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CONTENTS
CHAPTER 1 GENERAL INFORMATION 1
ENGINE IDENTIFICATION 1
INTERPRETATION OF MODEL NUMBER 1
SHORT BLOCKS 2
FUEL 2
ENGINE OIL 3
TUNE-UP PROCEDURE 3
STORAGE 4
CHAPTER 2 AIR CLEANERS 5
GENERAL INFORMATION 5
OPERATION 5
COMPONENTS 5
TROUBLESHOOTING OR TESTING 5
SERVICE 6
DISASSEMBLY PROCEDURE 6
POLYURETHANE-TYPE FILTER ELEMENT 6
PAPER-TYPE FILTER ELEMENT 6
CHAPTER 3 CARBURETORS AND FUEL SYSTEMS 7
GENERAL INFORMATION 7
OPERATION 8
FUEL PRIMERS 8
IMPULSE FUEL PUMPS 9
FLOAT STYLE CARBURETORS 9
DIAPHRAGM (PRESSURE DIFFERENTIAL) CARBURETORS 9
COMPONENTS 10
CARBURETOR IDENTIFICATION 11
DUAL SYSTEM CARBURETORS 11
SERIES 1 CARBURETORS 11
SERIES 3 & 4 CARBURETORS 11
DIAPHRAGM CARBURETORS 11
SERIES 6 CARBURETORS 4-CYCLE 12
SERIES 8 12
SERIES 9 12
SERIES 10 (EMISSION) 12
NON-TECUMSEH CARBURETORS -- DELLORTO CARBURETOR 12
ENGINE TROUBLESHOOTING CHART 13
CARBURETION TROUBLESHOOTING CHART 14
TESTING 15
SERVICE 15
CARBURETOR PRE-SETS AND ADJUSTMENTS 15
FINAL ADJUSTMENTS (NON-EMISSION ENGINES) 16
NON-ADJUSTABLE CARBURETOR 16
DISASSEMBLY PROCEDURE 17
FLOAT STYLE CARBURETORS 17
DIAPHRAGM CARBURETORS 19
FLOAT ADJUSTING PROCEDURE 19
INSPECTION 20
ASSEMBLY 21
STANDARD SERVICE CARBURETORS 24
CHAPTER 4 GOVERNORS AND LINKAGE 26
GENERAL INFORMATION 26
OPERATION 26
INTERNAL COMPONENTS (VARIOUS STYLES) 26
TROUBLESHOOTING 26
ENGINE OVERSPEEDING 27
ENGINE SURGING 27
SERVICE 27
GOVERNOR ADJUSTMENT 27
GOVERNOR ADJUSTMENT PROCEDURE FOR SHORT BLOCK INSTALLATIONS 27
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GOVERNOR GEAR AND SHAFT SERVICE 28
SPEED CONTROLS AND LINKAGE 29
CHAPTER 5 REWIND STARTERS 35
GENERAL INFORMATION 35
OPERATION 35
COMPONENTS 35
SERVICE 35
ROPE SERVICE 35
RETAINER REPLACEMENT 36
STYLIZED REWIND STARTER (TVS, HM, TVM, TVXL), AND STAMPED STEEL STARTER (HM, VM, TVM, TVXL) 36
STYLIZED REWIND STARTER WITH PLASTIC RETAINER 37
STANDARD STAMPED STEEL AND CAST ALUMINUM STARTER (HM, VM) 38
VERTICAL PULL STARTER HORIZONTAL ENGAGEMENT TYPE 39
VERTICAL PULL STARTER VERTICAL ENGAGEMENT TYPE 40
CHAPTER 6 ELECTRICAL SYSTEMS 42
GENERAL INFORMATION 42
OPERATION 42
STARTING CIRCUIT AND ELECTRIC STARTERS 42
CHARGING CIRCUIT 42
CONVERTING ALTERNATING CURRENT TO DIRECT CURRENT 43
