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Hires, Bill; And Others Small Engine Repair. Two-Stroke and Four-Stroke Cycle. Mid-America Vocational Curriculum Consortium, Stillwater, Okla.; Missouri Univ., Columbia. Instructional Materials Lab. 85 754p.; Revision of Comprehensive Small Engine Repair (ED 146 392). Some pages use colored paper. Mid-America Vocational Curriculum Consortium, 1500 West Seventh Avenue, Stillwater, OK 74074 (Catalog No. 800501--$28.00). Guides - Classroom Use - Guides (For Teachers) (052)

EDRS PRICE DESCRIPTORS

MF04 Plus Postage. PC Not Available from EDRS. *Auto Mechanics; Behavioral Objectives; Competency Based Education; *Electrical Systems; *Engines; Equipment Utilization; Hand Tools; Learning Activities; Lessor. Plans; Measurement Techniques; Power Technology; Safety; Secondary Education; *Small Engine Mechanics; *Trade and Industrial Education

ABSTRACT This curriculum guide is intended to assist persons

teaching a course in repairing two- and four-stroke cycle small engines. Addressed in the individual units of instruction are the following topics: safety, tools, fasteners, and measurement techniques; basic small engine theory (engine identification and inspection, basic engine principles and design, and operation principles of two- and four-stroke engines); electrical systems (basic electricity and ignition, charging, and starting systems); and engine service (parts management; lubrication, cooling, fuel, governor, and exhaust systems; troubleshooting; and overhaul of fourand two-stroke cycle engines). Each unit contains some or all of the following: performance objectives, suggested activities for teachers and students, information sheets, transparency masters, assignment sheets, job sheets, tests, and answers to the tests. (MN)

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Reproductions supplied by EDRS are the best that can be made from the original document.

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SMALL ENGINE REPAIR

Two-Stroke and Four-Stroke Cycle

(Revised Edition of Comprehensive Small Engine Repair)

Written by

Bill Hires Mark Taylor Mike Bundy

Revised by Amon Herd

Edited by Jane Huston

Developed by

The Mid-America Vocational Curriculum Consortium

In cooperation with the Instructional Materials Laboratory University of Missouri-Columbia

Board of Directors

James Dasher, Arkansas, Chairman

Les Abel, Kansas, Vice Chairman

Wiley Lewis, Colorado, Parliamentarian

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John Van Ast, Iowa David Poston, Louisiana

U S DEPARTMENT Of EDUCATION Of e of Educational Research end Improvement

ED CATIONAL RESOURCES INFORMATION CENTER (ERIC)

This document has been reproduced as received from the person or Organization originating it 7 Minor changes have been made to improve reproduction duality

Points of ment do

view not

or opinions neCssanly

srteapterdesinenthtisodfOfiCciual

OERI position or policy

Harley Sohlichting, Missouri

Merle Rudebusch, Nebraska Ron Mehrer, North Dakota

Bob Patton, Oklahoma Larry Lyngstad, South Dakota

Pat Lindley, Texas

Greg Pierce, Executive Director

"PERMISSION TO REPRODUCE THIS MATERIAL IN MICROFICHE ONLY HAS BEEN GRANTED BY

TO THE EDUCATIONAL RESOURCES INFORMATION CENTER (ERIC)"

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1985 by the Mid-America Vocational Curriculum Col isortium, Inc.

All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from the publisher.

Printed in the United States of America by the Oklahoma State Department of Vocational-Technical Education Stillwater, Oklahoma 74074

Mid-America Vocational Curriculum Consortium, Inc. 1500 West Seventh Stillwater, Oklahoma 74074

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SMALL ENGINE REPAIR

Two-Stroke and Four-Stroke Cycle

TABLE OF CONTENTS

Section A Orientation

Unit I: Unit II: Unit III: Unit IV:

Safety Tools Fasteners Measuring

Section B Basic Small Engine Theory

Unit I: Unit II: Unit III: Unit IV:

Engine Identification and Inspection Basic Engine Principles and Design Principles of Operation Four-Stroke Cycle Principles of Operation Two-Stroke Cycle

Section C Electrical Systems

Unit I: Unit II: Unit III: Unit IV:

Basic Electricity Ignition Systems Charging Systems Starting Systems

Section D Engine Service

Unit I: Unit II: Unit III: Unit IV: Unit V: Unit VI: Unit VII: Unit VIII: Unit IX:

Parts Management Lubrication Systems Cooling Systems Fuel Systems Governor Systems Exhaust Systems Troubleshooting Overhaul Four-Stroke Cycle Engine Overhaul Two-Stroke Cycle Engine

