Chicago Electric 65414 User guide

3000 RATED WATTS/3500 MAX. WATTS
PORTABLE GENERATOR
CERTIFIED FOR ALL STATES EXCEPT CALIFORNIA
Model 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.
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©2009 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.
Manual Revised 09j

Page 2 For technical questions, please call 1-800-444-3353. SKU 65414
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
EXTENSION CORDS .........................7
BASIC SPECIFICATIONS ............. 8
FUNCTIONS .......................................8
UNPACKING .................................. 8
CONTROLS ................................... 9
OPERATING INSTRUCTIONS .... 10
STARTING THE ENGINE .................10
CHECKING AND FILLING
ENGINE OIL .............................10
CHECKING AND FILLING FUEL 11
START PROCEDURE ................. 11
BREAK-IN PERIOD ....................12
EQUIPMENT OPERATION...............12
CONTROL PANEL FEATURES .......13
TECHNICAL SPECIFICATIONS.. 14
SERVICING.................................. 14
MAINTENANCE PROCEDURES .....14
ENGINE OIL CHANGE ............... 14
AIR FILTER ELEMENT
MAINTENANCE .......................14
SPARK PLUG MAINTENANCE..15
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 ........................................16
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 AND MUFFLER
ASSEMBLY....................................27
PARTS LIST AND DIAGRAM F -
FUEL SUPPLY SYSTEM ...............27
PARTS LIST AND DIAGRAM G -
STARTER AND GENERATOR
ASSEMBLY....................................28
WIRING DIAGRAM...........................29
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 30
EMISSION CONTROL SYSTEM
WARRANTY .............................. 30

Page 3For technical questions, please call 1-800-444-3353.SKU 65414
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.
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 are1.
ammable, and potentially explosive.
Use proper fuel storage and handling
procedures. Do not store fuel or
other ammable materials nearby.
Have multiple ABC class re 2.
extinguishers nearby.
Operation of this equipment may3.
create sparks that can start res
around dry vegetation.

Page 4 For technical questions, please call 1-800-444-3353. SKU 65414
A spark arrestor may be required.
The operator should contact
local re agencies for laws or
regulations relating to re prevention
requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.
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 equipment,2.
especially while it is operating.
Do not leave the equipment unattended3.
when it is running. Turn off the
equipment (and remove safety keys, if
available) before leaving the work area.
Wear ANSI-approved safety goggles and4.
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 necessary when near
the engine’s magneto or recoil starter.
Use only accessories that are6.
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.
Do not operate in explosive7.
atmospheres, 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 operating
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 footing9.
and balance at all times. This enables
better control of the equipment in
unexpected situations.
Dress properly. Do not wear loose10.
clothing or jewelry. Keep hair, clothing
and gloves away from moving parts.
Loose clothes, jewelry or long hair can
be caught in moving parts.

Page 5For technical questions, please call 1-800-444-3353.SKU 65414
Parts, especially exhaust system11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment12.
during operation.
Keep the equipment, engine, and13.
surrounding area clean at all times.
Use the equipment, accessories, etc., in14.
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.
Do not operate the equipment with15.
known leaks in the engine’s fuel system.
This product contains or, when used,16.
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.)
When spills of fuel or oil occur, they must17.
be cleaned up immediately. Dispose
of uids and cleaning materials 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 from moving18.
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 accidents
are caused by poorly maintained
equipment.
Use the correct equipment for the20.
application. Do not modify the
equipment and do not use the equipment
for a purpose for which it is not intended.
CAUTION:21. 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 should be operated
on approved inverter type generators or
pure sine wave generators.
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 efciently powered
by a portable generator.
Note: When using a generator to
provide home standby electricity, a
transfer switch (sold separately) is
needed to prevent back feeding power
into the utility line.
Connections for standby power to a
building electrical system must be made
by a qualied electrician. The connection
must isolate the generator power from
utility power, and must comply with all
applicable laws and electrical codes.
WARNING: 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
res when utility power is restored.
Consult the utility company or a qualied
electrician.
*Sensitive electronic equipment
includes, but is not limited to, audio/
video equipment, some television
sets, computers, and printers.

