
14  
Insulator  
3
Starting Clutch  
Starter Motor Assy.  
Base, Starter  
15  
Bolt (M5x14)  
Screw (M4x6)  
Packing Ring  
Screw (M5x32)  
Nut (M6)  
4
16  
5
17  
6
Housing, Starter Clutch  
Drive Gear  
18  
7
19  
8
Brush, Comp.  
Stator Assy.  
20  
Bolt (M6x35)  
Spring Washer (4mm)  
Screw (M4x14)  
Washer (4mm)  
Set Pin (8x14)  
9
ꢀ1  
10  
11  
1ꢀ  
Spring, Brush  
Reducing Gear  
Stay, Brush  
ꢀꢀ  
ꢀ3  
ꢀ4  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ6  
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PARTS LIST/dIAGRAM - STARTER & cONTROL bOX  
Part  
1
description  
Clamp Ring  
Q’ty  
Part  
11  
description  
Control Rear Cover  
Q’ty  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gasket  
1ꢀ  
Attachment Bolt  
Protector  
3
Bolt (M4x10)  
Control Front Cover  
Diode  
13  
4
14  
Fixed Mount  
Spring  
5
15  
6
Nut (M4)  
16  
Cover  
7
Fixed Mount  
Ignition Switch  
Safety  
17  
Protector Assy.  
Bolt (M3x12)  
Ignition Key  
8
18  
9
19  
10  
Diode Assy.  
IMPORTANT  
When ordering parts from the above Parts List, make sure to specify the following:  
a. The MOdEL NuMbER (either 99856 or 96154) of the Engine for which you are ordering.  
b. The PART NuMbER listed to the left of the part description.  
c. The NAME Of THE PARTS LIST from which you are ordering (located at the top of this page).  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 27  
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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. Elsewhere within the United States, new off-road, spark-ignition engines certified for model year 1997 and later, must  
meet similar 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 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 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 unapproved modifications.  
- 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 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 Customer  
Service Department at 1-800-444-3353.  
Harbor freight Tools Emission control defects Warranty Provisions  
1. Length of coverage  
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.  
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 1-800-444-3353.  
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 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ8  
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EMISSION cONTROL SySTEM WARRANTy – (cONT.)  
Harbor freight Tools Emission control defects Warranty Provisions  
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.  
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.  
PLEASE REAd THE fOLLOWING cAREfuLLy  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM-  
BLY DIAGRAM IN THIS MANUALAS 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 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.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page ꢀ9  
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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,  
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  
MERCHANTABILITY AND FITNESS.  
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 com-  
plaint 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.  
This warranty gives you specific legal rights and you may also have other rights  
which vary from state to state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
NOTE:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 99856-96154  
for technical questions, please call 1-800-444-3353.  
Page 30  
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