SE-1-A SE-45-A SE-87-A SE-141-A

SE-1-B SE-25-B SE-75-B SE-109-B

SE-1-C 3E-59-C SE-129-C SE-161-C

SE-1-D SE-31-D SE-73-D SE-91-D SE-181-D SE-205-D SE-219-D SE-247-D SE-323-D

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FOREWORD

The Mid-America Vocational Curriculum Consortium (MAVCC) was organized for the purpose of developing instructional materials for its eleven member states. Priorities for developing MAVCC materials are determined annually based on the needs as identified by all member states. One of the priorities identified was the revision of Comprehensive Small Engine Repair. The success of this publication is due, in large part, to the capabilities of the personnel who worked with its original development and revision. The technical writers have numerous years of industry as well as teaching experience. Assisting them in their efforts were representatives of each of the member states who brought with them technical expertise and the experience related to the classroom and to the trade. To assure that the materials would parallel the industry environment and be accepted as a transportable basic teaching tool, organizations and industry representatives were involved in the developmental phases of the manual. Appreciation is extended to them for their valuable contributions to the manual. This publication is designed to assist teachers in improving instruction. As it is used, it is hoped that student performances will improve and that students will be better able to assume a role in thei. chosen occupation, small engine repair. Instructional materials in this publication are written in terms of student performance using measurable objectives. This is an innovative approach to teaching that accents and augments the teaching/learning process. Criterion referenced evaluatior instruments are provided for uniform measurement of student progress. In addition to evaluating recall information, teachers are encouraged to evaluate the other areas including process and product as indicated at the end of each instructional unit. It is the sincere belief of the MAVCC personnel and all those members who served on the committees that this publication will allow students to become better prepared and more effective members of the work force.

James Dasher, Chairman Board of Directors Mid-America Vocational

Curriculum Consortium

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PREFACE

If one stops to think about the many and varied uses of some type of small engine, it is easy to understand why educators have felt the need for iistructional materials to improve the quality of their training programs. It is not so much that there is a shortage of materials available, but that there are so many that no single instructor has the time to compile them for use. To this task, the Mid-America Vocational Curriculum Consortium developed the original Comprehensive Small Engine Repair manual which was released in 1977.

Utilization of these units of instruction has far exceeded anything which we had anticipated. Therefore, it seemed only natural that we should look at it on a regular basis in order to provide the book with the technical update needed to keep the user current. The result of this work is the revised publication, Small Engine Repair: Two-Stroke and Four-Stroke Cycle.

Be assured that teachers, industry representatives, and various others have been involved to make this publication usable, readable, and by all means basic enough to be easily used. It is hoped that once you have used these materials which address the information needed to be able to repair most two and four cycle engines, you will consider the various supplements which MAVCC has also developed. They include:

Outdoor Power Equipment Repair

Chain Saw Repair

Motorcycle Repair

Outboard Repair

Snowmobile Repair

Because we wish to continue the process of updating and revising, we invite you to notify us of any suggestions and/or corrections which you feel would increase the quality of this publication. A postage paid postcard has been enclosed for this purpose.

Best wishes for the successful use of Small Engine Repair.

Greg Pierce Executive Director Mid-America Vocational

Curriculum Consortium, Inc.

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ACKNOWLEDGEMENTS

Appreciation is extended to those individuals who contributed their time and ta;ent to the development and revision of Comprehensive Small Engine Repair

The contents of this publication were reviewed by:

Mid-America Vocational Curriculum Consortium Committee

Richard Carter, Small Engine Instructor Gordon Cooper Area Vo-Tech School Shawnee, Oklahoma

Joe Rush, Small Engine Instructor Iowa State Boys Training School Eldora, Iowa

Wayne Helbling, Owner Small Engine Repair Shop Mandan, North Dakota

James Sharpton, Curriculum Specialist Curriculum Instructional Materials Center State Dept. of Vo-Tech Stillwater, Oklahoma

Amon Herd, Associate Director Instructional Materials Laboratory University of Missouri Columbia, Missouri

The contents of this publication were originally planned by:

George Alexander Kent Boyer Thomas Cary Barton Elmore Arnold Garcia Jack Hardway Jim Hein Wayne Helbling Wilbur Hull Bob Jackson Larry Judd Jerome Kohl Thomas Owen James Schnaible Curtis Weston Alan Mikkilson

Lincoln, Nebraska Albuquerque, New Mexico Fargo, North Dakota Hot Springs, Arkansas Ponderosa, Nex Mexico

Shawnee, Oklahoma Greeley, Colorado Mandan, North Dakota Austin, Texas

Commerce, Texas Mesa, Arizona Lincoln, Nebraska

Topeka, Kansas Rapid City, South Dakota Columbia, Missouri Minot, North Dakota

Thanks are extended to Robert Robinson, State Director of Industrial Education, Jefferson City, Missouri and Glen Shinn, Teacher Educator from the University of Missouri at Columbia

for their assistance and input into the development of this publicatico.

Special thanks are extended to Amon Herd, Associate Director, Instructional Materials Laboratcry, University of Missouri-Columbia and his staff for their contributions toward the development of this book. Special appreciation goes to Briggs and Stratton Corporation and to Dan

Stapleton, graphic designer, and Paul Hughes, illustrator, with the Instructional Materials Lab-

oratory, University of Missouri-Columbia, for the illustrations and drawings used in this publication.

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Gratitude is also expressed to the businesses and indusl.ies who provided us with reference materials; to Jane Huston for her assistance in editing; to Tom Harriman and John Hanson for their assistance in checking technical content; to Kim Hale for his assistance in revising artwork; to Leslie Mathis for typing; and to the printing staff of the Oklahoma State Department of Vocational and Technical Education for printing this publication.

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