Chicago Electric 65414 User guide

3000 RUNNING WATTS/3500 STARTUP WATTS
PORTABLE GENERATOR
65414
SET UP, OPERATING, AND SERVICING
INSTRUCTIONS
Using an engine indoors CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside
a home or garage,
EVEN IF doors and
windows are open.
Only use OUTSIDE
and far away from
windows, doors, and
vents.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2008 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Revised 09g

Page 2For technical questions, please call 1-800-444-3353.SKU 65414
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
EXTENSION CORDS .........................7
BASIC SPECIFICATIONS ............. 8
UNPACKING .................................. 8
OPERATING INSTRUCTIONS ...... 8
STARTING THE ENGINE ...................9
CHECKING AND FILLING
ENGINE OIL ...............................9
CHECKING AND FILLING FUEL..9
START PROCEDURE ...................9
BREAK-IN PERIOD ....................10
EQUIPMENT OPERATION............... 10
CONTROL PANEL FEATURES ....... 11
CONTROL PANEL CHART..............13
TECHNICAL SPECIFICATIONS.. 14
SERVICING.................................. 15
MAINTENANCE PROCEDURES .....15
ENGINE OIL CHANGE ............... 15
AIR FILTER ELEMENT
MAINTENANCE .......................15
SPARK PLUG MAINTENANCE..16
CLEANING, MAINTENANCE, AND
LUBRICATION SCHEDULE ..........16
AFTER INITIAL 20
OPERATION HOUR PERIOD...16
EVERY 25 OPERATION
HOURS THEREAFTER:...........16
EVERY 50 OPERATION
HOURS:....................................16
EVERY 100 OPERATION
HOURS:....................................16
EVERY 300 OPERATION
HOURS:....................................16
STORAGE ........................................17
ENGINE TROUBLESHOOTING.......18
EQUIPMENT
TROUBLESHOOTING ..................20
MAIN PARTS LIST....................... 21
DIAGRAM .................................... 22
PARTS LIST AND DIAGRAM A -
CRANKCASE ASSEMBLY............ 23
PARTS LIST AND DIAGRAM B -
CYLINDER HEAD ASSEMBLY .....24
PARTS LIST AND DIAGRAM
C - CRANKSHAFT, PISTON,
CONNECTING ROD,
CAMSHAFT AND FLYWHEEL
ASSEMBLIES ................................25
PARTS LIST AND DIAGRAM
D - RECOIL STARTER AND
IGNITION COIL ASSEMBLY .........26
PARTS LIST AND DIAGRAM E -
AIR CLEANER ASSEMBLY ..........27
PARTS LIST AND DIAGRAM F -
FUEL SUPPLY SYSTEM ...............28
PARTS LIST AND DIAGRAM G -
STARTER AND GENERATOR
ASSEMBLY....................................29
WIRING DIAGRAM...........................30
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 31
EMISSION CONTROL SYSTEM
WARRANTY .............................. 31

Page 3For technical questions, please call 1-800-444-3353.SKU 65414
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
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.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
WARNING! Read all instructions.
Failure to follow all instructions
listed below may result in re,
serious injury and/or DEATH.
The warnings and precautions
discussed in this manual cannot
cover all possible conditions and
situations that may occur. It must
be understood by the operator that
common sense and caution are
factors which cannot be built into
this product, but must be supplied
by the operator.
SAVE THESE INSTRUCTIONS
SET UP PRECAUTIONS
Gasoline fuel and fumes are amma-1.
ble, and potentially explosive. Use
proper fuel storage and handling pro-
cedures. Do not store fuel or other
ammable materials nearby.
Have multiple ABC class re extin-2.
guishers nearby.
Operation of this equipment may cre-3.
ate sparks that can start res around
dry vegetation.
A spark arrestor may be required.
The operator should contact local re
agencies for laws or regulations relat-
ing to re prevention requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.

