Pacific hydrostar 95977 User manual

2” PORTABLE
CLEAR WATER PUMP
With 6.5 HP Gas Engine
Model 95977
ASSEMBLY AND OPERATION INSTRUCTIONS
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©2007 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. 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 10c
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.

Page 2For technical questions, please call 1-800-444-3353.SKU 95977
REV 08k, 08l
SPECIFICATIONS
Suction Port Diameter 2” NPT
Discharge Port
Diameter 2” NPT
Maximum Suction
Head 25 ft.
Total Head 82 ft.
Maximum Discharge
Flow 145 GPM
Pump Type Centrifugal / Self-Priming*
Engine Specications
6.5 HP, OHV / Recoil Start
Air Cooled / 4-Stroke
Displacement: 196cc
Rotation: Counterclockwise
(from shaft side)
Unleaded Fuel: Min. 87 Octane
Fuel Tank Capacity: 1.0 Gal.
Estimated Run Time: 3.0 Hours
Low Oil Shut Off
Oil Capacity: 27 Oz.
Included
Accessories
Plastic Basket Filter
Hose Coupling
Hose Adapters / Barbed Fittings /
Gasket / Wire Clamps
* The Water Pump is self-priming. However, for initial use
the Pump Housing must be lled with water (see page 9).
IMPORTANT! THIS PUMP IS FOR CLEAR WATER
USE ONLY. Clear water is water that contains
little to no solids.
IMPORTANT! This product requires oil and fuel
to be added before starting. Attempting to
start the Engine without oil WILL ruin the
Engine and void the warranty.
NOTE: The Engine’s carburetor may need to be
adjusted by a qualied mechanic for efcient
high-altitude use.
The Emission Control System for
this Water Pump’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 two
pages of this manual.
SAVE THIS MANUAL
You will need this manual for safety
warnings and precautions, assembly,
operating, inspection, maintenance and
cleaning procedures, parts list and assembly
diagram. Keep invoice with manual. Write
invoice number on inside of front cover. Write
product’s serial number in back of manual
near assembly diagram, or write month and
year of purchase if product has no number.
Keep manual and invoice in a safe and dry
place for future reference.
Pump Applications
Clear Water ** •
Slimy Water •
Muck Water •
Silt Water •
High Solid Content N/A
Slow Seepage N/A
Fast Seepage •
Manholes •
Cofferdams •
Quarries •
Septic Tanks N/A
Deep Piling N/A
Industrial/ Agricultural Chemicals N/A
This Water Pump can be used to supply water to:
Mixer or Paver •
Concrete Curing •
Water Wagons ** •
Sprinklers or Nozzle N/A
** Non Potable Only
N/A = Not Applicable
Available Accessories (not included)
Item 65989 20 Ft. Suction Hose
Item 95390
or 95392 25 Ft. Discharge Hose

Page 3For technical questions, please call 1-800-444-3353.SKU 95977
GENERAL SAFETY RULES
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
WORK AREA
Keep your work area clean and well1.
lit. Cluttered and dark areas invite
accidents.
Do not operate power tools in2.
explosive atmospheres, such as in the
presence of ammable liquids, gases,
or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep bystanders, children, and3.
visitors away while operating a power
tool. Distractions can cause you to lose
control. Protect others in the work area
from debris such as chips and sparks.
Provide barriers or shields as needed.
Children should never be allowed in the
work area.
PERSONAL SAFETY
Stay alert. Watch what you are1.
doing, and use common sense when
operating a power tool. Do not use
a power tool while tired or under
the inuence of drugs, alcohol, or
medication. A moment of inattention
while operating power tools may result in
serious personal injury.
Dress properly. Do not wear loose2.
clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves
away from moving parts. Loose
clothes, jewelry, or long hair can be
caught in moving parts.
Remove adjusting keys or wrenches3.
before turning the power tool on. A
wrench or a key that is left attached to a
rotating part of the power tool may result
in personal injury.
Do not overreach. Keep proper4.
footing and balance at all times.
Proper footing and balance enables
better control of the power tool in
unexpected situations.
5. Use safety equipment.
Wear ANSI-approved eye
protection. Dust mask,
nonskid safety shoes, hard
hat, or hearing protection must be used
for appropriate conditions. Always wear
ANSI-approved safety goggles when
using or performing maintenance on this
tool.
TOOL USE AND CARE
Do not force the tool. Use the correct1.
tool for your application. The correct
tool will do the job better and safer at
the rate for which it is designed. Do not
force the tool and do not use the tool for
a purpose for which it is not intended.
Do not use the power tool if the2.
Engine’s Power Switch (109) does not
turn it on or off. Any tool that cannot
be controlled with the Power Switch is
dangerous and must be replaced.
Disconnect the Spark Plug Wire3.
from the Engine before making any
adjustments, changing accessories,
or storing the tool. Such preventive