Page 6 For technical questions, please call 1-800-444-3353. SKU 65414
Before connecting an appliance or1.
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.
If an appliance begins to operate2.
abnormally, becomes sluggish or
stops suddenly, turn it off immediately.
Disconnect the appliance, and determine
whether the problem is the appliance, or
if the rated load capacity of the generator
has been exceeded.
Make sure that the electrical rating of3.
the tool or appliance does not exceed
that of the generator. Never exceed the
maximum power rating of the generator.
Power levels between rated and
maximum may be used for no more than
30 minutes.
Substantial overloading will open the4.
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.
SERVICE PRECAUTIONS
Before service, maintenance, or1.
cleaning:
Turn the engine switch to its “OFF”a.
position.
Allow the engine to completely cool.b.
Then, remove the spark plug wire(s)c.
from the spark plug(s).
Keep all safety guards in place and in2.
proper working order. Safety guards
include mufer, air cleaner, mechanical
guards, and heat shields, among other
guards.
Do not alter or adjust any part of the3.
equipment or its engine that is sealed
by the manufacturer or distributor.
Only a qualied service technician
may adjust parts that may increase or
decrease governed 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 important
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 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.
Store equipment out of the reach of7.
children.
Follow scheduled engine and equipment8.
maintenance.
Refueling Precautions:9.
Do not smoke, or allow sparks, ames, a.
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.
AC APPLICATIONS

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 supply2.
outlet increases, you must use a
heavier gauge extension cord. Using
extension cords with inadequately
sized wire causes a serious drop in
voltage, resulting in loss of power and
possible 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 extension4.
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 is7.
properly wired and in good electrical
condition. 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 8 For technical questions, please call 1-800-444-3353. SKU 65414
BASIC SPECIFICATIONS
Fuel Type 91+ octane premium
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
Ignition Recoil Start with Electronic
Ignition
Electrical Plugs
One 20A duplex NEMA
120V~receptacle
One 25A NEMA 120V 3 prong
twist lock receptacle
One T-Type 12V outlet
Note: Additional specications found
in the TECHNICAL ENGINE
SPECIFICATIONS chart in this
manual.
The emission control system for
this Generator’s Engine is warranted for
standards set by the U.S. Environmental
Protection Agency. For warranty
information, refer to the last pages of this
manual.
At high altitudes, the engine’s
carburetor, governor (if so equipped), and
any other parts that control the fuel-air
ratio will need to be adjusted by a qualied
mechanic to allow efcient high-altitude
use and to prevent damage to the engine
and any other devices used with this
product.
Functions
This unit can power items such as the
following:
ITEM RUNNING
WATTS
START-UP
WATTS
Belt Sander 1200 2400
Refrigerator/Freezer 700 2200
1/2 HP Sump Pump 1050 2150
1/2 HP Well Pump 1000 2100
Miter Saw 1650 3000
1-1/2 HP Capacitor Start
& Run Motor
1400 3100
Note: The above wattages are estimates.
Check nameplate wattages on all
loads before connecting to generator.
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 1-800-444-
3353 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
damage. They must be removed before
use. See the photo above.

Page 9For technical questions, please call 1-800-444-3353.SKU 65414
CONTROLS
Note: Be sure to use the proper plug for the amps needed.
Plug for up
to 20A
Figure 1
Plug for up
to 15A
120V Duplex
Receptacle
for 15A or 20A
plugs
Engine Power Switch
Power Indicator Light AC Circuit
Breaker Switch
120 V~ Duplex
Receptacle
120 V~
Twist Lock Receptacle
AC Reset
Switch
DC Circuit
Breaker Switch
Ground Wire
Connection
12 VDC Outlet
MAIN BREAKER
20A
RESET
120V AC OUTLETS ONLY

Page 10 For technical questions, please call 1-800-444-3353. SKU 65414
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.
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.
Before starting, rst familiarize
yourself with proper shut down
and emergency shut down
procedures.
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.
Wipe dipstick exterior with a clean1.
cloth. Remove the dipstick and wipe
it off with a clean rag. Pour engine oil
into the oil ll hole until the level of oil
is even with the bottom edge of the
oil ll hole (if you cannot see the oil
through the oil ll hole, then the oil is
too low and more oil must be added).
Reinsert the dipstick into the oil2.
ller neck, but do not screw in, then
remove 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.
THIS GENERATOR HAS AN AUTO-SHUTDOWN
OIL SENSOR. IF ENGINE STOPS OR WILL
NOT START, CHECK OIL LEVEL.
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
shut down 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

Page 11For technical questions, please call 1-800-444-3353.SKU 65414
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
Check the fuel level. If the fuel level1.
is more than 1” below the ll neck of
the fuel tank, add more fuel.
Note: Do not overll the fuel tank.
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-
ventilated area away from ignition
sources. Do not smoke.
To ll the Fuel Tank, rst wipe off the 2.
Fuel Tank Cap and the surrounding
area.
Unscrew, and remove the Fuel Tank3.
Cap.
Mix fuel stabilizer (not included)4.
with 91 octane (or better) premium
unleaded gasoline according to fuel
stabilizer directions.
Note: Use only premium octane unleaded
gasoline.
Fill the Fuel Tank to about 1 inch5.
under 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 theb.
proper amount and type of
fuel and oil.
Read the Equipmentc.
Operation section that
follows.
Unplug loads from the Generator and1.
make sure the AC Circuit Breaker
Switch is in the OFF position before
starting to prevent permanent
generator 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. Then, pull the starter
handle with a rapid, full arm stroke.
Once again while holding the handle,
allow the rope to rewind. 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 run at
no load until warm (1-5 minutes) to
stabilize.
Move the AC Circuit Breaker Switch7.
to its ON or RUN position.

