Small engine mechanics training

Lesson 1 • Major Engine Components Overview

Identifies and describes every primary engine component and its function. Provides the vocabulary needed for diagnosis and repair tasks.

Lesson 2 • Four-Stroke Combustion Cycle

Explains intake, compression, power, and exhaust strokes in sequence. Links thermodynamic principles to mechanical motion inside the engine.

Lesson 3 • Shop Safety and Tool Identification

Establishes personal protective equipment use, hazard awareness, and proper tool selection. Safe habits introduced here apply throughout the entire course.

Lesson 4 • Small Engine Types and Applications

Covers two-stroke and four-stroke engine classifications and their common uses. Establishes context for all subsequent mechanical study.

Lesson 1 • Electrical and Ignition Diagnostic Tools

Introduces multimeters, timing lights, and spark testers for ignition system diagnosis. Electrical faults are among the most common small engine failures.

Lesson 2 • Reading Service Manuals and Specifications

Trains students to locate torque values, clearances, and procedures in manufacturer documentation. Proper spec use prevents over-repair and component damage.

Lesson 3 • Compression and Leak-Down Testing

Covers compression tester and leak-down tester procedures to assess cylinder health. Results guide decisions on ring, valve, or head gasket service.

Lesson 1 • Ethanol Fuel Issues and Prevention

Addresses phase separation, varnish deposits, and material degradation caused by ethanol blends. Preventive practices reduce repeat fuel system failures.

Lesson 2 • Carburettor Cleaning and Rebuilding

Provides step-by-step disassembly, ultrasonic or chemical cleaning, and reassembly procedures. Proper rebuild restores fuel metering accuracy and engine performance.

Lesson 3 • Fuel Pump and Primer Bulb Service

Covers diaphragm fuel pump testing, primer bulb replacement, and pulse line inspection. Faulty pumps cause lean conditions that mimic carburettor problems.

Lesson 4 • Fuel System Components and Flow

Maps fuel flow from tank through filter, pump, and carburettor to the intake. Understanding flow sequence is essential for systematic diagnosis.

Lesson 1 • Ignition Coil and Armature Service

Tests coil resistance, sets air gap, and replaces defective armatures. Correct air gap is critical for consistent spark energy at all speeds.

Lesson 2 • Capacitor-Discharge Ignition Systems

Explains CDI module operation, trigger coil function, and module replacement procedures. CDI systems are common on two-stroke and newer four-stroke engines.

Lesson 3 • Spark Plug Inspection and Service

Covers reading plug condition, gapping, torquing, and selecting correct heat range. Spark plug condition is a direct indicator of combustion quality.

Lesson 4 • Ignition Timing Verification and Adjustment

Uses timing marks and timing lights to verify and correct ignition timing. Proper timing maximises power output and prevents engine damage.

Lesson 1 • Liquid-Cooled System Service

Covers coolant flush, thermostat testing, and water pump inspection on liquid-cooled small engines. Proper coolant maintenance prevents corrosion and overheating.

Lesson 2 • Engine Lubrication Principles

Explains splash, pressure, and combination lubrication systems used in small engines. Lubrication knowledge prevents premature wear and catastrophic failure.

Lesson 3 • Air-Cooled System Maintenance

Addresses fin cleaning, shroud inspection, and airflow path restoration on air-cooled engines. Blocked cooling fins are the leading cause of small engine overheating.

Lesson 1 • Component Reconditioning Decisions

Teaches repair vs. replace decision-making based on wear limits and cost analysis. Sound reconditioning decisions ensure durability and customer value.

Lesson 2 • Engine Reassembly and Break-In

Guides torque sequences, sealant application, and controlled break-in run procedures. Correct reassembly technique prevents immediate post-repair failures.

Lesson 3 • Pre-Disassembly Preparation

Establishes cleaning, documentation, and parts organisation practices before teardown begins. Proper preparation prevents lost parts and assembly errors.

Lesson 4 • Bottom-End Disassembly and Inspection

Details crankcase splitting, crankshaft inspection, and bearing assessment procedures. Bottom-end condition determines whether a full rebuild is justified.

Lesson 1 • Wiring Harness and Switch Diagnosis

Traces wiring diagrams, tests safety switches, and repairs harness faults. Safety interlock switches cause many no-start complaints on riding equipment.

Lesson 2 • Recoil Starter Service

Covers recoil spring replacement, rope routing, and pawl mechanism repair. Recoil starters are the most frequently serviced starting system component.

Lesson 3 • Charging System Diagnosis

Tests stator output, rectifier-regulator function, and charging voltage under load. A failed charging system drains the battery and disables electric start.

Lesson 4 • Electric Starter Motor Service

Tests starter motor current draw, inspects brushes and commutator, and diagnoses solenoid faults. Electric start failures are often electrical rather than mechanical.

Lesson 1 • Performance Tuning Fundamentals

Introduces air filter upgrades, carburettor jetting, and valve timing adjustments for performance gains. Tuning decisions must balance power, reliability, and application requirements.

Lesson 2 • Governor System Diagnosis and Adjustment

Covers mechanical and pneumatic governor operation, speed setting, and hunting diagnosis. Governor faults cause speed instability and potential engine overspeed.

Lesson 3 • Emissions and Regulatory Compliance

Covers exhaust emission standards, tamper-proof carburettor requirements, and compliance documentation. Technicians must understand regulatory limits to perform legal repairs.

Lesson 4 • Systematic Diagnostic Strategy

Teaches symptom-based diagnostic trees, root cause analysis, and verification testing. Structured diagnosis reduces repair time and prevents misdiagnosis.