[Engine hard to start]

Yes
Remove spark plug and check spark No Are sparks produced when
Faulty Spark Plug
by cranking engine while having the spark plug is replaced? Replace
Yes against engine block.
plug touched Yes No
Faulty ignition coil
WARNING Correct
Keep the plug as far away as possible  Incorrect air gap
from the spark plug hole. Yes  Faulty Flywheel Replace
Are sparks produced when
To avoid an electric shock do not hold
ignition coil is replaced? No
the plug itself.  No Fuel in the tank Add
Make sure to hold the plug cap.  Entry of dust or air into
fuel hose or filter.
Make starting attempts a
Yes No  Plugged air hole in tank Clean
Is compression sufficient? number of times and then
cap and fuel pump.
remove spark plug and
 Plugged fuel line
observe electrodes. Are
Remove the plug and
No they wet? Yes
 Excessive use of choke turn the crankshaft
without loading.

 Plugged air cleaner Clean or replace

 Too high fuel level in float Adjust

bowl
Replace
 Worn Piston/Piston Rings
Clean or replace
 Stuck piston rings
Bore or replace
 Worn cylinder bore

 Loose cylinder head bolt Retighten

Check Carburettor  Check for plugged fuel line  Faulty contact of valve seat Lap
 Check for plugged air passage
 Plunge –up by valve Adjust valve clearance
 Check float level
 Check carburettor setting  Warped cylinder head

 Broken Valve spring Replace

 Burned Head gasket

 Stuck Valve Clean or replace

Problem in the governor system  Incorrect governor linkage Correct
adjustment
Replace
 Faulty governor spring
 Governor assy malfunctioning Check
[Engine malfunctions at high speed]
Is revolution fluctuation of YES  Plugged air hole in tank cap
relatively large period produced  Entry of dust and air into fuel Clean
when a load is applied? filter or fuel pipe

[Engine malfunctions at low speed]

Remove spark plug and check  Faulty plug insulation
WEAK Replace
spark by cranking engine while  Faulty ignition coil
having the plug touched against
 Fouled electrodes Clean
engine block.
 Incorrect air gap
Correct
WARNING
Keep the plug as far away as
possible from the plug hole.
STRONG
To avoid electric shock, do not hold
the plug itself.
Make sure to hold the plug cap.
 Overrich fuel system Check fuel system

YES  Air leak at throttle body or Check

Is unusual smoke emitted out of
manifold
muffler? Adjust valve clearance
 Incorrect valve clearance
NO
 Wrong valve timing Correct alignment of
timing gear mark.
Directly and gradually open YES
throttle valve by hand. Does the  Plugged in carburettor interior Disassemble and clean
revolution drop or does the engine
stall at a certain position?
NO

Is air sucked through carburettor YES  Loose flange nuts Retighten

flange?
 Damaged gasket Replace
NO

Are valve clearances of normal NO  Compression leakage Adjust valve clearance

values?
YES Correct alignment of
 Wrong valve timing
timing gear marks

Is alignment of timing gear mark Correct alignment of

NO  Largely deviated valve timing
correct? timing gear marks
[Engine power loss]  Crankcase low on oil Adjust level
Yes Yes
Is engine overheated?  Too much oil in crankcase Adjust level or add
 Excessive engine load
 Carb not properly adjusted Decrease Load
No  Carbon deposit in combustion Adjust
chamber
 Clogging of cooling system Clean
 Damaged cooling fan
Replace

Is the ignition spark No  Wrong spark plug

Replace
normal?  Faulty ignition coil
 Incorrect air gap
Yes Adjust gap

Is lubricating condition  Too much or too little oil in Correct

No
normal? crankcase
 Excessively contaminated Change
lubricating oil
Yes
 Defective Oil filter
 Faulty relief valve Replace
 Faulty oil pump
 Clogging oil system Clean
Yes
Is unusual smoke  Carbon deposit in exhaust hole Clean
emitted out of muffler? and muffler
 Carb. Not properly adjusted Adjust
No
 Too much oil in crankcase
 Worn piston/piston rings Adjust Level
 Worn cylinder bore
Replace
 Plugged air cleaner elements
No 
Is compression
sufficient?  See “Engine hard to Start”
Yes

