Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
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.
REV 16g
Using a generator indoors CAN
Using an engine indoors
KILL YOU IN MINUTES.
CAN KILL YOU IN MINUTES.
Generator
exhaust
contains
Engine
exhaust
contains
carbon monoxide.
carbon
monoxide.
This see
is aorpoison
This is a poison you cannot
smell.
you cannot see or smell.
NEVER use inside
a home or garage,
NEVER
use inside
EVEN
IF doors
and
windows
aregarage,
open.
a home or
EVEN IF doors and
windows are open.
Only use OUTSIDE
and Only
far away
from
use
OUTSIDE
windows, doors,
and
far
away
from
and vents.
windows, doors,
and vents.
Visit our website at: http://www.harborfreight.com
Email our technical support at:
productsupport@harborfreight.com
Email our Engine support at: predator@harborfreight.com
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2011 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 assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Table of Contents
Safety.......................................................... 2
Maintenance............................................... 16
Setup........................................................... 6
Parts List and Diagram............................... 21
Specifications.............................................. 6
Warranty....................................................... 
SAFETY
Operation.................................................... 10
WARNING SYMBOLS AND DEFINITIONS
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
SETUP
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
OPERATION
INSTRUCTIONS PERTAINING TO A RISK OF FIRE,
ELECTRIC SHOCK, OR INJURY TO PERSONS
WARNING – When using tools, basic precautions should always be followed, including the following:
Set up 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 extinguishers nearby.
MAINTENANCE
3. Operation of this equipment 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.
4. Set up and use only on a flat, level,
well‑ventilated surface.
Page 2
5. All connections and conduits from the Generator
to the load must only be installed by trained and
licensed electricians, and in compliance with all
relevant local, state, and federal electrical codes and
standards, and other regulations where applicable.
6. Connections for standby power to a building
electrical system must be made by a qualified
electrician. The connection must isolate the
generator power from utility power, and must comply
with all applicable laws and electrical codes.
7. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during set up.
8. Use only lubricants and fuel
recommended in this manual.
For Generator technical questions, please call 1-888-866-5797.
Item 68525
9. Improper connections to a building electrical
system can allow electrical current from the
generator to backfeed into the utility lines. Such
backfeed may electrocute utility company workers
or others who contact the lines during a power
outage, and the generator may explode, burn, or
cause fires when utility power is restored. Consult
the utility company and a qualified electrician if
intending to use the generator for back up power.
10. Do not operate the Generator before grounding.
The Generator must be earth-grounded
in accordance with all relevant electrical
codes and standards before operation.
SAFETY
Set up Precautions (cont.)
Operating Precautions
7. Fire Hazard! Do not fill gas tank while engine is
running. Do not operate if gasoline has been spilled.
Clean spilled gasoline before starting engine.
Do not operate near pilot light or open flame.
SETUP
8. Do not touch engine during use. Let
engine cool down after use.
9. Never store fuel or other flammable
materials near the engine.
11. Before connecting an appliance or power cord
to the generator: Make sure that it is in good
working order. Faulty appliances or power cords
can create a potential for electrical shock.
Only use OUTSIDE and far away from windows,
doors, and vents.
2. Never use a generator indoors, including in
garages, basements, crawlspaces and sheds.
Opening doors and windows or using fans will NOT
prevent carbon monoxide build up in the home.
3. When using generators, keep them outdoors
and far away from open doors, windows,
and vents to avoid toxic levels of carbon
monoxide from building up indoors.
4. If you start to feel sick, dizzy, or weak while
using a generator, get to fresh air right away.
The carbon monoxide from generators can
quickly lead to full incapacitation and death.
5. Keep children away from the equipment,
especially while it is operating.
6. Keep all spectators at least six feet
from the Engine during operation.
Item 68525
12. Do not exceed the maximum power rating of the
generator. Make sure that the total electrical rating
of the all of the tools or appliances plugged into
the generator at the same time does not exceed
that of the generator. Check that the startup surge
will not be beyond the limit of the Generator.
Power levels between rated and maximum
may be used for no more than 30 minutes.
OPERATION
NEVER use inside a home or garage, EVEN IF doors
and windows are open.
10. If the plugged in product operates abnormally
or unusually slow, immediately stop using the
generator as a power source. Always read and
adhere to the instruction manual of the product
to be powered, to make sure that it can be safely
and efficiently powered by a portable generator.
13. Avoid substantially overloading which will trip the
circuit breaker. Exceeding the time limit for maximum
power operation or slightly overloading the generator
may not switch the circuit breaker or circuit protector
OFF, but will shorten the service life of the generator.
14. Do not attempt to connect or disconnect
load connections while standing in
water, or on wet or soggy ground.
15. Do not touch electrically energized parts of
the Generator and interconnecting cables or
conductors with any part of the body, or with
any non-insulated conductive object.
For Generator technical questions, please call 1-888-866-5797.
Page 3
MAINTENANCE
CARBON MONOXIDE HAZARD
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon
monoxide. This is a poison you cannot
see or smell.
1.
16. Connect the Generator only to a load or
electrical system (120 volt or 240 volt) that is
compatible with the electrical characteristics
and rated capacities of the Generator.
17. Insulate all connections and disconnected wires.
29. Stay alert, watch what you are doing and
use common sense when operating this
piece of equipment. Do not use this piece of
equipment while tired or under the influence
of drugs, alcohol or medication.
SAFETY
18. Guard against electric shock. Prevent body
contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerators.
30. 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.
19. Only use a suitable means of transport and
lifting devices with sufficient weight bearing
capacity when transporting the generator.
31. Parts, especially exhaust system components,
get very hot during use. Stay clear of hot parts.
20. Secure the Generator on transport vehicles to
prevent the tool from rolling, slipping, and tilting.
21. Industrial applications must follow
OSHA requirements.
SETUP
22. Do not leave the Generator unattended when it is
running. Turn off the Generator (and remove safety
keys, if available) before leaving the work area.
23. The Generator engine can produce high noise
levels. Prolonged exposure to noise levels
above 85 dBA is hazardous to hearing. Always
wear ear protection when operating or working
around the gas engine while it is operating.
24. Wear ANSI-approved safety glasses,
hearing protection, and NIOSH-approved
dust mask/respirator during use.
OPERATION
25. 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.
32. Do not cover the generator or its
engine during operation.
33. Keep the generator, its engine, and
surrounding area clean at all times.
34. Use the generator, accessories, etc., in accordance
with these instructions and in the manner intended for
the particular type of equipment, taking into account
the working conditions and the work to be performed.