Page 4For technical questions, please call 1-800-444-3353.SKU 65414
Wear ANSI-approved safety goggles,5.
heavy-duty work gloves, and dust
mask/respirator during set up and
use.
Use only oil and fuel recommended6.
in the “Specications” section of this
manual.
OPERATING PRECAUTIONS
1. CARBON MONOXIDE
HAZARD
Using an engine indoors
CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon
monoxide. This is a poison you
cannot see or smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are
open.
Only use OUTSIDE and far away
from windows, doors, and vents.
Keep children away from the equip-2.
ment, especially while it is operating.
Do not leave the equipment unat-3.
tended when it is running. Turn off
the equipment (and remove safety
keys, if available) before leaving the
work area.
Wear ANSI-approved safety goggles4.
and hearing protection during use.
People with pacemakers should5.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to a heart pacemaker could
cause pacemaker interference or
pacemaker failure. Caution is neces-
sary when near the engine’s magneto
or recoil starter.
Use only accessories that are recom-6.
mended 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.
Do not operate in explosive atmo-7.
spheres, such as in the presence of
ammable liquids, gases, or dust.
Gasoline-powered engines may ignite
the dust or fumes.
Stay alert, watch what you are doing8.
and use common sense when operat-
ing this piece of equipment. Do not
use this piece of equipment while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper foot-9.
ing and balance at all times. This en-
ables better control of the equipment
in unexpected situations.
Dress properly. Do not wear loose10.
clothing or jewelry. Keep hair, cloth-
ing and gloves away from moving
parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
Parts, especially exhaust system11.
components, get very hot during use.
Stay clear of hot parts.

Page 5For technical questions, please call 1-800-444-3353.SKU 65414
Do not cover the engine or equipment12.
during operation.
Keep the equipment, engine, and sur-13.
rounding area clean at all times.
Use the equipment, accessories, etc.,14.
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 differ-
ent from those intended could result
in a hazardous situation.
Do not operate the equipment with15.
known leaks in the engine’s fuel sys-
tem.
This product contains or, when used,16.
produces a chemical known to the
State of California to cause cancer
and birth defects or other reproduc-
tive harm. (California Health & Safety
Code § 25249.5, et seq.)
When spills of fuel or oil occur, they17.
must be cleaned up immediately.
Dispose of uids and cleaning materi-
als as per any local, state, or federal
codes and regulations. Store oil rags
in a bottom-ventilated, covered, metal
container.
Keep hands and feet away from18.
moving parts. Do not reach over or
across equipment while operating.
Before use, check for misalignment19.
or binding of moving parts, breakage
of parts, and any other condition that
may affect the equipment’s operation.
If damaged, have the equipment
serviced before using. Many ac-
cidents are caused by poorly main-
tained equipment.
Use the correct equipment for the20.
application. Do not modify the equip-
ment and do not use the equipment
for a purpose for which it is not in-
tended.
SERVICE PRECAUTIONS
Before service, maintenance, or1.
cleaning:
Turn the engine switch to itsa.
“OFF” position.
Allow the engine to completelyb.
cool.
Then, remove the spark plugc.
wire(s) from the spark plug(s).
Keep all safety guards in place and in2.
proper working order. Safety guards
include mufer, air cleaner, mechani-
cal guards, and heat shields, among
other guards.
Do not alter or adjust any part of3.
the equipment or its engine that is
sealed by the manufacturer or dis-
tributor. Only a qualied service
technician may adjust parts that
may increase or decrease gov-
erned engine speed.
W4. ear ANSI-approved safety goggles,
heavy-duty work gloves, and dust
mask/respirator during service.
Maintain labels and nameplates on5.
the equipment. These carry impor-
tant information. If unreadable or
missing, contact Harbor Freight Tools
for a replacement.
Have the equipment serviced by a6.
qualied repair person using only
identical replacement parts. This will
ensure that the safety of the equip-
ment is maintained. Do not attempt

Page 6For technical questions, please call 1-800-444-3353.SKU 65414
any service or maintenance proce-
dures not explained in this manual
or any procedures that you are un-
certain about your ability to perform
safely or correctly.
Store equipment out of the reach of7.
children.
Follow scheduled engine and equip-8.
ment maintenance.
Refueling Precautions:9.
Do not smoke, or allow sparks,a.
ames, or other sources of ignition
around the equipment, especially
when refuelling.
Do not rell the fuel tank while the b.
engine is running or hot.
Do not ll fuel tank to the top. Leave c.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.d.
SAVE THESE
INSTRUCTIONS.

