TOOLS

Basic Hand Tools:

Standard ______ sizes ¼ through 1 in. Metric _______ sizes 6 through 24 Needle nose ______ _______ jaw pliers Standard and metric ___ wrenches ________ head screw drivers ________ screw drivers Ball peen _______ _______ _______

TOOLS

Specialty Tools:

_______ wrench or Strap wrench

Flywheel _____ Three _____ puller _____ wrench Micrometer __________ gauge Compression _____ _______ tester _____ expander Ring _______

______ grinding tool Cylinder ______ Spark plug _______ ______ compressor ______ set Magnetic ______ tool

DEMONSTRATING BASIC MAINTENANCE PROCEDURES Read and ______ all service publication instructions!

Service manuals are a student’s ____ _____. Read! Read! Read! When in doubt _____ again.

SHOP SAFETY AND SMALL ENGINES

• _____ _____ must be worn at all times.

• Keep hands and feet away from all ______ parts during operation.

• Keep all _______ sources away from the work area.

• Stop engine and allow it to _____ before refueling.

• Handle gasoline _______ if possible.

• Disconnect the spark plug lead when making adjustment to ________ accidental start-up.

• Never disengage any of the ________ equipment or devices.

SHOP SAFETY AND SMALL ENGINES

• Keep all ______ in place.

• Do not operate engines above the specified ____.

• Never _______ engines or force equipment beyond it the designed capacity.

• Never use _______ as a solvent to clean parts.• Only start and run engines

where ________ is adequate, preferably outdoors.

• Never pour gasoline or oil on the ______ or down a ______, dispose of it in the correct container to be recycled.

BASIC MAINTENANCE

__ ______ can become clogged over time and should be changed (_____! Blow out an air filter with compressed air!) This can damage the filter and cause immediate engine damage.

BASIC MAINTENANCE

____ ______ can also become clogged over time and should be changed (_____! Blow out a fuel filter with compressed air!) This can damage the filter and cause immediate engine damage.

OLD NEW

BASIC MAINTENANCE

______ & ______ can also become clogged over time however these items can be clean with solvent and blown out with ___ volume compressed air.

BASIC MAINTENANCE

__________ can be adjusted although it is rarely necessary. Commonly small engines are factory preset and will not require adjustment. However, in the case that adjustment is necessary there are usually __ adjustment points on a carburetor.

BASIC MAINTENANCE

1. _________________ - this screw adjusts the fuel to air mixture ratio by allowing more or less liquid fuel into the carburetor to mix with air to be combusted.

2. _________________- this screw adjusts the idle air to fuel mixture.

3. _________________- this screw adjusts the idle speed by changing the position of the throttle valve.

BASIC MAINTENANCE

____________ is very important it is necessary to deduce whether or not the engine has a pressurized lube system or not. This is a simple deduction.1. _________ systems- utilize the use of an oil filter 2. Non-__________- does not utilize an oil filter.

BASIC MAINTENANCE

Different engines require different oils of different viscosities. _____________- is the thickness of the oil

Many non-pressurized engines call for non-___________, single viscosity oils such as ND__

Many pressurized engines call for multi-viscosity oils such as __w__

______-viscosity- is the thickness of the oil at different operating temperatures

Dip sticks must also be located and checked _________ according to service manual.

BASIC MAINTENANCE

_________ system- usually can be blown out with compressed air in air cooled and liquid cooled applications. May require coolant checks for adequate level and ratio in liquid cooled applications.

_____ Cooled ________ Cooled

BASIC MAINTENANCE

_________ system- somewhat maintenance free with the exception of the ________ plug and a few switches which requires replacement at implied intervals.

REPAIR PROCEDURE

KIS- Keep It Simple, Always check the easy things first. If an engine suddenly stops running, chances are the solution is an _____ fix.

As we learned in the previous chapter the principles of operation must happen sequentially for an engine to run. If one or more of these steps are incomplete the engine will ______ to run.

REPAIR PROCEDURE

We must know how to use specialty tools like:

• __________- measuring tool used to check components for wear

• __________- t-shaped tool used to measure cylinder wear

• __________- threadlike material used to measure connecting rod bearing clearance

• ______ _______- used to tighten fasteners to specific tolerances

• _______-________- used to compress piston rings for piston installation

• _________ wrench or strap wrench- used to hold flywheel to remove nut

• Flywheel _______- used to pull stuck flywheels

• ________tester- used to safely test spark

• _________ compressor- used to compress valve springs

• __________gauge- used to check clearances

• _________grinder- used to grind and lap valves

TROUBLESHOOTING

Check for _____. If the engine cranks but will not start it may not be _______. Use a spark tester to identify spark. Lack of spark may be a faulty plug, armature coil, breaker points, or ground switch

TROUBLESHOOTING

Check for _____. Make sure there is plenty of fuel in the tank and that the fuel is fresh. Remove the fuel line from the carburetor to be sure that the fuel flows _______ from the tank, through the line and into the carburetor. If it doesn’t you must find the blockage and remove it.

TROUBLESHOOTING

After cranking several times and no start remove the spark plug and examine it.

• ____- you have a fuel delivery issue inside the carburetor.

• _________ ___- the carburetor is flooding the engine.

____________

TROUBLESHOOTING

If you have spark and fuel but the engine fails to start or sounds like it is backfiring or is hard to crank, the _______ key could be to blame.

• A flywheel ____ is designed to take the brunt of a blow if the engine is stopped abruptly.

• If the key is sheared the ________ will be affected because it adjusts the position of the permanent magnet found in the flywheel

• This adjustment causes the spark plug to _____ at the wrong time hence the backfiring or no start condition.

TROUBLESHOOTINGWhen all of the above methods have been exerted and found to be ineffective, you should run a cylinder ___________ test. Compression test results will act as a guide and let you know which route to take.

• If the compression tests well then the prior steps may need to be repeated because you may have missed something simple.

• If the compression tests _______ then the repair may have just gotten more costly.

TROUBLESHOOTINGEngines lose compression for three primary reasons:

1. ______ and tear

2. Blown ______ gasket

3. Off _______

In no-tolerance engines if timing is off the ______ could come in contact with the valves and cause serious component damage.

SUMMARY4) What do we need to know to be able to establish troubleshooting

techniques using sequential procedure? 1. Check for _______.2. Check for _______.3. Check for ___________.4. Do not ___________ engine unless absolutely necessary!

MYSTERY TOOLS? 3.1. 2. 2. 3.

1.

4.