Use of the equipment for operations different from
those intended could result in a hazardous situation.
35. Do not operate the generator with known
leaks in the engine’s fuel system.
36. WARNING: 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.)
37. WARNING: This product contains di (2-ethylhexyl)
phthalate (DEHP), 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.)
26. Use only accessories that are recommended
by Harbor Freight Tools for your model.
Accessories that may be suitable for one
piece of equipment may become hazardous
when used on another piece of equipment.
38. 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.
27. 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.
39. Keep hands and feet away from moving parts. Do
not reach over or across generator while operating.
MAINTENANCE
28. 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.
40. Before use, check for misalignment or binding
of moving parts, breakage of parts, and any
other condition that may affect the generator’s
operation. If damaged, have the generator
serviced before using. Many accidents are
caused by poorly maintained equipment.
41. Use the correct generator for the application. Do not
modify the generator or its engine, and do not use the
generator for a purpose for which it is not intended.
Page 4
For Generator technical questions, please call 1-888-866-5797.
Item 68525
b. Turn the engine switch to its “OFF” position.
c. Allow the engine to completely cool.
d. Then, remove the spark plug
cap from the spark plug.
2. Keep all safety guards in place and in
proper working order. Safety guards include
muffler, air cleaner, mechanical guards,
and heat shields, among other guards.
9. Store equipment out of the reach of children.
10. Follow scheduled engine and
equipment maintenance.
3. Make sure the Engine Switch is in its “OFF”
position before moving the Generator and
before performing any service, maintenance,
or cleaning procedures on the unit.
Refueling:
4. Keep all electrical equipment clean and dry.
Replace any wiring where the insulation is
cracked, cut, abraded, or otherwise degraded.
Replace terminals that are worn, discolored, or
corroded. Keep terminals clean and tight.
2. Do not refill the fuel tank while the
engine is running or hot.
5. Do not alter or adjust any part of the
equipment or its engine that is sealed by the
manufacturer or distributor. Only a qualified
service technician may adjust parts that may
increase or decrease governed engine speed.
6. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during service.
3. TO PREVENT FUEL LEAKAGE AND FIRE
HAZARD, Do not overfill with fuel. Fill with
fuel according to the Fuel Level information
below the Specification chart for your model.
4. Do not fill fuel tank to the top. Leave a little
room for the fuel to expand as needed.
5. Refuel in a well-ventilated area only.
6. Wipe up any spilled fuel and allow excess
to evaporate before starting engine. To
prevent FIRE, do not start the engine
while the smell of fuel hangs in the air.
SAVE THESE
INSTRUCTIONS.
MAINTENANCE
7. Maintain labels and nameplates on
the equipment. These carry important
information. If unreadable or missing, contact
Harbor Freight Tools for a replacement.
1. Do not smoke, or allow sparks, flames,
or other sources of ignition around the
equipment, especially when refuelling.
SETUP
a. Unplug all devices from the generator.
8. Have the equipment serviced by a qualified repair
person using only identical replacement parts.
This will ensure that the safety of the equipment
is maintained. Do not attempt any service or
maintenance procedures not explained in this
manual or any procedures that you are uncertain
about your ability to perform safely or correctly.
OPERATION
1. Before service, maintenance, or cleaning:
SAFETY
Service Precautions
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 5
Functional Description
Specifications
SAFETY
Generator
Output
120/240VAC, 60Hz
7,200 Running Watts (9000 Peak Watts)
Battery needed for electric start
(not included)
12V, lead acid, 9Ah
Electrical Receptacle
Displacement
Engine Type
Cooling System
Engine
Type
Capacity
Fuel
SETUP
Type SAE
Engine Oil
Capacity
Run Time @ 50% load
Operational Volume
Available accessories
Two 3-Prong, duplex NEMA #5-15 120V
One 3-Prong, NEMA #L5-20 twistlock 120V
One 4-Prong, NEMA #L14-30 twistlock 120V/240V
One DC Outlet 12VDC
420cc
Horizontal Single Cylinder 4 stroke OHV
Forced air cooled
87+ octane stabilizer treated unleaded gasoline
6.6 Gallons (25L)
10W-30 above 32° F
5W-30 at 32° F or below
1.16 Quart (1.1L)
12 hr.
76 dB
Wheel kit (sold separately)
The emission control system for this Generator’s Engine is warranted for standards set by the U.S. Environmental
Protection Agency and by the California Air Resources Board (also known as CARB). For warranty information, refer
to the last pages of this manual.
Components and Controls
OPERATION
Fuel Cap
DC Receptacle
DC Circuit Breaker
Fuel Valve
AC Circuit Breakers
Choke
AC Receptacles
MAINTENANCE
Air Filter
Frame
Ground Terminal
Starter
Handle
Page 6
Power Switch
Low Oil Indicator
For Generator technical questions, please call 1-888-866-5797.
Item 68525
Components and Controls (cont.)
START
I
O
ON
OFF
3. Circuit Breakers: The circuit breaker protects the
Generator from overloading. The rating of the breaker
and the load it protects are marked near the breaker.
Should any of the Circuit Breakers trip, the Generator
will stop the electricity output. If this happens, unplug
all loads from the Generator. Allow the Generator to
cool down. Then, press the tripped Circuit Breaker,
restart the Engine, and re-attach loads.
SAFETY
The following are descriptions of the controls
on the power panel. Your generator has
sockets to power your products with circuit
breakers to protect the voltage flow.
1. Engine Switch: Used to start and stop the Engine.
2. AC Receptacles: The Generator contains several
AC Receptacles to power tools and equipment.
a. 3-Prong, duplex
120 volt receptacle
(NEMA #5-15)
5. Grounding Terminal: Prior to each use, set
up the ground wire (not included) connection
to the Grounding Terminal to properly ground
the Generator. See Set up instructions
to properly ground the Generator.
OPERATION
b. 3-Prong, twistlock,
120 volt receptacle
(NEMA #L5-20)
SETUP
4. 12 VDC Receptacle: 12 VDC Receptacle provides a
power source for 12 volt DC items.
c. 4-Prong, twistlock,
120/240 volt receptacle
(NEMA #L14-30)
Item 68525
For Generator technical questions, please call 1-888-866-5797.
MAINTENANCE
WARNING! Connect tools and equipment
only to the Receptacle (120 volt or 240 volt)
that is compatible with the electrical
characteristics and rated capacities of the
tools and equipment being used.
Page 7
Initial Tool Set Up/Assembly
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
SAFETY
TO PREVENT SERIOUS INJURY:
Operate only with proper spark arrestor installed.
Operation of this equipment 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.