Page 7For technical questions, please call 1-800-444-3353.SKU 65414
Extension Cords
Grounded1. tools require a three wire
extension cord. Double Insulated
tools can use either a two or three
wire extension cord.
As the distance from the supply outlet2.
increases, you must use a heavier
gauge extension cord. Using exten-
sion cords with inadequately sized
wire causes a serious drop in voltage,
resulting in loss of power and pos-
sible tool damage.
(See Table A.)
The smaller the gauge number of the3.
wire, the greater the capacity of the
cord. For example, a 14 gauge cord
can carry a higher current than a 16
gauge cord.
(See Table A.)
When using more than one exten-4.
sion cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(See Table A.)
If you are using one extension cord5.
for more than one tool, add the
nameplate amperes and use the sum
to determine the required minimum
cord size.
(See Table A.)
If you are using an extension cord6.
outdoors, make sure it is marked with
the sufx “W-A” (“W” in Canada) to
indicate it is acceptable for outdoor
use.
Make sure the extension cord is prop-7.
erly wired and in good electrical con-
dition. Always replace a damaged
extension cord or have it repaired by
a qualied electrician before using it.
Protect the extension cords from8.
sharp objects, excessive heat, and
damp or wet areas.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD LENGTH
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A * Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.

Page 8For technical questions, please call 1-800-444-3353.SKU 65414
BASIC SPECIFICATIONS
Fuel Type 87+ octane unleaded
gasoline
Capacity 4 Gallons
Engine Oil
Type
SAE 10W-30 above 32°F
SAE 5W-30 at 32°F or
below
Capacity 2/3 Quart; Low Oil
Shutdown Sensor
Spark Plug Gap 0.030”
Run Time @ 50%
Load 9 Hours with full tank
Engine Type 6.5 HP Four-stroke
Overhead Valve Design
Electrical Plugs
Dula NEMA
120V~receptacle
One NEMA 120/240V
4 prong twist lock
receptacle
One T-Type 12V outlet
Note: Additional specications found in
the TECHNICAL ENGINE SPECIFI-
CATIONS chart in this manual.
The emission control system for this
Generator’s Engine is warranted for stan-
dards set by the U.S. Environmental Pro-
tection Agency. For warranty information,
refer to the last pages of this manual.
At high altitudes, the engine’s carbu-
retor, governor (if so equipped), and any
other parts that control the fuel-air ratio will
need to be adjusted by a qualied me-
chanic to allow efcient high-altitude use
and to prevent damage to the engine and
any other devices used with this product.
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
Remove these bolts and
brackets before use.
There are two metal brackets that
secure the generator to the bottom of the
crate. These brackets hold the generator
in place during shipment to prevent dam-
age. They must be removed before use.
See the photo above.
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.
TO PREVENT
SERIOUS INJURY:
Operate only with proper
spark arrestor installed.
REV 09a; 09f

Page 9For technical questions, please call 1-800-444-3353.SKU 65414
Operation of this equipment
may create sparks that
can start res around dry
vegetation.
A spark arrestor may be
required.
The operator should contact
local re agencies for laws
or regulations relating to re
prevention requirements.
Starting the Engine
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 xed properly.
Checking and Filling Engine Oil
CAUTION! Your Warranty is VOID if the
engine’s crankcase is not properly
lled 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. Check the oil
level with the engine stopped and
in a level position.
Remove the dipstick and wipe it off1.
with a clean rag.
Reinsert the dipstick into the oil ller 2.
neck, but do not screw in, then re-
move it to check the oil level. The oil
level should reach the upper limit (H)
mark on the dipstick (bottom edge of
the oil ll hole).
If the oil level is not to the upper limit3.
mark (bottom edge of the oil ll hole),
add the appropriate type of oil until
the oil level reaches the upper limit
mark.
Engine Oil SAE 10W-30 above 32°F
SAE 5W-30 at 32°F or below
Replace the Oil Dipstick.4.
The Oil Sensor will automatically
shutdown the engine before the oil
level falls below the safe/low limit.
To avoid nuisance tripping of the
Oil Sensor and damage to property,
check that the oil level is at the
bottom edge of the oil ll hole before
each start-up.
CAUTION! DO NOT run the engine with
low oil or no oil; the engine will be
permanently damaged.
Checking and Filling Fuel
Visually check the fuel level. A fuel1.
level from about 1 inch under the ll
neck or higher is full.
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-venti-
lated area away from ignition sourc-
es. Do not smoke.
To ll the Fuel Tank, rst wipe off the 2.
Fuel Tank Cap and the surrounding
area.
REV 09a

