Small Engine Course

Lesson 1 • Tools and Measuring Instruments

Introduces hand tools, power tools, and precision measuring instruments used in small engine service. Correct tool selection prevents damage and ensures accurate diagnosis.

Lesson 2 • Types and Applications of Small Engines

Covers two-stroke, four-stroke, and rotary engine classifications and their common equipment applications. Builds the vocabulary needed for all subsequent diagnostic and repair work.

Lesson 3 • Service Documentation and Work Orders

Teaches reading service manuals, recording findings, and completing work orders accurately. Proper documentation supports quality control and customer communication.

Lesson 1 • Two-Stroke Cycle Operation

Contrasts two-stroke port timing, crankcase compression, and lubrication with four-stroke design. Students can select the correct service approach for each engine type.

Lesson 2 • Engine Performance Metrics

Introduces horsepower, torque, volumetric efficiency, and brake specific fuel consumption. Metrics guide tuning decisions and help set realistic repair expectations.

Lesson 3 • Combustion Principles and Thermodynamics

Explains air-fuel mixture combustion, heat release, and pressure generation inside the cylinder. Links thermodynamic concepts to observable engine behavior.

Lesson 1 • Piston, Ring, and Cylinder Inspection

Teaches piston removal, ring gap measurement, and cylinder bore gauging techniques. Findings determine whether honing, boring, or replacement is required.

Lesson 2 • Pre-Disassembly Procedures

Covers fuel draining, compression testing, and external cleaning before teardown begins. Systematic preparation prevents contamination and preserves diagnostic evidence.

Lesson 3 • Cylinder Head Removal and Inspection

Details head bolt loosening sequences, gasket removal, and valve train disassembly. Students evaluate head warpage, valve seating, and guide wear accurately.

Lesson 4 • Camshaft and Valve Train Assessment

Covers lobe lift measurement, timing gear inspection, and tappet clearance evaluation. Camshaft condition directly affects valve timing and engine power output.

Lesson 1 • Crankshaft and Bearing Installation

Addresses bearing shell placement, crankshaft seating, and main cap torque sequences. Achieving specified oil clearance is critical to long-term engine durability.

Lesson 2 • Piston and Ring Installation

Teaches ring orientation, gap staggering, piston pin fitting, and ring compressor use. Correct installation prevents blow-by and ensures proper oil control.

Lesson 3 • Cylinder Head Reconditioning

Covers valve grinding, seat cutting, lapping, and head resurfacing procedures. Proper reconditioning restores compression sealing and heat transfer efficiency.

Lesson 4 • Break-In Procedures and Initial Start

Details oil priming, initial start sequence, and break-in run protocols for reconditioned engines. Proper break-in seats rings and bearings for maximum service life.

Lesson 1 • Carburetor Theory and Circuit Operation

Explains float, main, idle, choke, and accelerator circuits and their interaction. Understanding circuit function is prerequisite to accurate mixture diagnosis.

Lesson 2 • Primer Bulbs and Fuel Pumps

Covers diaphragm pump operation, pulse line testing, and primer bulb replacement. Fuel pump faults mimic carburetor problems and must be isolated systematically.

Lesson 3 • Carburetor Disassembly and Cleaning

Covers ultrasonic and chemical cleaning, passage verification, and parts kit selection. Thorough cleaning eliminates varnish deposits that cause lean or rich conditions.

Lesson 4 • Fuel Tanks, Lines, and Filters

Addresses tank inspection, ethanol damage assessment, line replacement, and filter service. Clean fuel delivery is essential for consistent carburetor and injector performance.

Lesson 1 • Magneto and Solid-State Module Service

Covers flywheel magnet inspection, armature air gap setting, and module resistance testing. Correct air gap is the most common adjustment affecting spark quality.

Lesson 2 • Ignition Timing Verification and Adjustment

Covers static and dynamic timing methods using timing lights and degree wheels. Correct timing maximizes power while preventing detonation and overheating.

Lesson 3 • Ignition System Fundamentals

Explains magnetic flux, primary and secondary coil induction, and spark generation principles. Foundational theory enables logical fault isolation rather than parts substitution.

Lesson 4 • Capacitor Discharge Ignition Systems

Addresses CDI stator, trigger coil, and capacitor module diagnosis on two-stroke engines. CDI faults require voltage-based testing rather than resistance-only methods.

Lesson 1 • Liquid-Cooled System Service

Teaches coolant testing, thermostat function, water pump inspection, and radiator flushing. Liquid-cooled small engines require the same systematic approach as automotive cooling systems.

Lesson 2 • Air-Cooled System Maintenance

Covers fin cleaning, shroud integrity, and cooling airflow path inspection on air-cooled engines. Blocked fins raise cylinder head temperature and accelerate valve and piston wear.

Lesson 3 • Exhaust System Inspection and Repair

Covers muffler carbon buildup, spark arrestor cleaning, exhaust port inspection, and gasket replacement. Restricted exhaust raises back pressure and reduces power output significantly.

Lesson 4 • Lubrication System Types and Oil Selection

Covers splash, pressure, and pre-mix lubrication systems and viscosity grade selection. Matching oil type to engine design prevents accelerated wear and deposit formation.

Lesson 1 • Systematic Diagnostic Strategy

Establishes a structured symptom-to-cause diagnostic process using elimination and verification. Systematic thinking reduces diagnostic time and prevents unnecessary parts replacement.

Lesson 2 • Scan Tool and Diagnostic Data Use

Covers connecting scan tools, reading live data, retrieving fault codes, and interpreting freeze-frame data. Data-driven diagnosis eliminates guesswork on EFI-equipped engines.

Lesson 3 • Sensor and Actuator Testing

Teaches multimeter and oscilloscope testing of sensors, injectors, and solenoids. Component-level testing confirms root cause before replacement is authorized.

Lesson 4 • Intermittent Fault Diagnosis

Addresses thermal, vibration, and load-related intermittent faults using data logging and wiggle testing. Intermittent faults are the most time-consuming and require disciplined methodology.