At high altitudes, the engine’s carburetor, governor, and any other parts that control the fuelair 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.
Battery Setup Instructions
SETUP
All Generators can be started using the recoil method. This generator requires installation of a
battery to operate the electric start feature. Connect the battery to the generator engine:
1. Place a fully charged, lead-acid 12 V, 9 Ah battery (not included) in the battery holder on the generator.
2. Bolt in place using the hardware included with the battery.
3. Attach the positive (red) cable connector from the engine to the Positive Terminal
on the battery. Connect cable securely to prevent disconnection and short circuits.
Positive Negative
Connector Connector
4. Attach the negative (black) cable connector to the negative battery terminal.
Battery
Grounding
Hardware
OPERATION
The Generator must be properly grounded before use. Have the unit grounded
by a qualified electrician if you are not qualified to do so.
To ground the Generator, connect a #6 AWG grounding wire (not included) from the
Grounding Terminal on the Control Panel to a grounding rod (not included) that has been
driven at least 24 inches deep into the earth. The grounding rod must be an earth-driven
copper or brass rod (electrode) which can adequately ground the Generator.
NOTICE: This generator is not intended to power sensitive electronic equipment without the addition of an
appropriate line conditioner and surge protector (both not included). Sensitive electronic equipment includes,
but is not limited to, audio/video equipment, some television sets, computers, and printers. Sensitive
electronic equipment should be operated on approved inverter type generators or pure sine wave generators.
Note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
MAINTENANCE
Note: Wheel Kit, item # 68531 (sold separately) can be used with this generator.
Page 8
For Generator technical questions, please call 1-888-866-5797.
Item 68525
High Altitude Operation Above 3000 feet
NOTICE Warranty void if necessary adjustments are not made for high altitude use.
At high altitudes, the engine’s carburetor, governor, 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. The fuel system on this engine may be influenced by operation
at higher altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 ft.
above sea level. At elevations above 8000 ft, the engine may experience decreased performance, even with
the proper main jet. Operating this engine without the proper altitude kit installed may increase the engine’s
emissions and decrease fuel economy and performance. The kit should be installed by a qualified mechanic.
1. Turn off the engine.
SAFETY
WARNING! TO PREVENT SERIOUS INJURY FROM FIRE:
Follow instructions in a well-ventilated area away from ignition sources.
If the engine is hot from use, shut the engine off and wait for it to cool before proceeding. Do not smoke.
Nuts
2. Close the fuel valve.
Deflecting Plate
3. Move the air cleaner housing aside to allow access to the carburetor:
Foam Filter
a. Loosen the knob and remove air cleaner cover.
SETUP
b. Remove the foam filter and deflecting plate.
c. Remove the nuts to allow the air cleaner housing to be moved aside.
4. Place a bowl under the fuel cup to catch any spilled fuel.
5. Unthread the screws holding the solenoid in place.
CAUTION! Carburetor bowl may have gas in it which
will leak upon removing the solenoid/bolt.
Air Cleaner
Housing
Air
Cleaner
7. Unthread the bolt holding the fuel cup.
Cover
8. Remove the bolt, Bolt Seal, fuel cup, Fuel Cup Seal and Main Jet from the body of the carburetor assembly.
A carburetor screwdriver (not included) is needed to remove and install the Main Jet.
6. Disconnect the solenoid and solenoid seal from the bolt.
9. Replace the Main Jet with the replacement Main Jet
needed for your altitude range (part 1a or 2a).
Carburetor
Assembly
Note: The Fuel Cup Seal and Bolt Seal may be damaged during
removal and should be replaced with the new ones from the kit.
Fuel Cup Seal
NOTICE: Do not cross thread bolt when tightening.
Finger tighten first and then use a wrench to
make sure the bolt is properly threaded.
11. Replace the solenoid and Solenoid Seal (5a),
and tighten in place with screws.
12. Reassemble the air cleaner and reattach all hoses to it.
13. Wipe up any spilled fuel and allow excess to evaporate
before starting engine. To prevent FIRE, do not start the
engine while the smell of fuel hangs in the air.
High Altitude Kit Parts List - A
Part
Description
Qty
1a Main Jet 3000-6000 ft.
1
2a Main Jet 6000-8000 ft.
1
3a Bolt Seal
1
4a Fuel Cup Seal
1
5a Solenoid Seal
1
Both altitude kits are included with this item.
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Mixing Tube
(might remain
inside carburetor)
Main Jet
Fuel Cup
Bolt Seal
Bolt
Solenoid Seal
Solenoid
Screws
Page 9
MAINTENANCE
10. Replace the Fuel Cup Seal (4a), fuel cup,
Bolt Seal (3a), and bolt. Tighten in place.
OPERATION
Note: The mixing tube is held in place by the Main Jet and might fall out when it is removed. If it falls out,
replace it in the same orientation before replacing the Main Jet.
Operating Instructions
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
SAFETY
Inspect tool before use, looking for damaged, loose, and missing parts.
If any problems are found, do not use tool until repaired.
Generator Pre-Start Checks
SETUP
Inspect engine and equipment, looking for
damaged, loose, and missing parts before set
up and starting. If any problems are found,
do not use equipment until fixed properly.
6. Thread the dipstick back in clockwise.
Checking and Filling Engine Oil
Checking and Filling Fuel
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.
WARNING! TO PREVENT SERIOUS
INJURY FROM FIRE:
Fill the fuel tank in a well-ventilated area
away from ignition sources. If the engine is
hot from use, shut the engine off and wait
for it to cool before adding fuel.
Do not smoke.
CAUTION! Do not run the engine with too little oil.
The engine will be permanently damaged.
1. Make sure the engine is stopped and is level.
1. Clean the Fuel Cap and the area around it.
2. Close the Fuel Valve.
3. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
OPERATION
Full level
Full level
4. Reinsert the Dipstick without threading it in and
remove it to check the oil level. The oil level
should be up to the full level as shown above.
5. If the oil level is at or below the low mark add the
appropriate type of oil until the oil level is at the
proper level. SAE 10W‑30 oil is recommended
for general use. (The SAE Viscosity Grade chart
on page 17 in the Service section shows other
viscosities to use in different average temperatures.)
2. Unscrew and remove the Fuel Cap.
3. If needed, fill the Fuel Tank to about 1 inch
under the fill neck with 87 octane or higher
unleaded gasoline that has been treated with
a fuel stabilizer additive. Follow fuel stabilizer
manufacturer’s recommendations for use.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
Note: Do not use gasoline that has been stored in a
metal fuel container or a dirty fuel container. It can
cause particles to enter the carburetor, effecting
engine performance and/or causing damage.