Page 10For technical questions, please call 1-800-444-3353.SKU 65414
Unscrew, and remove the Fuel Tank3.
Cap.
Mix fuel stabilizer (not included) with4.
87 octane (or better) unleaded gaso-
line according to fuel stabilizer direc-
tions.
Fill the Fuel Tank to about 1 inch un-5.
der the ll neck of the gasoline tank
with the stabilized unleaded gasoline
mixture.
Then replace the Fuel Tank Cap.6.
Start Procedure
Before starting the engine:
Inspect the equipment anda.
engine.
Fill the engine with the prop-b.
er amount and type of fuel
and oil.
Read the Equipment Opera-c.
tion section that follows.
Unplug loads from the Generator1.
and make sure the AC circuit breaker
switch is in the OFF position before
starting to prevent permanent gen-
erator damage.
Turn the engine fuel valve to its ON2.
or OPEN position.
Turn the engine power switch to its3.
ON or RUN position.
Then, turn the engine choke lever to4.
its “CHOKE” position. Set the choke
lever in the “RUN” position when
starting a warm engine.
Grasp the starter handle, and pull5.
slowly until resistance is felt. While
holding the handle, allow the starter
rope to rewind slowly. Then, pull the
starter handle with a rapid, full arm
stroke. Once again while holding
the handle, allow the rope to rewind
slowly. Repeat as necessary, until
the engine starts.
After the engine starts and warms6.
up, slowly move the choke lever to its
“RUN” position.
IMPORTANT: Allow the engine to run7.
at no load until warm (1-5 minutes)
with no load after each start-up to al-
low the engine to stabilize.
Move the AC circuit breaker switch to8.
its ON or RUN position.
Break-in Period
Breaking-in the engine will help to1.
ensure proper equipment and engine
operation, and will extend the en-
gine’s lifespan. The warranty is void
if the engine is not broken in properly.
The rst 20 hours of operation is the
break-in period.
During the rst 3 hours of use:2.
Do not apply a heavy load to the•
equipment.
Do not operate the engine at its•
maximum speed.
After the rst 20 hours of use:3.
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
schedule explained in the MAINTE-
NANCE AND SERVICING section.

Page 11For technical questions, please call 1-800-444-3353.SKU 65414
Equipment Operation
TO PREVENT
SERIOUS INJURY
AND DEATH:
DO NOT CONNECT
GENERATOR DIRECTLY TO
HOUSEHOLD WIRING.
A portable electric generator
that is connected to your
household wiring without a
proper cut off switch can
‘back feed’ into the power
lines connected to your home.
Power created by your
generator can injure or even
kill a utility lineman making
outage repairs many miles
away.
Only a certied electrician can
safely connect the generator
to your home’s wiring.
Make sure your generator is properly1.
grounded to avoid electrical shocks.
Connect a 10 GA. or larger insulated
copper wire to the Ground Con-
nection on the Control Panel. Con-
nect this wire to a suitable external
ground, such as a metal stake in the
ground.
Don’t overload the generator. The2.
total wattage used by the appliances
should be less than the output rating
of the generator. If you put too many
appliances on the generator, it could
seriously damage the appliances and
electronics. Overloading the gen-
erator could also cause res in the
power cord. This generator is rated at
3000 / 3500 Watts. NOTE: At start-
up, appliances draw more power in a
surge than they do during continuous
operation. When guring total watt-
age of all appliances connected to
this generator, use the higher start-up
amperage rating of each appliance.
Do not exceed the current limit speci-3.
ed for any one receptacle.
Move the AC Circuit Breaker switch4.
to the ON position.
Plug in your extension cord or appli-5.
ance.
Be sure that all appliances are in6.
good working order before connect-
ing them to the generator. If an appli-
ance begins to operate abnormally,
becomes sluggish, or stops suddenly,
turn off the circuit breaker and the
generator engine switch immediately.
Then disconnect the appliance and
examine it for signs of malfunction.
Note: If an overloaded circuit causes the
AC circuit breaker to switch off, re-
duce the electrical load on the circuit
and wait a few minutes before reset-
ting the circuit breaker.
The DC terminal may be used to op-7.
erate 12 Volt DC portable appliances
only.
CAUTION! Do not use this genera-
tor to charge 12VDC batteries.
Directly charging a 12 Volt battery
may cause the battery to overheat
and possibly explode.
CAUTION: Do not attempt to start
an automobile engine with this
generator. Voltage back feed from
the alternator may damage the
generator.
Note: The DC terminal may be used while
the AC power is in use. An overload-
ed DC circuit will trip the DC circuit
protector (push button comes out).
If this happens, wait a few minutes