Page 4For technical questions, please call 1-800-444-3353.SKU 95977
safety measures reduce the risk of
starting the tool accidentally. Always
disconnect the Spark Plug Wire
before performing any inspection,
maintenance, or cleaning procedures.
Store idle tools out of reach of4.
children and other untrained persons.
Tools are dangerous in the hands of
untrained users.
Maintain tools with care. Keep5.
the Water Pump clean. Properly
maintained tools are less likely to
malfunction and are easier to control. Do
not use a damaged tool. Tag damaged
tools “Do not use” until repaired.
Check for misalignment or binding of6.
moving parts, breakage of parts, and
any other condition that may affect
the tool’s operation. If damaged,
have the tool serviced before using.
Many accidents are caused by poorly
maintained tools.
Use only accessories that are7.
recommended by the manufacturer
for your model. Accessories that may
be suitable for one tool may become
hazardous when used on another tool.
SERVICE
Tool service must be performed only1.
by qualied repair personnel. Service
or maintenance performed by unqualied
personnel could result in a risk of injury.
When servicing a tool, use only2.
identical replacement parts. Follow
instructions in the “Inspection,
Maintenance, And Cleaning” section
of this manual. Use of unauthorized
parts or failure to follow maintenance
instructions may create a risk of injury.
SPECIFIC SAFETY RULES
IMPORTANT! Your Warranty is voided1.
if you do not put engine oil in the
Engine’s crankcase prior to its rst
use. Before each use, check the oil
level. Never run the Engine with low or
no engine oil. Running the Engine with
low or no Engine oil will permanently
damage the Engine.
Maintain labels and nameplates on2.
the Water Pump. These carry important
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
Maintain a safe working environment.3.
Make sure there is adequate surrounding
workspace.
Avoid unintentional starting.4. Make
sure you are prepared to begin work
before turning on the Water Pump.
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.
Never leave the Water Pump6.
unattended when it is running. Turn
off the Engine of the Water Pump before
leaving the work area.
Always use the Water Pump on a at, 7.
level surface.
Make sure to keep hands, ngers, and 8.
feet away from all moving parts of the
Water Pump.
Keep all safety guards of the Water9.
Pump in place and in proper working
order.

Page 5For technical questions, please call 1-800-444-3353.SKU 95977
Keep a safe clearance around the10.
Water Pump. Keep all people (except
the operator) a minimum of six feet from
the Pump during operation.
This product is designed to pump11.
only clear water. Never attempt to
pump combustible or corrosive liquids
with this Water Pump. “Clear water” is
water that contains little to no solids.
TOXIC FUMES, FIRE, AND
EXPLOSION PRECAUTIONS
This Water Pump is designed for1.
outdoor use only. Do not operate the
Pump in a closed area or in a poorly
ventilated area. When running, the
Engine of this unit produces carbon
monoxide, a colorless, odorless,
toxic fume that, when inhaled, can
cause serious personal injury or
death. Whenever possible, use a
carbon monoxide detector (not included)
to detect excessive carbon monoxide
fumes in the work area and in the
surrounding area.
Gasoline fuel and fumes are2.
ammable, and potentially explosive.
Use proper fuel storage and handling
procedures. Always have multiple ABC
class re extinguishers nearby.
Keep the Water Pump, its Engine, and3.
surrounding areas clean at all times.
When spills of fuel or oil occur, they4.
must 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
covered metal container.
Never store fuel or other ammable 5.
materials near the Water Pump.
Do not smoke, or allow sparks,6.
ames, or other sources of ignition
around the Water Pump.
Keep grounded conductive objects,7.
such as tools, away from exposed,
live electrical parts and connections
to avoid sparking or arcing. These
events could ignite fumes or vapors.
Do not rell the Fuel Tank while the 8.
Engine is running or hot.
Do not operate the Water Pump with9.
known leaks in the Engine’s fuel
system.
Use only recommended oil and fuel.10.
Do not use gasoline containing more11.
than 10% ethanol (E10). Do not use
E85 ethanol.
MECHANICAL PRECAUTIONS
Prior to performing service,1.
maintenance, or cleaning procedures,
always make sure the Engine’s
Ignition Switch is in its “OFF”
position. Allow the Engine to
completely cool. Then, remove the
Spark Plug Wire from the Spark Plug.
Do not alter or adjust any part of2.
the Water Pump or its Engine that
is assembled and supplied by the
manufacturer or distributor.
Always follow and complete3.
scheduled Engine maintenance.
CHEMICAL PRECAUTIONS
Avoid contact with hot fuel, oil,1.
exhaust fumes, and solid surfaces.
Avoid body contact with fuels, oils,2.
and lubricants used in the Engine.
If swallowed, seek immediate medical
treatment. Do not induce vomiting if