4. Then replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess
to evaporate before starting engine. To
prevent FIRE, do not start the engine while
the smell of fuel hangs in the air.
MAINTENANCE
Page 10
For Generator technical questions, please call 1-888-866-5797.
Item 68525
Using the Generator
Basic Generator Use Procedure - See
following pages for specific instructions
1. Check that the generator can handle the
wattage needed to power your products.
2. Start the Engine, and allow the Engine and
Generator to run and warm up for five minutes
after starting with no electrical load.
3. Plug in products.
6. Allow the Generator and its Engine to
completely cool. Then store the unit in a
clean, dry, safe location out of reach of
children and other unauthorized people.
IMPORTANT: After starting the engine, allow it to
run at no load for five minutes with no load after
each start‑up so that the engine can stabilize.
7. Break-in Period:
a. Breaking-in the engine will help to ensure
proper equipment and engine operation.
b. The operational break-in period will last
about 3 hours of use. During this period:
• Do not apply a heavy load to the equipment.
c. The maintenance break-in period will last
about 20 hours of use. After this period:
• Change the engine oil.
Under normal operating conditions
subsequent maintenance follows the schedule
explained in the SERVICE section.
MAINTENANCE
OPERATION
4. When finished using the Generator,
disconnect all electrical loads.
5. Turn off the Engine.
SAFETY
Before starting the engine:
a. Follow the Set Up Instructions
to prepare the Generator.
b. Unplug all loads from the Generator.
c. Inspect the Generator and engine.
d. Fill the engine with the proper
amount and type of both
stabilizer-treated fuel and oil.
Note: Do not allow generator to run
out of fuel with loads attached.
SETUP
Before Starting the Generator Engine
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 11
Starting the Engine
1. To start a cold engine, move the Choke to the
CHOKE position.
To restart a warm engine, leave the Choke in the
RUN position.
SAFETY
2. Open the Fuel Valve.
OFF
SETUP
ON
3.
For MANUAL START
For ELECTRIC START
A. Turn the Engine Switch to ON.
Turn the Engine Switch to START.
START
I
O
OPERATION
B. Grip the Starter Handle of the Engine
loosely and pull it slowly several times to
allow the gasoline to flow into the Engine’s
carburetor. Then pull the Starter Handle
gently until resistance is felt. Allow Cable
to retract fully and then pull it quickly.
Repeat until the engine starts. Note: Do
not let the Starter Handle snap back
against the engine. Hold it as it recoils so
it doesn't hit the engine.
START
ST AR T
I
O
Note: To prolong starter life, use
short starting cycles (5 seconds
maximum). Then wait one minute
before attempting to start again.
4. Allow the Engine to run for several seconds. Then,
if the Choke lever is in the CHOKE position, move
the Choke Lever very slowly to its RUN position.
MAINTENANCE
Note: Moving the Choke Lever too fast could stall the engine.
IMPORTANT: Allow the engine to run at no load for five minutes with no
load after each start‑up so that the engine can stabilize.
Page 12
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Item 68525
Connecting Electrical Loads
400
200 00
1,2
WARNING! Connect only properly wired plugs to the generator.
A plug that is spliced onto a different cord may be hazardous.
Only a qualified electrician should wire a plug onto a cord.
CAUTION Never exceed the rated capacity for this
Generator, as serious damage to the Generator and/
or appliances, tools, and equipment could result from
an overload. Starting and running wattage requirements
should always be calculated when matching this
Generator’s wattage capacity to the appliance, tool, or equipment.
0
4,20
atts )
0
W
2
1, 0
ng 3,200
nni
tts
Ru than
0
a
l
4
a
W
, 0
Tot less
up
ds 5
e
rt- l loa )
st b l Sta
00
al
(mu itiona d for an 4,0
e
h
d
d
d
ee less t
A
n
t
ges
atts be
Lar up W ust
(m
art
t
S
l
Must b e
Less than
7,000
SAFETY
Familiarize yourself with the engine controls, power panel and how to start the engine before using the generator.
Calculate the wattage of the products you will use with the generator and verify that the generator can handle the
0
total load.
1,00
Must b e
Less than
8,750
Use the DC12V Receptacle to power 12VDC equipment.
WARNING! Do not charge batteries without a proper charge controller. Do not overcharge.
b. Connect “inductive” load appliances, tools, and equipment next. Inductive
loads are small hand tools and some small appliances.
c. Connect any lights next.
d. Voltage sensitive appliances, tools, and equipment should be the last to be connected to the Generator.
Plug voltage sensitive items such as TVs, DVD players, microwaves, and cordless telephones into a UL®
Listed voltage surge protector (not included). Then, connect the surge protector into the Generator.
SETUP
a. Connect the items that require the most wattage first.
IMPORTANT! Failure to connect and operate appliances, tools, and equipment in this sequence can cause
damage to the Generator, appliances, tools, and equipment and will void the Warranty of this Generator.
OPERATION
Note: If Engine speed or voltage fluctuates with a load below the Generator’s running watts, move the Engine Choke
Lever to the
position.
IF ANY CIRCUIT BREAKERS TRIP CHECK THE FOLLOWING:
1. Make sure that ALL circuit breakers are reset
before starting the generator again.
Evenly distributed
over outlets:
2. Adjust the plugs so the loads are
shared across outlet circuits.
MAINTENANCE
To achieve rated output from the generator,
distribute loads over outlets.
Item 68525
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Page 13
Calculating Total Wattage of Devices Used with the Generator
SAFETY
Before using the Generator, check that the products
you want to plug into the unit are below the rated and
maximum wattage ratings of the Generator. Use the
Wattage Calculation Table below, and the watts listed
on your products, to help calculate multiple
wattage totals.
Wattage Estimate Charts
Note: Wattages listed below are estimates for that
type of equipment only. Check nameplate wattages
on all loads before connecting to Generator.
EMERGENCY
To use the table:
1. Add up the Running Watts for all items you
would like to use at any given time
2. Make sure that this total is under the 7,200
running wattage of the generator.
3. Find the single highest starting watts for
the selected items and add to the total.
4. Make sure that this total is under the
9,000 peak wattage of the generator.
5. Plug in and turn on products from largest wattage
to smallest.