Page 12For technical questions, please call 1-800-444-3353.SKU 65414
before pushing in the circuit protector
to resume operation.
Disconnect all loads from the8.
generator before shutting off. To
prevent accidents, turn off the engine
and disconnect its spark plug wire
after use. Wait for the engine to cool,
clean external parts with clean cloth,
then store the equipment out of chil-
dren’s reach according to the Storage
instructions in this manual.
Control Panel Features
Motor Kill Switch must be in ON posi-1.
tion for engine to start and run. Move
to OFF position to stop engine.
Power Indicator Light, when lit, shows2.
that the generator is producing elec-
tricity.
AC Breaker Switch protects circuits3.
when using AC (120 V~ or 240 V~)
power.
120 V~ duplex outlet provides two4.
grounded outlets for standard 110-
120 V~ household appliances.
240 V~ twist lock receptacles pro-5.
vides a grounded outlet for one
240 Volt appliance, such as a water
heater, stove or dryer.
12 VDC outlet provides a power6.
source for 12 volt DC items, such as
automotive accessories.
12 VDC Breaker Switch provides7.
circuit protection for 12 VDC acces-
sories.
REV 09f; 09g

Page 13For technical questions, please call 1-800-444-3353.SKU 65414
Control Panel Chart
Motor Kill Switch
Power Indicator Light A Breaker Switch
120 V~ Duplex Receptacle
240 V~
Twist Lock Receptacle
DC Breaker Switch
Ground Wire Connection 12 VDC Outlet
REV 09f; 09g

Page 14For technical questions, please call 1-800-444-3353.SKU 65414
TECHNICAL SPECIFICATIONS
Item Description Initial Specica-
tion in mm
Wear Limit
in mm
Piston Skirt External Diameter 67.985 67.845
Clearance between Piston and Cylinder Wall 0.015-0.05 0.12
Piston Pin Hole Internal Diameter 18.002 18.048
Piston Pin External Diameter 18.0 17.954
Gap between Piston Pin and its Hole 0.002-0.014 0.06
Clearance between Piston Ring and Cylinder Wall 0.015-0.045 0.15
Air Ring Width 1.5 1.37
Oil Ring Width 2.5 2.37
Air Ring Ends Gap 0.2-0.4 1.0
Oil Ring Ends Gap 0.15-0.35 1.1
Internal Diameter, Tie Rod Big End 30.02 30.066
Internal Diameter, Tie Rod Small End 18.002 18.07
Big Head Gap, Tie Rod 0.04-0.063 0.12
Big Head Side Gap, Tie Rod 0.1-0.7 1.1
Diameter Gap, Intake Valve Tappet 0.15 ± 0.02
Diameter Gap, Exhaust Valve Tappet 0.20 ± 0.02
Diameter, Intake Valve Stem 5.48 5.318
Diameter, Exhaust Valve Stem 5.44 5.275
Internal Diameter, Intake Valve Pipe 5.5 5.572
Gap between Intake Valve and Guide Pipe hole 0.02-0.044 0.10
Gap between Exhaust Valve and Guide Pipe hole 0.06-0.087 0.12
Spark Plug Gap 0.030” n/a
Note: These manufacturer specication tables are provided for reference only. All en-
gine repairs must be undertaken by a qualied service technician only.
Valve Timing Settings
Intake Open ATDC 10°
Intake Closed ABTC 20°
Exhaust Open BBTC 30°
Exhaust Closed BTDC 10°
Important Bolt Torques
Cylinder Head Bolts 24
Crankcase Cover Bolts 24
Tie Rod Bolts 12
Fly Wheel Bolts 78 - 80