HALF WAVE RECTIFIER SINGLE DIODE 43
FULL WAVE RECTIFIER BRIDGE RECTIFIER 43
COMPONENTS 43
BATTERY 43
WIRING 43
ELECTRICAL TERMS 44
BASIC CHECKS 45
TROUBLESHOOTING ELECTRICAL STARTER CIRCUIT FLOW CHART 46
TROUBLESHOOTING ELECTRICAL CHARGING CIRCUIT FLOW CHART 47
TESTING PROCEDURE 48
STARTING CIRCUIT 48
CHARGING CIRCUIT 48
VOLTAGE REGULATIONS 56
LOW OIL SHUTDOWN SWITCHES 56
SERVICE 57
12 VOLT OR 120 VOLT ELECTRIC STARTERS WITH EXPOSED SHAFT 57
12 VOLT D.C. OR 120 VOLT A.C. ELECTRIC STARTERS WITH THE STARTER GEAR UNDER
THE CAP ASSEMBLY 57
INSPECTION 58
CHAPTER 7 FLYWHEEL BRAKE SYSTEMS 59
GENERAL INFORMATION 59
OPERATION 59
BOTTOM SURFACE SYSTEM 59
INSIDE EDGE SYSTEM 60
COMPONENTS 60
SERVICE 61
FLYWHEEL REMOVAL 61
BRAKE LEVER AND PAD 61
IGNITION GOUNDOUT TERMINAL 61
STARTER INTERLOCK SWITCH 62
CONTROL CABLE 62
BRAKE BRACKET REPLACEMENT 62
CHAPTER 8 IGNITION 63
GENERAL INFORMATION 63
OPERATION 63
SOLID STATE IGNITION SYSTEM (CDI) 63
MAGNETO IGNITION SYSTEM (POINTS) 63
IDENTIFICATION OF TECUMSEH IGNITION SYSTEMS 64
COMPONENTS 64
IGNITION TROUBLESHOOTING 66
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TESTING PROCEDURE 67
SPARK PLUG SERVICE 68
CONDITIONS CAUSING FREQUENT SPARK PLUG FOULING 68
IGNITION TIMING PROCEDURE 68
SERVICE TIPS 71
CHAPTER 9 INTERNAL ENGINE AND CYLINDER 72
GENERAL INFORMATION 72
OPERATION 72
4-CYCLE ENGINE THEORY 72
LUBRICATION SYSTEMS 73
COUNTERBALANCE SYSTEMS 73
COMPONENTS 74
ENGINE OPERATION PROBLEMS 75
TESTING 77
ENGINE KNOCKS 77
ENGINE OVERHEATS 77
SURGES OR RUNS UNEVENLY 77
ENGINE MISFIRES 77
ENGINE VIBRATES EXCESSIVELY 78
BREATHER PASSING OIL 78
EXCESSIVE OIL CONSUMPTION 78
LACKS POWER 78
DISASSEMBLY PROCEDURE 79
CYLINDERS 81
CYLINDER HEADS 82
PISTONS, RINGS AND CONNECTING RODS 82
CRANKSHAFTS AND CAMSHAFTS 84
VALVES 85
CRANKCASE BREATHERS 86
CYLINDER COVER, OIL SEAL, AND BEARING SERVICE 87
CRANKSHAFT BEARING SERVICE 88
COUNTERBALANCE SERVICE 89
FLYWHEEL
CHAPTER 10 ENGINE SPECIFICATIONS 90
FOUR CYCLE TORQUE SPECIFICATIONS 91
ENGINE SPECIFICATIONS STANDARD POINT IGNITION 93
SOLID STATE AND EXTERNAL IGNITION 97
CHAPTER 11 EDUCATION MATERIALS AND TOOLS 102
DECIMAL / FRACTION CONVERSIONS
SEARS CRAFTSMAN CROSS REFERENCE SUPPLEMENT INCLUDED IN BACK OF BOOK
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