SETUP
Wattage Calculation Table
Running
Watts
Equipment
Running
Watts
Device
Refrigerator/Freezer
Radio
700
100
JOB SITE
Running
Watts
Device
Air Compressor - 1/2 HP
Table Saw - 10"
Belt Sander - 3"
Hand Drill - 1/2"
Halogen Work Light
Recipricating Saw
Running
Watts
AM/FM Radio
Electric Grill
Inflator Pump
CD/DVD Player
Box Fan - 20"
Coffee Maker
100
1700
50
100
200
600
OPERATION
Example
Equipment
Electric Water Heater (2,000 + 0)
Television (400 + 0)
Lawn Mower (1,200 + 1,200)
Hand Drill (600 + 600)
Total Running Watts
(must be less than 7,200)
Largest Additional Start-up Watts
Total Startup Watts needed for all loads
(must be less than 9,000)
Running
Watts
2,000
400
1,200
600
4,200
1,200
5,400
Additional
Start-up
Watts
0
0
100
0
200
0
HOUSEHOLD
Largest Additional Start-up Watts
Total Startup Watts needed for all loads
(must be less than 9,000)
1000
1700
1200
600
1000
900
Additional
Start-up
Watts
1000
1300
1200
600
0
900
RECREATION
Device
Total Running Watts
(must be less than 7,200)
Additional
Start-up
Watts
1500
0
Running
Watts
Device
Computer w/ Monitor
Electric Clothes Dryer
Electric Range
Electric Water Heater
Light Bulb - 100 watts
Microwave - 1000 watts
Sump Pump - 1/2 HP
Television
Washing Machine
Well Pump - 1/2 HP
800
5500
2100
2000
100
1000
1000
400
1100
1000
Additional
Start-up
Watts
0
500
0
0
0
200
1100
0
1100
1000
LAWN & GARDEN
MAINTENANCE
A generator that is rated more than the minimum
required peak watts will last much longer than a
generator that only supplies the exact watts needed.
To Calculate Wattage
Volts and amps can be multiplied together to get watts
(volts x amps = watts).
To Calculate Additional Start-Up Watts
(If They Are Not Listed)
For equipment with a motor: Use the rated watts
amount as an estimate of additional Start-up Watts.
For most lights or heaters:
there are no additional start-up watts.
Page 14
Running
Watts
Device
Hedge Trimmer
Pressure Washer
Lawn Mower
Edger
400
1200
1200
1000
Additional
Start-up
Watts
400
1200
1200
1000
HEATING & COOLING
Device
Running
Watts
Central AC - 10,000 BTU
Furnace Fan - 1/2 HP
Space Heater
Window AC - 10,000 BTU
For Generator technical questions, please call 1-888-866-5797.
1500
900
1800
1200
Additional
Start-up
Watts
1500
1400
0
600
Item 68525
Stopping the Engine in an Emergency
SAFETY
1. To stop the engine in an emergency,
turn the Engine Switch off.
START
I
O
NOTICE: Generator shut-off under load may damage
the generator and attached equipment.
OFF
Stopping the Engine Under Normal Conditions
SETUP
1. Before turning off the Engine,
turn off all electrical loads,
then unplug them.
2. Turn the Engine Switch off.
START
OFF
OPERATION
I
O
3. Close the Fuel Valve.
OFF
MAINTENANCE
ON
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 15
User‑Maintenance Instructions
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
SAFETY
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch of the generator to its “OFF” position, wait for the engine to cool, and disconnect
the spark plug cap before performing any inspection, maintenance, or cleaning procedures.
TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE:
Do not use damaged equipment. If abnormal noise, vibration, or excess
smoking occurs, have the problem corrected before further use.
Follow all service instructions in this manual. The engine may fail critically if not serviced properly.
Many maintenance procedures, including any not detailed in this manual, will need to be
performed by a qualified technician for safety. If you have any doubts about your ability to safely
service the equipment or engine, have a qualified technician service the equipment instead.
SETUP
Cleaning, Maintenance, and Lubrication
Note: This maintenance schedule is intended solely as a general guide. If performance decreases or if
equipment operates unusually, check systems immediately. The maintenance needs of each piece of equipment
will differ depending on factors such as duty cycle, temperature, air quality, fuel quality, and other factors.
Note: The following procedures are in addition to the regular checks and maintenance
explained as part of the regular operation of the engine and equipment.
Before
Each Use
Procedure
Monthly or
Every 3 mo. or Every 6 mo. or
every 20
50 hr. of use 100 hr. of use
hr. of use
Yearly or
every 300
hr. of use
Every
2 Years
Brush off outside of engine
OPERATION
Check engine oil level
Check air cleaner
Check deposit cup
Change engine oil
Clean/replace air cleaner
Check and clean spark plug
1. Check/adjust idle speed
*
2. Check/adjust valve clearance
3. Clean fuel tank, strainer
and carburetor
4. Clean carbon build-up from
combustion chamber
Replace fuel line if necessary
**
**
**
MAINTENANCE
*Service more frequently when used in dusty areas.
**These items should be serviced by a qualified technician.
Page 16
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Item 68525
Checking and Filling Fuel
2. Unscrew and remove the Fuel Cap.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
Engine Oil Change
CAUTION! Oil is very hot during operation and can
cause burns. Wait for engine to cool before changing oil.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. If needed, fill the Fuel Tank to about 1 inch
under the fill neck with 87 octane or higher
unleaded gasoline that has been treated with
a fuel stabilizer additive. Follow fuel stabilizer
manufacturer’s recommendations for use.
4. Replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess
to evaporate before starting engine. To
prevent FIRE, do not start the engine while
the smell of fuel hangs in the air.
Note: Do not thread the dipstick in
when checking the oil level.
The SAE Viscosity Grade chart shows other
viscosities to use in different average temperatures.
SAE Viscosity Grades
3. Place a drain pan (not included) underneath
the crankcase’s drain plug.
30
4. Remove the drain plug and, if possible,
tilt the crankcase slightly to help drain
the oil out. Recycle used oil.
10W-30
5. Replace the drain plug and tighten it.
5W-30
-20
0
20
40
60
80
Average outdoor temperature
100°F
8. Thread the dipstick back in clockwise.
Full level
CAUTION! Do not run the engine with too little oil.
The engine will be permanently damaged.
OPERATION
6. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Full level
SAFETY
1. Clean the Fuel Cap and the area around it.
Note: Do not use gasoline that has been stored in a
metal fuel container or a dirty fuel container. It can
cause particles to enter the carburetor, effecting
engine performance and/or causing damage.
SETUP
WARNING! TO PREVENT SERIOUS
INJURY FROM FIRE:
Fill the fuel tank in a well-ventilated area
away from ignition sources. If the engine is
hot from use, shut the engine off and wait
for it to cool before adding fuel.
Do not smoke.
7. Add the appropriate type of oil until the
oil level is at the full level. SAE 10W‑30
oil is recommended for general use.