Page 12 For technical questions, please call 1-800-444-3353. SKU 65414
Break-in Period
Breaking-in the engine will help1.
to ensure proper equipment and
engine operation, and will extend
the engine’s lifespan. The warranty
is void if the engine is not broken
in properly. The 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.
After the rst 20 hours of use:3.
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows
the schedule explained in the
MAINTENANCE AND SERVICING
section.
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 gauge or larger
insulated copper wire to the Ground
Connection on the Control Panel.
Connect 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
generator 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 gur-
ing total wattage of all appliances
connected to this generator, use the
higher start-up amperage rating of
each appliance.
Do not exceed the current limit3.
specied for any one receptacle.
Move the AC Circuit Breaker switch4.
to the ON position.
Plug in your extension cord or5.
appliance.
Be sure that all appliances are in6.
good working order before connecting
them to the generator. If an appliance
begins to operate abnormally,
becomes sluggish, or stops suddenly,
turn off the AC Circuit Breaker and
the generator Engine Power Switch
immediately. Then disconnect the
appliance and examine it for signs of
malfunction.

Page 13For technical questions, please call 1-800-444-3353.SKU 65414
Note: If an overloaded circuit causes the
AC Circuit Breaker to switch off,
reduce the electrical load on the
circuit and wait a few minutes before
resetting the circuit breaker.
The DC terminal may be used7.
to operate 12 Volt DC portable
appliances only.
CAUTION! Do not use this
generator 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
overloaded DC circuit will trip the DC
circuit protector (push button comes
out). If this happens, wait a few
minutes 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 children’s reach according to the
Storage instructions in this manual.
Control Panel Features
Engine Power Switch must be in ON1.
position for engine to start and run.
Move to OFF position to stop engine.
Power Indicator Light, when lit,2.
shows that the generator is producing
electrical energy.
AC Circuit Breaker Switch protects3.
circuits when using AC power.
120 V~ duplex outlet provides two4.
grounded outlets for standard 110-
120 V~ household appliances.
The outlets are congured for both
standard 15A plugs or 20A plugs -
See Figure 1 “Controls”.
120 V~ twist lock receptacle provides5.
a grounded outlet for one 120 Volt
appliance, such as a water heater.
12 VDC outlet provides a power6.
source for 12 volt DC items, such
as automotive accessories. 12 VDC
Circuit Breaker Switch provides circuit
protection for 12 VDC accessories.

Page 14 For technical questions, please call 1-800-444-3353. SKU 65414
TECHNICAL
SPECIFICATIONS
Engine Type 4 Stroke, OHV
Bore x Stroke 68 x 54mm
Compression Ratio 8.5:1
Displacement 196cc
Fuel Type 91+ octane premium
unleaded gasoline
Capacity 4 Gallons
Engine Oil Type
SAE10W-30 above 32° F
SAE 5W-30 at 32° F or
below
Capacity 2/3 Quarts
Spark
Plug
Compatible
Types
NGK BP61S
Bosch W6DC
Champion N11YC
Gap 0.030”
Valve
Clearance
Intake 0.1mm
Exhaust 0.15mm
Speed 3600 RPM
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
maintenance and servicing
procedures are not followed.
Engine Oil Change
CAUTION! Oil is very hot during
operation and can cause burns. Wait
for engine to cool before changing oil.
Place a drain pan (not included)1.
underneath the crankcase’s drain
plug.
Remove the Drain Plug (1a) and, if2.
possible, tilt the crankcase slightly to
help drain the oil out. Recycle used
oil.
If the Drain Plug Washer (2a) is3.
damaged, replace with a new
Washer.
Re-install the Drain Plug and tighten4.
it in place.
Rell the oil to the proper level 5.
following the instructions under the
Starting the Engine section.
Air Filter Element Maintenance
Wipe off the air cleaner cover.1.