Page 15For technical questions, please call 1-800-444-3353.SKU 65414
SERVICING
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
STARTING:
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool, and disconnect the
spark plug wire(s) 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.
Maintenance Procedures
Many maintenance procedures,
including those not detailed
in this manual, will need to
be performed by a qualied
technician for safety. If you
have any doubts about your
ability to safely service the
equipment or engine, have a
qualied technician service the
equipment instead.
Note: Warranty is void if proper mainte-
nance and servicing procedures are
not followed.
Engine Oil Change
CAUTION! Oil is very hot during opera-
tion and can cause burns. Wait for
engine to cool before changing oil.
Place a drain pan (not included) un-1.
derneath the crankcase’s drain plug.
Remove the drain plug and, if pos-2.
sible, tilt the crankcase slightly to help
drain the oil out. Recycle used oil.
Replace the drain plug (and gasket, if3.
supplied) and tighten it.
Rell the oil to the proper level follow-4.
ing the instructions under the Starting
the Engine section.
Air Filter Element Maintenance
Wipe off the air cleaner cover.1.
The air cleaner cover is held in place2.
by a wing nut or clamps. Remove it.
Remove the air lter element.3.
Cleaning:4.
For “paper” lter elements:a.
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 lter from the side oppo-
site the lter’s normal air ow (the
“clean” side of the lter).
If this does not get the lter reason-
ably clean, replace it.
For foam lter elements:b.
Wash the element in warm water
and mild detergent several times.
Rinse. Squeeze out excess water
and allow it to dry completely. Soak
the lter in lightweight oil briey, then
squeeze out the excess oil.

Page 16For technical questions, please call 1-800-444-3353.SKU 65414
Install the new lter or the cleaned 5.
lter. Secure the Air Cleaner Cover
before use.
Spark Plug Maintenance
Disconnect spark plug wire from1.
end of plug. Clean out debris from
around spark plug.
Using a spark plug wrench, remove2.
the spark plug.
Inspect the spark plug:3.
If the electrode is oily, clean it using a
clean, dry rag.
If the electrode has deposits on it,
polish it using emery paper.
If the white insulator is cracked or
chipped, the spark plug needs to be
replaced.
When installing a new spark plug, ad-4.
just the plug’s gap to the specication
on the Technical specication chart.
Do not pry against the electrode or
the insulator, the spark plug can be
damaged.
Install the new spark plug or the5.
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.
Apply dielectric spark plug boot6.
protector (not included) to the end of
the spark plug and reattach the wire
securely.
Cleaning, Maintenance, and
Lubrication Schedule
Note: This maintenance schedule is
intended solely as a general guide.
If performance decreases or if equip-
ment operates unusually, check sys-
tems 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: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular op-
eration of the engine and equipment.
After Initial 20 Operation Hour Period:
Change engine oil.a.
Every 25 Operation Hours Thereafter:
Clean/replace air lter element.a.
Inspect/clean spark plug.b.
Every 50 Operation Hours:
Change engine oil.a.
Replace fuel lter (if equipped).b.
Check spark plug. Clean and re-gapc.
as needed.
Every 100 Operation Hours:
Replace spark plug.a.
Replace air lter element.b.
Clean fuel tank and fuel strainer.c.
Note: All maintenance procedures sched-
uled for 25, 50, and 100 operation
hours should be performed at least
yearly.
Every 300 Operation Hours:
Clean fuel tank and carburetor.a.