Page 6For technical questions, please call 1-800-444-3353.SKU 95977
fuel is swallowed. For skin contact,
immediately wash with soap and water.
For eye contact, immediately ush eyes
with clean water.
NOISE PRECAUTION
Prolonged exposure to high noise
levels is hazardous to hearing.
Wear ANSI-approved hearing protection
when operating or working around the
Water Pump when it is running.
UNPACKING
When unpacking, check to make sure
all of the parts shown on the Parts List in
this manual are included. If any parts are
missing or broken, please call Harbor Freight
Tools at the number shown on the cover (and
at the bottom of each page) of this manual as
soon as possible.
CONTROLS AND FEATURES
DIPSTICK (58)
PRIMING CAP
(9A)
STARTER HANDLE
(13)
INTAKE PORT (3A)
DISCHARGE PORT (4A)
FUEL TANK CAP
(72)
FUEL TANK (70)
POWER
SWITCH
(109)
MUFFLER
(77)
TUBE FRAME
(23A)
DRAIN PLUG
(49)
Figure 1
FUEL FILTER (74)
(Under Cap)
HOSE COUPLING (20A) (SUCTION HOSE CONNECTOR)
HOSE COUPLING (20A) (DISCHARGE HOSE CONNECTOR)

Page 7For technical questions, please call 1-800-444-3353.SKU 95977
CONNECTING HOSES
The Suction Hose (not included)
MUST be reinforced with braided material
or have non-collapsible construction. Do
not use Hose with inside diameter smaller
than 2” (pump’s Intake Port (3A) diameter).
Slide Hose Coupler (19A) over Hose1.
Coupling (20A). Insert Coupling Gasket
(21A) into end of Hose Coupler. See
Figure 2, below.
Screw Hose Coupler (19A) clockwise2.
onto Intake Port (3A) until fastened
securely. See Figure 3, below.
Slide Hose Clamp (18A) over end of3.
Suction Hose (not included). Slide Hose
onto Hose Coupling. Use a screwdriver
(not included) to tighten Hose Clamp
until secure. See Figure 4, below.
Slide second Hose Clamp over other end4.
of Suction Hose. Attach Hose to Intake
Filter (17A). Use a screwdriver to tighten
Hose Clamp until secure. See Figure 5.
For the Discharge Hose (not included),5.
slide the other Hose Coupler (19A) over
the other Hose Coupling (20A). Insert
the other Coupling Gasket (21A) into the
end of Hose Coupler.
Thread the Hose Coupler (19A)6.
clockwise onto Discharge Port (4A) until
tightened securely. See Figure 6.
Slide other Hose Clamp over end7.
of Discharge Hose and then slide
Discharge Hose onto Hose Coupling.
Use a screwdriver to tighten Hose Clamp
until secure. See Figure 6.
WARNING!8. Do not over-tighten Hose
Clamps as the clamp may damage the
hose.
Figure 2
HOSE COUPLER (19A) HOSE COUPLING (20A)
COUPLING
GASKET (21A)
INTAKE PORT
(3A)
HOSE
COUPLER
(19A)
Figure 3
HOSE COUPLER
(19A)
HOSE CLAMP
(18A)
SUCTION HOSE
(SKU 65989)
Figure 4
HOSE CLAMP
(18A)
SUCTION
HOSE
(SKU 65989)
INTAKE
FILTER
(17A)
Figure 5
HOSE CLAMP
(18A)
DISCHARGE
HOSE
(SKU 95390
or 95392)
HOSE COUPLER
(19A)
DISCHARGE
PORT
(4A)
Figure 6