1. Remove the air filter cover and the air filter elements
and check for dirt. Clean as described below.
2. Cleaning:
• For “paper” filter elements:
To prevent injury from dust and debris,
wear ANSI-approved safety goggles,
NIOSH‑approved dust mask/respirator, and
heavy-duty work gloves. In a well‑ventilated
area away from bystanders, use pressurized
air to blow dust out of the air filter. If this does
not get the filter clean, replace it.
Item 68525
• For foam filter elements:
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.
3. Install the cleaned filter. Secure the
Air Cleaner Cover before use.
For Generator technical questions, please call 1-888-866-5797.
Page 17
MAINTENANCE
Air Filter Element Maintenance
Spark Plug Maintenance
1. Disconnect spark plug cap from end of plug.
Clean out debris from around spark plug.
SAFETY
2. Using a spark plug
wrench, remove
the spark plug.
Spark Plug
3. Inspect the spark
plug:
If the electrode is
oily, clean it using
a clean, dry rag.
Cylinder
If the electrode has
Assembly
deposits on it, polish
it using emery paper. If the white insulator is cracked
or chipped, the spark plug needs to be replaced.
SETUP
NOTICE: Using an incorrect spark plug may
damage the engine. See the Specifications chart
for your Generator for the type and gap required.
4. When installing a new spark plug, adjust
the plug’s gap to the specification on the
Specifications chart. Do not pry against the
electrode, the spark plug can be damaged.
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.
Non-gasket-style: Finger-tighten until the plug
contacts the head, then about 1/16 turn more.
NOTICE: Tighten the spark plug properly.
If loose, the spark plug will cause the engine
to overheat. If overtightened, the threads
in the engine block will be damaged.
6. Apply dielectric spark plug boot protector
(not included) to the end of the spark
plug and reattach the wire securely.
Storage
When the equipment is to remain idle for longer than
20 days, prepare the Engine for storage as follows:
c. Replace spark plug, but leave
spark plug cap disconnected.
1. CLEANING:
Wait for Engine to cool, then clean Engine with
dry cloth. NOTICE: Do not clean using water.
The water will gradually enter the Engine
and cause rust damage. Apply a thin coat
of rust preventive oil to all metal parts.
d. Pull Starter Handle 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).
2. FUEL:
OPERATION
To protect the fuel tank during storage, fill the
tank with gasoline that has been treated with
a fuel stabilizer additive. Follow fuel stabilizer
manufacturer’s recommendations for use.
Refer to Checking and Filling Fuel on page
Checking and Filling Fuel on page 10.
WARNING! TO PREVENT SERIOUS
INJURY FROM FIRE:
Fill tank in a well-ventilated area away from
ignition sources. If the engine is hot from
use, shut the engine off and wait for it to
cool before adding fuel. Do not smoke.
3. LUBRICATION:
4. STORAGE AREA:
Cover and store in a dry, level, well-ventilated
area out of reach of children. Storage area should
also be away from ignition sources, such as
water heaters, clothes dryers, and furnaces.
NOTICE: During extended storage periods the
Engine must be started every 3 months and allowed
to run for 15 – 20 minutes or the Warranty is VOID.
5. AFTER STORAGE:
Before starting the Engine during or after
storage, keep in mind that untreated gasoline
will deteriorate quickly. Drain the fuel
tank 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.
MAINTENANCE
a. Change engine oil.
b. Clean out area around spark plug.
Remove spark plug and pour one tablespoon of
engine oil into cylinder through spark plug hole.
Page 18
For Generator technical questions, please call 1-888-866-5797.
Item 68525
Troubleshooting
FUEL RELATED:
FUEL RELATED:
1. No fuel in tank or fuel valve closed.
1. Fill fuel tank with fresh 87+ octane stabilizer
treated unleaded gasoline and open fuel valve.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Choke not in CHOKE position, cold engine.
2. Move Choke to CHOKE position.
3. Gasoline with more than 10% ethanol used. 3. Clean out ethanol rich gasoline from fuel
(E15, E20, E85, etc.)
system. Replace components damaged by
ethanol. Use fresh 87+ octane stabilizer
treated unleaded gasoline only.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
4. Low quality or deteriorated, old gasoline.
4. Use fresh 87+ octane stabilizer treated
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Carburetor not primed.
5. Pull on Starter Handle to prime.
6. Dirty fuel passageways.
6. Clean out passageways using fuel additive.
Heavy deposits may require further cleaning.
7. Carburetor needle stuck. Fuel
can be smelled in the air.
7. Gently tap side of carburetor float
chamber with screwdriver handle.
8. Too much fuel in chamber. This can be
caused by the carburetor needle sticking.
8. Turn Choke to RUN position. Remove spark
plug and pull the start handle several times
to air out the chamber. Reinstall spark
plug and set Choke to CHOKE position.
9. Clogged Fuel Filter.
9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
IGNITION (SPARK) RELATED:
1. Spark plug cap not connected securely.
1. Connect spark plug cap properly.
2. Spark plug electrode wet or dirty.
2. Clean spark plug.
3. Incorrect spark plug gap.
3. Correct spark plug gap.
4. Spark plug cap broken.
4. Replace spark plug cap.
5. Circuit breaker tripped (electric
start models only).
5. Reset circuit breaker. Check wiring and
starter motor if breaker continues to trip.
6. Incorrect spark timing or
faulty ignition system.
6. 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.
SAFETY
Probable Solutions
SETUP
Engine will not start
Possible Causes
OPERATION
Problem
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
mis‑adjusted or stuck.
4. Have qualified technician diagnose/
repair ignition system.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 19
MAINTENANCE
2. Loose or broken spark plug. (Hissing noise 2. Tighten spark plug. If that does not work,
will occur when trying to start.)
replace spark plug. If problem persists,
may have head gasket problem, see #3.
Troubleshooting (cont.)
Problem
Engine misfires
Possible Causes
SAFETY
1. Check wire connections.
2. Incorrect spark plug gap or
damaged spark plug.
2. Re-gap or replace spark plug.
3. Defective spark plug cap.
3. Replace spark plug cap.
4. Old or low quality gasoline.
4. Use only fresh 87+ octane stabilizer treated
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Incorrect compression.
Engine stops
suddenly
Probable Solutions
1. Spark plug cap loose.
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.
2. Fuel tank empty or full of impure or low
quality gasoline.
2. Fill fuel tank with fresh 87+ octane stabilizer
treated unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
3. Defective fuel tank cap creating
vacuum, preventing proper fuel flow.