Page 17For technical questions, please call 1-800-444-3353.SKU 65414
Clean carbon build-up from combus-b.
tion chamber.
Check oil tube condition and replacec.
as needed.
Storage
Wait for engine to cool, then clean1.
engine with clean cloth.
When the equipment is to remain idle2.
for longer than 20 days, prepare the
engine for storage as follows:
Change engine oil and empty fuela.
tank.
Either leave fuel tank empty orb.
rell fuel tank with fresh unleaded
gasoline mixed with a fuel stabilizer
intended for long term engine stor-
age (not included). After lling, run
engine for about 5-10 minutes to cir-
culate the treated gasoline through
the carburetor. Wait for engine to
cool before proceeding.
Clean out area around spark plug.c.
Remove spark plug and pour one
tablespoon of engine oil into cylinder
through spark plug hole.
Reinstall spark plug, but leave sparkd.
plug wire disconnected.
Pull recoil starter to distribute oil ine.
cylinder. Stop after one or two revo-
lutions when you feel the piston start
the compression stroke (when you
start to feel resistance).
Disconnect battery cables (iff.
equipped).
Apply a thin coat of rust preventive oil3.
to all uncoated metal parts.
Cover and store in a dry, well-ventilat-4.
ed area out of reach of children.
Before starting the engine after stor-5.
age, keep in mind that untreated gas-
oline will deteriorate quickly. Drain
the fuel tank and lter, and change
to fresh fuel if untreated gasoline has
been sitting for a month, if treated
gasoline has been sitting beyond the
fuel stabilizer’s recommended time
period, or if the engine does not start
properly.

Page 18For technical questions, please call 1-800-444-3353.SKU 65414
Engine Troubleshooting
Problem: Low power output. Engine bogs down or stops under load. Excess exhaust or
unburned fuel in exhaust. See chart below:
Engine System Possible Cause Possible Solution
Ignition System Incorrect Ignition Timing Adjust Engine Advance Angle
Fuel Supply System Air in fuel line or fuel line clogged.1.
Main Jet not adjusted properly.2.
Metering Jet or Main Jet clogged3.
Fuel Cock clogged4.
Carbon Fouling in Combustion5.
Chamber
Clogged Air Filter6.
Intake Manifold leaking.7.
Remove air or clear obstruction.1.
Readjust Main Jet.2.
Clean and Readjust.3.
Clean or replace as needed.4.
Clean out Combustion Chamber5.
and Manifolds.
Clean or replace Air Filter.6.
Repair or replace as needed.7.
Poor Compression Worn Piston, Piston Ring or1.
Cylinder Wall.
Leaking Cylinder Head Gasket.2.
Worn Valves, Valve Seats, Stems3.
or Valve Guides.
Check compression and wear1.
tolerances, repair or replace as
needed.
Check compression, replace as2.
needed.
Check wear tolerances, repair or3.
replace as needed.
Problem: Engine does not start or does not run smoothly. See chart below:
Symptom Possible Cause Possible Solution
Engine is Pinging Excess wear of Piston, Cylinder1.
Wall or Rings.
Excess wear of Piston Pin or2.
Piston Pin Hole
Excess wear of Tie Rod small3.
end
Excess wear of Crankshaft Roller4.
Bearing.
Check wear, replace as needed.1.
Check wear, replace as needed.2.
Check wear, replace as needed.3.
Check wear, replace as needed.4.
Abnormal Com-
bustion or engine
running hot or
excess smoking.
Combustion chamber carbon1.
fouling.
Dirty or old gasoline or oil in gas.2.
Clean out Combustion chamber and1.
spark plug.
Drain gas, clean out fuel lter and 2.
replace with fresh gas, minimum
octane 87.
Engine does not
start.
Engine Switch in OFF position.1.
Water in Carburetor Bowl.2.
Spark Plug gap damaged or not3.
set properly.
Incorrect Ignition Timing.4.
Damaged coil or ignition wires.5.
Low Oil level.6.
Move Switch to ON position.1.
Drain carburetor Bowl, clean Fuel2.
Filter.
Clean and re-gap plug at 0.030”. 3.
Replace plug if needed.
Check timing and adjust.4.
Check for damaged wires, test output.5.
Check oil level, top off as needed.6.