Page 8For technical questions, please call 1-800-444-3353.SKU 95977
LOCATING THE WATER PUMP
Make sure the Water Pump is located1.
on a at, level, sturdy surface capable of
supporting the weight of the Pump and
any additional tools and equipment.
For best Pump performance, place the2.
Pump near the water level and use
hoses that are no longer than necessary.
That will allow the Pump to produce the
greatest output with the least self-priming
time. See diagram below.
As the head (pumping height) increases,
pump output decreases. The length,
type, and size of the suction and
discharge hoses can also signicantly
affect Pump output.
Discharge head capability is always
greater than suction head capability.
Which means pumping height for the
Intake Hose (suction head) should be
shorter than the pumping height for the
Discharge Hose.
Minimizing suction head (placing the
Pump closer to the water level) will also
help reduce self-priming time. This is the
time it takes the Pump to bring the water
from the water level to the Pump during
the initial operation.
Route the Intake Hose with the Intake3.
Filter fully immersed in the water supply
source.
Place Filter into water to be pumped.4.
WARNING! Filter must be fully
immersed in water. Do not operate
Pump without Filter connected to end
of suction hose. Keep Filter out of sand
or silt by placing Filter in bucket or on
stones. See diagram below.
Secure the Intake Hose in place to keep5.
it from moving once the Pump is turned
on. The Intake Hose should be as short
as possible for more efcient operation.
Route the discharge hose to the desired6.
discharge location. If necessary, connect
additional discharge hoses to direct the
discharge to the desired location. Then
make sure to secure the discharge hose
in place to keep it from moving once the
Water Pump is turned on. The discharge
hose should be kept as short as possible
for more efcient operation.
CAUTION!7. Be aware of the following
problems during operation, and how to
x them:
1. Cavitation: This is the sudden
formation and collapse of low-pressure
vapor (bubbles) across the vanes of the
impeller.
Cause: When the surface pressure
on a liquid becomes low enough, the
REV 08l
Total Head
Suction
Head
Water Pump
Discharge Head
Filter

Page 9For technical questions, please call 1-800-444-3353.SKU 95977
liquid will begin to boil (even at room
temperature). With centrifugal pumps,
cavitation can occur when the suction
vacuum becomes too great, allowing
water vapor or bubbles to form at the
impeller. The rapid pressure increase
can cause impeller damage.
Solution: Minimizing suction head and
using the largest practical suction hose
diameter will reduce the likelihood of
cavitation. Do not use a suction hose
with a diameter smaller than the
Pump’s Intake Port (2” diameter).
2. Water Hammer Pressure: This is
energy sent back to the Pump due to
sudden stoppage of water owing from
the Pump.
Cause: Water hammer pressure is more
likely to occur when using a very long
discharge hose. If the ow of water at
the end of the discharge hose is shut
off suddenly, energy is sent back to the
pump. This causes a large pressure
spike in the Pump housing, leading to
potential damage to the Pump casing.
Solution: Use as short a discharge hose
as possible or shut off water ow slowly.
ENGINE PRE-START INSTRUCTIONS
Disconnect the Spark Plug Cap (21) from1.
the Engine of the Water Pump.
IMPORTANT! Your Warranty is voided2.
if you do not put engine oil in the
Engine’s crankcase prior to its rst
use. Before each use, check the oil
level. Never run the Engine with low or
no engine oil. Running the Engine with
no or low engine oil WILL permanently
damage the Engine.
The Engine MUST be lled with a high 3.
quality grade engine oil. If the Engine
will be run in temperatures above 32°
Fahrenheit, use SAE 30 weight oil. If
the Engine will be run in temperatures
below 32° Fahrenheit, use SAE 5W-30
weight oil.
To add engine oil, unscrew and remove4.
the Oil Dipstick (58). Pour engine oil into
the Dipstick Reservoir until the level of
oil is even with the bottom edge of the
Dipstick Receptacle. Then, make sure
to screw the Oil Dipstick back into its
Dipstick Hole. See Figure 7, below.
To ll the Fuel Tank (70), unscrew and 5.
remove the Fuel Tank Cap (72). Fill the
Fuel Tank with (minimum 87 octane)
unleaded gasoline. Then replace the
Fuel Tank Cap.
When necessary, rell the Fuel Tank. 6.
Periodically, check the Fuel Filter7.
(74) for excessive dirt and debris. If
necessary, remove the Fuel Filter and
clean with compressed air. Take care
not to damage the fuel lter. Replace if
damaged.
The water pump is self-priming.8.
However, for the initial use, the pump
housing must be lled with water.
DIPSTICK (58)
Figure 7
LOW OIL LEVEL
FULL OIL LEVEL