Is alignment of timing No Correct alignment of

 Largely deviated valve timing
gear marks correct? timing gear marks

 Spark Plug fouled, pitted or Replace or adjust

[Engine runs erratically]
gapped incorrectly

Problem in the fuel  Entry of dust or water into fuel

system (lack of fuel) pipe, fuel filter or fuel tank
 Air or vapour lock in fuel line Clean
 Plugged air vent of fuel tank cap
 Plugged air/fuel passes in carb
 Too little opening of carb pilot
screw Adjust
 Carb. Not properly adjusted
 Carb. Flange leaking at gasket
 Throttle body assy flange leaking Tighten or replace
at gasket.
 Worn carb. Body and throttle
Adjust level
shaft

[Fuel consumption is excessive]  High fuel level in carburettor float
Yes chamber (including overflow)
Is compression sufficient?  Too high idling R.P.M Adjust
 Excessively backed off carburettor
pilot screw
 Choke partially closed Open choke

 Worn piston/piston rings

 Worn cylinder bore Replace
No
 Broken valve spring
 Stuck piston
Clean or replace
 Stuck valve
 Insufficient cylinder head tightness Retighten

 Faulty valve seat contact Lap

 Plunge up of valve Adjust valve clearance

 Wrong valve timing Adjust

 Plugged oil ring groove.

[Oil consumption is excessive] Clean
 Clogged breather valve
Yes
Is compression sufficient?  Drain Back hole in breather
chamber plugged
 High oil level Adjust
 Worn valve stems and/or valve
guide
 Oil leakage from oil seal Replace
No
 Oil leakage along governor shaft
 Oil leakage from mounting surface Replace gasket
 Oil leakage from drain plug
Retighten or replace gasket
 Incorrect oil viscosity Correct

 Worn piston rings

 Worn cylinder bore Replace
 Broken piston ring
 Stuck piston rings Clean or replace

[Engine backfires]
 Loose carburettor or inlet manifold Retighten
 Lose cylinder head or leaking head
gasket Tighten
 Burned or sticking inlet valve
Replace
 Faulty ignition coil
 Carburettor not properly adjusted Adjust

[Engine knocks]  Stale fuel Change

 Excessive carbon deposit in engine Clean

 Excessive engine load Adjust

 Engine overheating See engine loss power

 Faulty ignition coil Replace

[Engine hard to stop]

Engine does not stop with control lever  Faulty contact of engine switch Inspect and clean
at the stop position of control panel
 Disconnection of engine switch
Replace
lead
 Faulty contact of control lever
and engine switch Inspect and repair

Engine does not stop within 3 seconds  Worn brake pad

when being braked  Brake arm not properly Replace
contacted
(Brake Equipped Model)
 Disconnection of spring Replace Part

[Faulty operation of priming pump]

(Priming start Model)  Entry of dust into pump cover Clean
hole
 Loose pump cover nut Tighten

 Disconnection of primer pipe Reassemble

 State priming pump Replace

Starter Motor Troubleshooting Guide

1. Disconnect spark plug caps from the spark plugs.

2. Turn engine switch to “START” position and check condition.

WARNING
Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test.

CAUTION
If starter does not stop by engine switch OFF, disconnect negative (-) cable from battery as soon as possible.

[Starter does not rotate]

NO
Is click sound from solenoid  Faulty battery Charge or replace
(switch)?  Faulty leads or connection
 Faulty engine switch Repair or replace
YES  Melted fuse
Replace
 Faulty solenoid (switch)

 Weak battery Charge or replace

 Faulty leads or connection
(Solenoid to motor) Repair or replace
 Faulty Starter Motor
 Faulty solenoid (switch)
Replace
(Main terminal in solenoid)

[Starter rotates but slow]
Is battery normal and well NO  Weak battery Charge or replace
charged?
 Faulty leads or connection
YES (Solenoid to motor)
 Faulty starter motor Repair or replace
 Faulty engine
 Faulty solenoid (switch) Replace
(Main terminal in solenoid)
[Starter rotates but engine can not crank]
NO
Does pinion mesh with ring  Worn pinion or ring gear Replace
gear?  Incorrect starter alignment Correct
YES
 Faulty pinion clutch Replace

 Faulty engine Repair or replace

[Starter does not stop in engine switch “OFF”]
NO
Can stop starter by engine  Faulty engine switch Repair or replace
switch “OFF”?
 Faulty solenoid (switch) Replace
YES
 Faulty pinion or ring gear.
 Faulty pinion return Repair or replace
mechanism
 Incorrect starter alignment Correct