Page 19For technical questions, please call 1-800-444-3353.SKU 65414
Problem: Engine stops suddenly while running. See chart below:
Engine System Possible Cause Possible Solution
Fuel Supply
System
Fuel is used up.1.
Fuel Filter is clogged.2.
Carburetor Float is leaking3.
Needle Valve sticks.4.
Check fuel level and rell as needed.1.
Clean Fuel Filter.2.
Replace if needed.3.
Clean and readjust.4.
Ignition System Engine Switch is in OFF position.1.
Spark Plug tip is burned through2.
or carbon fouled.
Spark Plug Wire is disconnected.3.
Ignition Coil is shorted or4.
damaged.
Spark Plug wire is shorting against5.
engine body or frame.
Move Switch to ON position.1.
Clean or replace spark plug. Reset2.
gap to 0.030”.
Check connections at both ends.3.
Check coil continuity and output.4.
Check condition of spark plug wire,5.
replace as needed.
Mechanical
problem
Engine Piston, Piston Rod, Valve1.
or Crankshaft may be damaged.
Generator Shaft may be seized.2.
Remove spark plug and attempt to1.
rotate engine by hand. Repair or
replace as needed.
Disconnect engine and attempt to2.
rotate generator shaft by hand. Repair
or replace as needed.
Problem: Engine runs excessively hot. See chart below:
Problem Possible Cause Possible Solution
Engine runs
excessively
hot
Improper Ignition Timing.1.
Running out of fuel.2.
Exhaust manifold, mufer or exhaust 3.
pipe damaged or clogged.
Intake Manifold leaking.4.
Dirty or clogged Cylinder Cooling Fins.5.
Cooling Fan loose or damaged.6.
Bent Piston Rod7.
Worn Piston, Piston Ring or Cylinder8.
Wall.
Improper engine speed.9.
Worn Crankshaft Main Bearing.10.
Check and reset Ignition Timing.1.
Check fuel level. Let engine cool2.
down, then ll as necessary.
Check condition of exhaust system,3.
repair as needed.
Check condition of intake manifold4.
and gasket. Repair as needed.
Clean Cylinder Wall Cooling Fins.5.
Check condition of cooling fan.6.
Repair or replace as needed.
Replace Piston Rod.7.
Check clearances, replace as8.
needed.
Engine speed is self-regulating. Be9.
sure choke if fully open. Reduce
electrical load on generator.
Check for wear. Replace as needed.10.

Page 20For technical questions, please call 1-800-444-3353.SKU 65414
Equipment Troubleshooting
Problem Possible Causes Probable Solutions
Engine Will Not Start No fuel in tank1.
Engine Switch in OFF position2.
Fuel Valve turned OFF3.
Engine Oil level low.4.
No spark at spark plug5.
No fuel reaching carburetor6.
Rell the fuel tank1.
Move the Switch to the ON position2.
Turn the fuel valve ON3.
Top off oil level4.
Clean and re-gap spark plug.5.
Replace if necessary.
Clean fuel lter cup. Check fuel line 6.
for leaks or obstructions.
Engine misses, is
hard to start or runs
poorly
Fuel lter dirty1.
Air cleaner dirty2.
Spark plug dirty or wrong gap3.
Check and clean the fuel lter.1.
Check and clean the air lter.2.
Check, clean and re-gap spark3.
plug.
Power Light does not
come on
Engine is running poorly1.
Ground wire is not connected2.
Generator is not functioning3.
Improve engine performance.1.
Connect ground wire.2.
Take generator to qualied service 3.
technician.
No or not enough
power at the AC
outlets.
AC Breaker switch in the OFF1.
position.
AC circuits overloaded.2.
Reset the Breaker Switch to the ON1.
position.
Disconnect some appliances to2.
reduce the load.
No power at the 12
VDC outlet.
DC Breaker Switch open. Disconnect the 12 Volt appliance, then
press the 12 VDC breaker switch IN.
Reconnect the 12 V accessory.
Follow all safety precautions whenever diagnosing or servicing the
equipment or engine.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT
HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE
UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL
PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO.
REV 09g