Page 10For technical questions, please call 1-800-444-3353.SKU 95977
Unscrew Priming Cap (9A) and add
water to the Pump Housing.
IMPORTANT! Always check for water
in the Pump Housing before each use.
Never attempt to run the Water Pump
without water inside the Pump Housing.
Running the Water Pump without
water for an extended period of time
will damage the Water Pump Gaskets
and void the Warranty.
TO START AND STOP THE ENGINE
Re-connect the Spark Plug Cap (21) to1.
the Spark Plug (25) of the Engine.
Turn the Engine’s Power Switch (109)2.
to its “ON” position. (See Figure 1 on
page 6.)
Turn Engine’s Choke to its3. “CHOKE”
position, to far right. See Figure 8.
NOTE: No choke is required if the
Engine is warm. Make sure the Choke
is in the “RUN” position when starting a
warm Engine.
Turn the Engine’s Throttle to its4. “FAST”
position (to the left). See Figure 7.
Note: This engine includes an automatic low
oil shutdown sensor that disables the
engine if the oil level is too low.
Grasp Starter Handle (13) and pull5.
slowly until resistance is felt. See Figure
9.
Allow Starter Rope (14) to rewind slowly.6.
Then pull the Starter Handle with a rapid,
full arm stroke. Allow the Starter Rope to
rewind slowly. If necessary, repeat this
procedure until the Engine starts.
Once the Engine starts, slowly move6.
the Engine Choke to its “RUN” position.
Then adjust the Engine Throttle to the
speed (RPM) you desire.
Once Engine starts, Water Pump will run7.
continuously until Engine is turned off.
To turn off Engine, turn Engine’s Power
Switch (109) to its “OFF” position.
Allow Water Pump and its Engine to8.
completely cool before moving or storing
the Pump.
REV 09i
STARTER
HANDLE
(13)
FIGURE 9
FUEL VALVE
CHOKE
THROTTLE
(FAST) (SLOW)
FIGURE 8

Page 11For technical questions, please call 1-800-444-3353.SKU 95977
MAINTENANCE AND
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 and, if possible,2.
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 following 4.
the instructions under the Starting the
Engine section.
Air Filter Maintenance
Wipe off the Air Cleaner Cover (44).1.
The Air Cleaner Cover is held in place by2.
a Wing nut (43). Remove it.
Remove the Air Filter (42).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 opposite the
lter’s normal air ow (the “clean” side
of the lter).
If this does not get the lter reasonably
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.
Install the new lter or the cleaned lter. 5.
Secure the Air Cleaner Cover before
use.

Page 12For technical questions, please call 1-800-444-3353.SKU 95977
Spark Plug Maintenance
Disconnect spark plug wire from end1.
of plug. Clean out debris from around
spark plug.
Using a spark plug wrench, remove the2.
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, adjust4.
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 the cleaned5.
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 boot protector6.
(not included) to the end of the spark
plug and reattach the wire securely.
Fuel Filter Replacement (if equipped)
WARNING! TO PREVENT
SERIOUS INJURY FROM FIRE:
Replace the fuel lter in a well-
ventilated area away from ignition
sources. Do not smoke.
Wait for engine to cool completely before1.
proceeding.
Wear protective gear including, ANSI-2.
approved safety goggles, NIOSH-
approved dust mask/respirator, and
nitrile gloves.
Close fuel valve leading from gas tank3.
completely.
Take note of the Fuel Filter (74)4.
orientation.
Place a suitable container under the fuel5.
lter.
Disconnect the fuel lines leading to and6.
from the fuel lter and allow fuel to drain
onto the container.
Install new fuel lter in the same 7.
orientation. Make sure to properly
secure both fuel lines.
Clean up and properly dispose of all fuel.8.
Wait for at least one hour before use to9.
allow all residual fuel vapors to dissipate.
To prevent FIRE, do not start the
engine while the smell of fuel hangs
in the air. Remember to open the fuel
valve before restarting the engine. It
may take a little longer than usual to start
the engine because the fuel needs to
rell the fuel line and new lter.
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.