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The air cleaner cover is held in place2.
by clamps. Remove the clamps and
the cover.
Remove the air lter element.3.
Cleaning:4.
There are two foam lter elements. a.
Wash them in warm water and mild
liquid soap several times. Rinse.
Squeeze out excess water and allow
it to dry completely.
Soak the lter in lightweight oil b.
briey, then squeeze out the excess
oil.
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 spark4.
plug, adjust 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.

Page 16 For technical questions, please call 1-800-444-3353. SKU 65414
Cleaning, Maintenance, and
Lubrication Schedule
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: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular
operation 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
scheduled for 25, 50, and 100
operation hours should be performed
at least yearly.
Every 300 Operation Hours:
Clean fuel tank and carburetor.a.
Clean carbon build-up fromb.
combustion 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
storage (not included). After lling,
run engine for about 5-10 minutes
to circulate 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 oile.
in cylinder. Stop after one or two
revolutions 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.

Page 17For technical questions, please call 1-800-444-3353.SKU 65414
Cover and store in a dry, well-4.
ventilated area out of reach of
children.
Before starting the engine after5.
storage, keep in mind that untreated
gasoline will deteriorate quickly.
Place a container below the carbure-a.
tor bowl and drain the fuel from the
fuel tank and carburetor bowl.
Discard the drained fuel properly asb.
per local ordinance.
Change to fresh fuel if untreatedc.
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 18 For 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 clogged.3.
Fuel Cock clogged.4.
Carbon Fouling in Combustion5.
Chamber.
Clogged Air Filter.6.
Intake Manifold leaking.7.
Purge air or clear obstruction.1.
Readjust Main Jet.2.
Clean and Readjust.3.
Clean as needed.4.
Clean out Combustion Chamber.5.
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, Cylinder Wall or Rings.•
Piston Pin or Piston Pin Hole.•
Connecting Rod Wrist Pin.•
Crankshaft Roller Bearing.•
Check wear, replace as needed.
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 91
octane premium unleaded gasoline.
Engine does not
start.
Engine Switch in OFF position.1.
Water in Carburetor Bowl.2.
Spark Plug gap not correct.3.
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
Engine not run-
ning Smoothly
Poor Fuel quality.1.
Incorrect choke setting.2.
Incorrect Timing.3.
Replace fuel with 91+ octane premium1.
unleaded gasoline.
Adjust the choke.2.
Have the timing checked by a qualied 3.
technician.
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 leaking.3.
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.
Spark Plug wire is shorting against4.
engine body or frame.
Ignition Coil is shorted or5.
damaged.
Move Switch to ON position.1.
Clean or replace spark plug. Reset2.
gap to 0.030”.
Check connections at both ends.3.
Check condition of spark plug wire,4.
replace as needed.
Check coil continuity and output.5.
Mechanical
problem
Engine Piston, Piston Rod, Valve1.
or Crankshaft may be damaged.
Generator Shaft may be seized.2.
Have serviced by a qualied 1.
technician.
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.
Exhaust manifold, mufer or exhaust 2.
pipe damaged or clogged.
Intake Manifold leaking.3.
Dirty or clogged Cylinder Cooling Fins.4.
Cooling Fan loose or damaged.5.
Bent Piston Rod6.
Worn Piston, Piston Ring or Cylinder7.
Wall.
Improper engine speed.8.
Worn Crankshaft Main Bearing.9.
Check and reset Ignition Timing.1.
Check condition of exhaust system,2.
repair as needed.
Check condition of intake manifold3.
and gasket. Repair as needed.
Clean Cylinder Wall Cooling Fins.4.
Check condition of cooling fan.5.
Repair or replace as needed.
Replace Piston Rod.6.
Check clearances, replace as7.
needed.
Engine speed is self-regulating. Be8.
sure choke if fully open. Reduce
electrical load on generator.
Check for wear. Replace as needed.9.

Page 20 For technical questions, please call 1-800-444-3353. SKU 65414
Equipment Troubleshooting
Problem Possible Causes Probable Solutions
Engine Will Not
Start
No fuel in tank.1.
Engine Switch in OFF position.2.
Fuel Valve turned OFF.3.
Engine Oil level low.4.
No spark at spark plug.5.
No fuel reaching carburetor.6.
Rell the fuel tank.1.
Move the Switch to the ON2.
position.
Turn the fuel valve ON.3.
Top off oil level.4.
Check that the spark plug wire is5.
not loose or disconnected. Clean
and re-gap spark plug. 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 dirty.1.
Air cleaner dirty.2.
Spark plug dirty or wrong gap.3.
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 poorly.1.
Ground wire is not connected.2.
Generator is not functioning.3.
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. Consult a qualied service technician for any
repairs beyond your training or ability.
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.