3. Test/replace fuel tank cap.
4. Faulty magneto.
4. Have qualified technician service magneto.
5. Disconnected or improperly
connected spark plug cap.
5. Secure spark plug cap.
Engine stops when
under heavy load
1. Dirty air filter.
1. Clean or replace element.
2. Engine running cold.
2. Allow engine to warm up prior
to operating equipment.
Engine knocks
1. Old or low quality gasoline.
1. Fill fuel tank with fresh 87+ octane stabilizer
treated unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Engine overloaded.
2. Do not exceed equipment’s load rating.
SETUP
1. Low oil shutdown.
OPERATION
3. Incorrect spark timing, deposit buildup,
3. Have qualified technician diagnose
worn engine, or other mechanical problems.
and service engine.
Engine backfires
Product doesn’t
have power.
MAINTENANCE
Product begins to
operate abnormally.
1. Impure or low quality gasoline.
1. Fill fuel tank with fresh 87+ octane stabilizer
treated unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Engine too cold.
2. Use cold weather fuel and oil
additives to prevent backfiring.
3. Intake valve stuck or overheated engine.
3. Have qualified technician diagnose
and service engine.
4. Incorrect timing.
4. Check engine timing.
1. Product not plugged in properly.
1. Turn off and unplug the product, then
plug it back in again and turn on.
2. Circuit Breaker tripped.
2. Turn off and unplug product, Reset Circuit
Breaker. Plug in product and turn on.
3. Product needs service.
3. Have product repaired.
1. Problem with appliance.
1. Immediately unplug appliance. Have
appliance repaired by a qualified
technician, or replace appliance.
2. Rated load capacity exceeded.
2. Lower the number of items plugged into the
generator to stay within the rated capacity,
or use a more powerful generator.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Page 20
For Generator technical questions, please call 1-888-866-5797.
Item 68525
Parts List and Diagram
Qty
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
1
1
1
1
2
7
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
2
2
2
Part
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
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
Description
Retainer, Valve Spring
Starter Assy, Recoil
Bolt
Shroud
Shroud, Cylinder Body
Bolt
Bolt
Carburetor Assy.
Gasket, Air Cleaner
Gasket, Carburetor
Plate, Carburetor Insulator
Gasket, Inlet
Clip
Sleeve, Breather Tube Fixing
Control Assy, Choke
Valve, One Way
Cleaner, Air
Nut
Nut, Flywheel
Starter Pulley
Impeller
Flywheel Sub.
Bolt
Coil, Ignition
Bolt
Clamp, Charge Coil
Bolt
Coil Sub, Charge
Bolt
Control Assy, Throttle
Spring, Throttle Valve Returning
Rod, Governor
Spring, Governor
Support Sub, Governor
Nut
Bolt, Governor Support
Collar
Motor, Starting
Bolt
Relay, Starting
Bolt
Muffler Assy.
Cover, Muffler Inner
Cushion, Muffler Insulator Rubber
Bracket,Muffler
Bolt
Cover, Muffler Side
Bolt
Cover, Muffler Outer
Gasket, Exhaust Outlet
Nut
Pipe, Exhaust
Bolt
Tank, Fuel
Sleeve, Fuel Tank Rubber
Bush
Washer
Bolt
Qty
1
1
3
1
1
1
5
1
2
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
2
1
2
1
1
3
1
4
1
7
1
2
2
1
2
1
4
4
4
4
Part
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
Description
Cover, Fuel Tank
Fuel Strainer
Screw
Leveler Assy, Oil
Cock Assy, Fuel
Collar
Tube, Fuel
Frame Assy, Engine
Nut
Cushion, Engine Frame
Cushion, Engine Frame Rear
Nut
Brace
Bolt
Socket Sub, Power Supply
Socket Sub, Power Supply
Protector, Overcurrent
Terminal Sub, Grounding
Socket Sub. DC
Switch Sub.
Socket Sub, Power Supply
Protector, Overcurrent
Protector, Overcurrent
Case, Panel Rear
Panel Sub, Control
Motor Assy.
Bracket, Motor
Stator Bolt
Washer
Rotor Bolt
Regulator, Voltage
Bolt
Brush Sub, Carbon
Bolt
Cover, Motor Rear
Bolt
Block, Terminal
Bolt
Band
Bolt
Stator Bolt
Washer
Stator Nut
Bolt
Stopper, Motor Right Cover
Shroud, Motor
Bolt
Bolt, Cylinder Head
Valve, One Way
Clamp
Hose, Fuel Steam Rubber
Clamp
Bolt
Collector, Fuel Steam
Clamp
Hose, Air Cleaner Rubber
Clamp
Qty
1
1
2
1
1
2
1
1
4
2
2
4
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
4
1
1
1
2
1
1
1
2
1
2
2
2
2
2
2
1
1
1
1
4
1
1
1
1
2
1
1
1
1
Record Product's 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.
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 21
SETUP
Description
Gasket, Cylinder Head
Cylinder Head Cover
Gasket, Cylinder Head Cover
Tube, Breather
Bolt Sub, Cylinder Head Cover
Stud
Stud
Pin
Plug, Spark
Head Sub, Cylinder
Crankcase Sub.
Seal, Oil
Sensor, Engine Oil
Bearing
Plug, Rubber
Protector, Oil
Bolt
Flat Washer
Bolt, Drain Plug
Clip
Arm, Governor
Seal, Oil
Pin
Flat Washer
Bolt
Cover, Crankcase
Gasket, Crankcase
Bearing
Dipstick Sub, Oil
Pin
Bolt
Bearing
Gear Assy, Governor
Seal, Oil
Crankshaft Assy.
Shaft Assy, Balancing
Ring Set, Oil
Clip, Piston Pin
Piston
Pin, Piston
Rod, Connecting
Primary Ring
Secondary Ring
Camshaft Assy.
Valve, Exhaust
Valve, Intake
Seat, Valve Spring
Exhaust Valve Retainer
Rotator, Valve
Guide, Seal
Tappet, Valve
Lifter Sub, Valve
Plate Sub, Lifter Stopper
Bolt, Valve Adjusting
Rocker, Valve
Valve Adjusting Nut
Nut, Valve Lock
Spring, Valve
OPERATION
1
2
3
4
5
6
7
8
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
46
47
48
49
50
51
52
53
54
55
56
57
58
MAINTENANCE
Part
SAFETY
Parts List
Page 22
106
5
9
2
3
For Generator technical questions, please call 1-888-866-5797.