Page 13For technical questions, please call 1-800-444-3353.SKU 95977
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.
Every 100 Operation Hours:
Replace spark plug.a.
Replace air lter element.b.
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 from combustionb.
chamber.
Storage
Wait for engine to cool, then clean1.
engine with clean cloth.
When the equipment is to remain idle for2.
longer than 20 days, prepare the engine
for storage as follows:
Change engine oil and empty fuel tank.a.
Either leave fuel tank empty or rell b.
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 (if equipped).f.
Empty the primer tank of all water.3.
Apply a thin coat of rust preventive oil to4.
all uncoated metal parts.
Cover and store in a dry, well-ventilated5.
area out of reach of children.
Before starting the engine after storage,6.
keep in mind that untreated gasoline
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 14For technical questions, please call 1-800-444-3353.SKU 95977
Troubleshooting
Problem Possible Causes Probable Solutions
Engine will
not start
ENGINE RELATED:
Low oil level.
ENGINE RELATED:
Fill oil to proper level. Check engine before EVERY use.
FUEL RELATED:
No fuel in tank.1.
Choke not in start position, especially2.
with cold engine.
Low quality or deteriorated, old3.
gasoline.
Carburetor not primed.4.
Dirty fuel passageways blocking fuel5.
ow.
Carburetor needle stuck. Fuel can be6.
smelled in the air.
Too much fuel in chamber. This can7.
be caused by the carburetor needle
sticking.
FUEL RELATED:
Fill fuel tank.1.
Move choke to start position if engine is cold.2.
Use only fresh 87+ octane unleaded gasoline.3.
Prime carburetor by pressing priming bulb specied 4.
number of times (if equipped).
Clean out passageways using fuel additive. Heavy5.
deposits may require further cleaning.
Gently6. tap side of carburetor oat chamber with
screwdriver handle.
Turn choke to run position. Remove spark plug7.
and pull the start handle several times to air out the
chamber. Reinstall spark plug and set choke to start
position.
IGNITION (SPARK) RELATED:
Spark plug wire not connected securely.1.
Spark plug electrode wet or dirty.2.
Incorrect spark plug gap.3.
Spark plug wire or spark plug broken.4.
Incorrect spark timing or faulty ignition5.
system.
IGNITION (SPARK) RELATED:
Connect spark plug wire properly.1.
Clean spark plug.2.
Correct spark plug gap.3.
Replace spark plug wire and/or spark plug.4.
Have qualied technician diagnose/repair ignition 5.
system.
COMPRESSION RELATED:
Cylinder not lubricated. Results in1.
problem after long storage periods.
Loose or broken spark plug. (Hissing2.
noise will occur when trying to start.)
Loose cylinder head or damaged head3.
gasket. (Hissing noise will occur when
trying to start.)
Engine valves or tappets mis-adjusted4.
or stuck.
COMPRESSION RELATED:
Pour tablespoon of oil into spark plug hole. Crank1.
engine a few times and try to start again.
Tighten spark plug. If that does not work, replace2.
spark plug. If problem persists, may have head
gasket problem, see #3.
Tighten head. If that does not remedy problem,3.
replace head gasket.
Adjust valve clearance. If that does not work, clean or4.
replace valves/tappets.
Engine
misres
Spark plug wire loose.1.
Incorrect spark plug gap or damaged2.
spark plug.
Defective spark plug wire.3.
Old or low quality gasoline.4.
Incorrect compression.5.
Check wire connections.1.
Re-gap or replace spark plug.2.
Replace spark plug wire.3.
Use only fresh 87 octane unleaded gasoline.4.
Diagnose and repair compression. (Use5. Engine will
not start: COMPRESSION RELATED section.)
Follow all safety precautions whenever diagnosing or servicing the equipment
or engine.