32
28
50
54 53
54
59
10
102
103
69
68
6
1 8
66
104
104
104
8
143
72
52
73
67
51
46
52 51
45
13
25
25
157
160
157
145
144
144
44
30
33
27
104
70
6
29
144
144
147
146
30
154
154
153
106
106
106
105
106
58
57 56 55
57
47
5655
49 48
4
148
150
155 149
7 7
58
108
101
26
164
109
164
109
100
164
164
107
162
110
108
111
106
111
106
163
31
31
31
34
31
31
31
31
156
151
155
MAINTENANCE
148
43
71
42
67
71
36
35
18
74
37
14
39
159
38
19
158
158
18
19
12
22
23
24
21
142
38
41
11
40
159
15
20
161
OPERATION
156
76 76
16
82
17
87
75
81
116
81
85
86
95
85
89
88
83
80
84
90 92
91
87
93
169
78
139
77
64
138
123
62
122
173
166
115
114
116
119
120
133
63
172
122
171
167
168
113
169 170
94
79
140
60
65
121
116
115
114
113
65
65
165
119
136 135
SETUP
152
65
65
118
117
133
134
137
132
131
130
116
115
114
113
132
141
61
125
128
99 99
130
61
61
128
126
124
129
116
115
114
113
112
97
97
96
125
127
98
128
128
126
125
SAFETY
152
125
127
Assembly Diagram
Item 68525
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 OF REPLACEMENT PARTS THERETO.
SAFETY
PLEASE READ THE FOLLOWING CAREFULLY
Warranties
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, EXCEPT FOR THE EMISSIONS CONTROL SYSTEM WARRANTY BELOW.
SETUP
Limited 90 Day Warranty (Retail)
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.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
The California Air Resources Board and Harbor Freight Tools (HFT) are pleased to explain the emissions control
system warranty on your 2016 Small Off-Road Engine, in addition to the Retail Warranty above. In California, new
equipment that uses small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog
standards. HFT must warrant that the emissions control system on your engine will be free from defects in material and
workmanship for two (2) years, provided there has been no abuse, neglect, or improper maintenance of your engine.
Your emissions control system may include parts such as the carburetor or fuel-injection
system, the ignition system, catalytic converter, fuel tanks, fuel lines, fuel caps, valves, canisters,
vapor hoses, clamps, connectors, and other emissions-related assemblies.
OPERATION
Emissions Control System Warranty
Where a warrantable condition exists, HFT will repair or replace, at our option,
your engine if at no cost to you, including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
OWNER’S WARRANTY RESPONSIBILITIES
As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual.
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 (including failure to follow the fuel use instructions
contained in this manual), neglect, improper maintenance, or unapproved modifications.
You are responsible for contacting HFT as soon as the problem exists in order to obtain warranty repair or replacement,
by doing either of the following: (a) contact HFT product support at 1-888-866-5797 or productsupport@harborfreight.com;
or (b) bring the to your nearest Harbor Freight Tools retail store. The nearest Harbor Freight Tools retail store
can be found on the internet at http://www.harborfreight.com. The warranty repairs or replacement should be
completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty
coverage, you should contact HFT product support at 1-888-866-5797 or productsupport@harborfreight.com.
Item 68525
For Generator technical questions, please call 1-888-866-5797.
Page 23
MAINTENANCE
This emissions control system is warranted for two years. If any emission-related part
on your engine is defective, the part will be repaired or replaced by HFT.
GENERAL EMISSIONS WARRANTY COVERAGE
a) The warranty period begins on the date the engine or equipment is delivered
to an ultimate purchaser. The warranty period is two years.
b) HFT warrants to the initial owner and each subsequent owner that the engine is:
1. Designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board; and
2. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.
c) The warranty on emissions-related parts is as follows:
1. Any warranted part that is not scheduled for replacement as required maintenance in the written
instructions provided, is warranted for the warranty period stated above. If any such part fails
during the period of warranty coverage, it will be repaired or replaced HFT. Any such part repaired
or replaced under the warranty will be warranted for the remaining warranty period.
2. Any warranted part that is scheduled only for regular inspection in the written instructions is
warranted for the warranty period stated above. A statement in the written instructions to the effect
of “repair or replace as necessary” does not reduce the period of warranty coverage. Any such part
repaired or replaced under warranty will be warranted for the remaining warranty period.
3. Any warranted part that is scheduled for replacement as required maintenance in the written instructions will be
warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the
first scheduled replacement, the part will be repaired or replaced by HFT. Any such part repaired or replaced under
warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
4. Repair or replacement of any warranted part under the warranty will be performed at no charge
to the owner at a retail store or by HFT paying for shipping the product for repair.
5. Notwithstanding the provisions herein, warranty services or repairs will be provided at all retail stores or
by contacting HFT product support at 1-888-866-5797 or productsupport@harborfreight.com.
6. The owner will not be charged for diagnostic labor that leads to the determination that a warranted
part is in fact defective, provided that such diagnostic work is performed at a retail store.
7. HFT is liable for damages to other engine components proximately caused
by a failure under warranty of any warranted part.
8. Throughout the emissions warranty period stated above, HFT will maintain a supply of
warranted parts sufficient to meet the expected demand for such parts.
9. Any replacement part may be used in the performance of any warranty maintenance or repairs and will be
provided without charge to the owner. Such use will not reduce the warranty obligations of HFT.
10. Add-on or modified parts that are not approved by HFT may not be used. The use of any non‑exempted
add-on or modified parts will be grounds for disallowing a warranty claim. HFT is not liable to warrant
failures of warranted parts caused by the use of a non-exempted add-on or modified part.
d) Emission Warranty Parts List.
1. Fuel Metering System
a. Carburetor and its internal parts (and/or
pressure regulator or fuel injection system).
b. Fuel tank.
c. Cold start enrichment system.
d. Air/fuel ratio feedback and control system.
2. Air Induction System
a. Controlled hot air intake system.
b. Intake manifold.
c. Air filter.
3. Ignition System
a. Spark plugs.
b. Magneto ignition system.
c. Spark advance/retard system.
4. Catalyst System (if so equipped)
a. Exhaust pipe stud/exhaust manifold.
b. Thermal reactor.
c. Catalytic converter (if so equipped).
5. Particulate Controls
a. Traps, filters, precipitators, and any other device
used to capture particulate emissions.
6. Miscellaneous Items Used in Above Systems
a. Vacuum, temperature and time sensitive
valves and switches.
b. Hoses, belts, connectors, and assemblies.
7. Evaporative Emission Control System
a. Fuel tank.
b. Fuel caps, valves, canisters, filters, vapor hoses,
clamps, connectors, belts, and assemblies.
HFT provides with each product written instructions for the maintenance and use of the product by the owner.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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