Page 15For technical questions, please call 1-800-444-3353.SKU 95977
Troubleshooting
Problem Possible Causes Probable Solutions
Engine stops
suddenly
Low oil shutdown.1.
Fuel tank empty or full of impure or low2.
quality gasoline.
Defective fuel tank cap creating3.
vacuum, preventing proper fuel ow.
Improper idle speed.4.
Faulty magneto, incorrect timing, or5.
clogged carburetor.
Fill engine oil to proper level. Check engine1.
oil before EVERY use.
Fill fuel tank with fresh 87+ octane unleaded2.
gasoline.
Test/replace fuel tank cap.3.
Properly adjust idle speed.4.
Have qualied technician diagnose and 5.
service engine.
Engine knocks Old or low quality gasoline.1.
Engine overloaded.2.
Incorrect spark timing, deposit buildup,3.
worn engine, or other mechanical
problems.
Fill fuel tank with fresh 87+ octane unleaded1.
gasoline.
Do not exceed equipment’s load rating.2.
Have qualied technician diagnose and 3.
service engine.
Engine
backres
Impure or low quality gasoline.1.
Engine too cold.2.
Choke not open after engine warm.3.
Engine not properly adjusted for high4.
altitude operation.
Intake valve stuck, choke stuck,5.
incorrect timing, clogged carburetor, or
overheated engine.
Fill fuel tank with fresh 87+ octane unleaded1.
gasoline.
Use cold weather fuel and oil additives to2.
prevent backring.
Move choke to run position after engine3.
warms up.
Qualied technician must adjust engine at 4.
altitudes greater than 5,000 feet above sea
level.
Have qualied technician diagnose and 5.
service engine.
Pump does not
pump water
Pump is not primed.1.
Filter (17A) clogged.2.
Air leak at connector.3.
Hose leaks.4.
Suction hose has collapsing wall.5.
Hose has too small diameter6.
Suction lift is too high.7.
Prime Pump.1.
Clean Filter or replace if damaged.2.
Replace Coupling Gasket or tighten clamp.3.
Replace hose.4.
Use hose with non-collapsible wall.5.
Use hose with diameter 2” or greater.6.
Adjust suction lift.7.
Low Pump
Output
Suction hose collapsed, damaged, too1.
long or diameter is too small.
Air leak at connector.2.
Filter clogged.3.
Discharge hose damaged, too long or4.
diameter too small.
Replace or adjust suction hose.1.
Replace Coupling Gasket or tighten Clamp.2.
Clean Filter.3.
Replace or adjust Discharge Hose.4.
Follow all safety precautions whenever diagnosing or servicing the equipment
or engine.

Page 16For technical questions, please call 1-800-444-3353.SKU 95977
PARTS LIST & ASSEMBLY DIAGRAM - WATER PUMP
Part Description Qty.
1A Pump Housing 1
2A Cover 1
3A Intake Port 1
4A Discharge Port 1
5A Impeller 1
6A Casing 1
7A Intake Valve 1
8A Discharge Seal 1
9A Priming Cap 2
10A O-Ring 2
11A O-Ring 1
12A Mechanical Seal 1
13A Hex Bolt (M8x50) 4
14A Washer (8mm) 4
Part Description Qty.
15A O-Ring 1
16A Bolt (M10x32) 11
17A Intake Filter 1
18A Hose Clamp 3
19A Hose Coupler 2
20A Hose Coupling 2
21A Coupling Gasket 2
22A Gasoline Engine 1
23A Tube Frame 1
24A Oscillation Absorber 4
25A Bolt (M6x12) 4
26A Bolt (M8x40) 4
27A Nut (M8) 4
23A
25A 27A
27A 25A
27A
27A 26A
26A
24A
24A
26A
24A
25A
26A
24A
25A
18A
17A
22A
2A
14A
13A
13A
12A
5A
6A
11A
16A
15A
8A
4A
16A
10A
9A
1A
10A
9A
7A
3A
16A
21A
20A
19A
18A 18A
19A20A
21A

Page 17For technical questions, please call 1-800-444-3353.SKU 95977
PARTS LIST - ENGINE
Part Description Qty.
1 Crankcase 1
2 Flywheel Assy. 1
3 Cooling Fan 1
4 Starter Pulley 1
5 Fan Cover 1
6 Set Screw, Ratchet Guide 1
7 Starting Ratchet 2
8 Clip 1
9 Recoil Starter Reel 1
10 Spiral Spring 1
11 Bolt (M6x10) 3
12 Recoil Starter Cover Assy. 1
13 Starter Handle 1
14 Starter Rope 1
15 Offsetting Spring 2
16 Ratchet Guide, Starter 1
17 Bolt (M6x12) 16
18 Flywheel Nut 1
19 Bolt (M6x25) 3
20 Ignition Coil 1
21 Spark Plug Cap 1
22 Dowel Pin (10x16) 2
23 Washer, Cylinder Head 1
24 Bolt Stud (M8x35), Exhaust Valve 2
25 Spark Plug 1
26 Valve Guide 2
27 Clip, Valve Guide 1
28 Flange Bolt (8x60) 4
29 Seal, Cylinder Head 1
30 Cylinder Head Cover Assy. 1
31 Air Duct 1
32 Cylinder Head Assy. 1
33 Bolt Stud (M6x113), Inlet Valve 2
34 Seal, Inlet Valve 1
35 Carburetor Shield 1
36 Washer, Carburetor 1
37 Carburetor Assy. (P19) 1
38 Nut (M6) 7
39 Air Filter Frame 1
40 Bolt (M6x20) 2
41 Air Filter Base 1
42 Air Filter 1
43 Winged Nut 2
Part Description Qty.
44 Air Cleaner Cover 1
45 Oil Seal (25x41.25x6) 2
46 Gasket, Oscillating Bar 1
47 Oscillating Bar 1
48 Gasket, Drain Plug 2
49 Drain Plug 2
50 Camshaft Assy. 1
51 Seal, Crankcase Cover 1
52 Dowel Pin (8x14) 2
53 Bearing (6205) 2
54 Seal Ring 2
55 Oil Cap 1
56 Flange Bolt (M8x32) 6
57 Crankcase Cover 1
58 Dipstick 1
59 Crankshaft Assy. 1
60 Governor Gear Assy. 1
61 Piston Ring Assy. 1
62 Snap Ring, Piston Pin 2
63 Piston 1
64 Piston Pin 1
65 Connecting Rod Assy. 1
66 Fuel Pipe Clip 2
67 Fuel Pipe 1
68 Connector 1
69 O-Ring (14mm) 1
70 Fuel Tank 1
71 Strap, Fuel Tank 1
72 Fuel Tank Cap 1
73 Packing Ring, Fuel Tank 1
74 Fuel Filter 1
75 Mufer Guard 1
76 Screw (M5x8) 4
77 Mufer 1
78 Nut (M8) 2
79 Spring Washer (8mm) 2
80 Washer, Mufer 1
81 Gasket, Air Supplement Valve 1
82 Spring (6mm) 2
83 Air Supplement Valve 1
84 Supporting Rubber, Carbon Pot 1
85 Shroud 1
86 Carbon Pot 1

Page 18For technical questions, please call 1-800-444-3353.SKU 95977
PARTS LIST - ENGINE (CONTINUED)
Part Description Qty.
87 Tube A 1
88 Tube B 1
89 Tappet 2
90 Push Rod, Valve 2
91 Push Rod Guide 1
92 Bolt, Rocker Arm Shaft 2
93 Rocker Arm 2
94 Rocker Arm Shaft 2
95 Adjusting Nut, Rocker Arm Shaft 2
96 Inlet Valve 1
97 Exhaust Valve 1
98 Oil Seal, Valve Stem 1
99 Valve Spring 2
100 Spring Seat, Inlet Valve 1
101 Spring Seat, Exhaust Valve 1
Part Description Qty.
102 Cap, Exhaust Valve 1
103 Governor Control Assy. 1
104 Offsetting Spring 1
105 T-Shape Bolt 1
106 Control Arm 1
107 Governor Rod 1
108 Throttle Return Spring 1
109 Power Switch 1
110 Spark Plug Wrench (not shown) 1
111 Screwdriver (not shown) 1
112 Oil Alert 1
113 Bolt (M6x16) 2
114 Oil Sensor 1
115 Nut (M10) 1
116 Side Air Bafe Plate 1
REV 10a

Page 19For technical questions, please call 1-800-444-3353.SKU 95977
ASSEMBLY DIAGRAM - ENGINE
109

Page 20For technical questions, please call 1-800-444-3353.SKU 95977
LIMITED 1 YEAR / 90 DAY
WARRANTY
Harbor Freight Tools Co. makes every effort
to assure that its products meet high quality and
durability standards, and warrants to the original
purchaser that for a period of ninety days from
date of purchase that the engine/motor, the belts
(if so equipped), and the blades (if so equipped)
are free of defects in materials and workmanship.
Harbor Freight Tools also warrants to the original
purchaser, for a period of one year from date of
purchase, that all other parts and components of
the product are free from defects in materials and
workmanship (90 days if used by a professional
contractor or if used as rental equipment). This
warranty does not apply to damage due directly
or indirectly, to misuse, abuse, negligence or
accidents, repairs or alterations outside our
facilities, normal wear and tear, or to lack of
maintenance. We shall in no event be liable
for death, injuries to persons or property, or for
incidental, contingent, special or consequential
damages arising from the use of our product.
Some states do not allow the exclusion or
limitation of incidental or consequential damages,
so the above limitation of exclusion may not apply
to you. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the
product or part must be returned to us with
transportation charges prepaid. Proof of purchase
date and an explanation of the complaint must
accompany the merchandise. If our inspection
veries 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 specic legal rights
and you may also have other rights which vary
from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 •
Camarillo, CA 93011 • [phone]
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.
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.