DeWalt DW168F User manual
DW168F, DW177F, DW188F
Engines
SHOP MANUAL INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
If you have questions or comments, contact us.
Pour toute question ou tout commentaire, nous contacter.
Si tiene dudas o comentarios, contáctenos.
1-800-4-De
2
Contents
SERVICE
SAFETY INFORMATION ...................................................................................... 3
DEFINITIONS: SAFETY GUIDELINES ............................................................... 3
SERVICE INFORMATION .................................................................................... 3
SERIAL NUMBER ................................................................................................ 3
SPECIFICATIONS......................................................................................................... 4-6
DIMENSIONAL DRAWINGS......................................................................................... 7-9
P.T.O. DIMENSIONAL DRAWINGS............................................................................... 10
WIRING DIAGRAMS...................................................................................................... 11
MAINTENANCE STANDARDS.................................................................................12-13
TORQUE TABLE ............................................................................................................ 13
MAINTENANCE
MAINTENANCE CHART .................................................................................... 14
CLEANING AIR FLITER ELEMENT................................................................... 14
OIL .............................................................................................................. 14
SPARK PLUG ..................................................................................................... 15
SPARK ARRESTER ........................................................................................... 15
VALVE CLEARANCE.......................................................................................... 15
FUEL SYSTEM................................................................................................... 16
HIGH ALTITUDE OPERATION SERVICE .......................................................... 16
TROUBLESHOOTING
ENGINE .............................................................................................................. 17
STARTER/BATTERY........................................................................................... 19
COMPRESSION................................................................................................. 20
PERFORM TEST CHECKS
SPEED/GOVERNOR ADJUSTMENT................................................................. 21
IGNITION TEST.................................................................................................. 21
OIL ALERT TEST ............................................................................................... 21
START MECHANISM.......................................................................................... 21
COMPRESSION TEST....................................................................................... 22
BREAKDOWNS
AIR FILTER......................................................................................................... 23
AIR CLEANER.................................................................................................... 24
MUFFLER...................................................................................................... 25-27
RECOIL STARTER ............................................................................................. 28
ASSEMBLY .................................................................................................. 29
INSPECTION ............................................................................................... 30
CARBURETOR.............................................................................................. 31-33
CLEANING................................................................................................... 34
GAS TANK .......................................................................................................... 35
GOVERNOR LINKAGE....................................................................................... 36
GOVERNOR ....................................................................................................... 37
FLYWHEEL IGNITION........................................................................................ 38
ADJUSTMENT............................................................................................. 39
INSPECTION ............................................................................................... 39
STARTER MOTOR ..................................................................................................... 40
STARTER SOLENOID ........................................................................................ 41
BRUSH LENGTH................................................................................................ 41
ARMATURE ........................................................................................................ 41
BRUSHES - CONTINUITY CHECK.................................................................... 41
OVERRUNNING CLUTCH.................................................................................. 41
CYLINDER HEAD VALVES
6.5 HORSEPOWER............................................................................................ 42
9 AND 13 HORSEPOWER................................................................................. 43
INSPECTION ..........................................................................................44-46
GOVERNOR/LOW OIL SHUT-OFF ............................................................................ 47
COMPRESSION RELIEF ................................................................................... 48
INSPECTION...................................................................................................... 48
PISTON .............................................................................................................. 49
INSPECTION................................................................................................. 50-52
3
seRVICe
The definitions below describe the level of severity for each signal word. Please read
the manual and pay attention to these symbols.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury which, if not avoided,
may result in property damage.
DANGER: If the service being performed requires the engine to be running operate it
only outside in clean, dry, well-ventilated areas. Exhaust from the gasoline engine contains
deadly carbon monoxide, which is odorless and toxic.
WARNING: Risk of explosion.
Spilled gasoline and it’s vapors can become ignited
from sparks from smoking products, electrical arcing, exhaust, flame, gases and hot engine
components such as the muffler.
Wipe any fuel spillage from engine.
WARNING: The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm. Wash
hands after handling.
WARNING: Risk of unsafe operation. Always wear gloves and c
ertified safety equipment:
ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields.
WARNING: Stop engine and remove the spark plug wire before servicing.
WARNING: Hot surfaces. Risk of burn. Engine (especially the muffler) and surrounding
parts are very hot, do not touch. Allow engine to cool before servicing.
WARNING:If protective covers must be removed during servicing
keep away from moving
parts and wires.
• Alwaysuseidenticalreplacementparts.
• Use tools designed for small engine repair, using incorrect tools could damage the
engine.
• Replaceallgaskets,O-rings,etc.whenreassembling.
• Cleanallparts innon flammablesolvent. Lubricate anyslidingsurfacesbefore reas-
sembly.
Theengineserialnumberisneededwhenorderingpartsandmakinginquiries.
SERIAL
NUMBER
y e a r
m o n t h e n g i n e n u m b e r
m o d e l
n u m b e r
4
speCIfICatIons
APPLICATION GENERATOR
MODEL DW168F-2F DW177FD-F DW188FD-F
TYPE SingleCylinder,4Stroke,OHV,SparkIgnition,AirCooled
MAX. HORSEPOWER * 6.5 hp 9 hp 13 hp
TOTAL DISPLACEMENT 196 cc 270 cc 389 cc
BORE AND STROKE 68 x 54 mm 77 x 58 mm 88 x 64 mm
RATED SPEED 3600 rpm 3600rpm 3600 rpm
MAX NO LOAD SPEED 3750 rpm. 3750 rpm. 3750 rpm.
IDLE SPEED no idle control 2750 rpm. 2,750 rpm.
DRY WEIGHT 30.9lbs.(14kg) 57.6lbs.(26.15kg) 68.3lbs.(31kg)
DIMENSIONS (L X W X H) IN (mm)15.2x13.1x10.4(385x335x265) 17.3x16.5x12.2(440x420x310) 16.1x19.3x12.8(410x490x325)
MOUNTING FLANGE Flange A per SAE J609a Flange B per SAE J609a Flange B per SAE J609a
COMPRESSION RATIO 8.5 to 1 8.2 to 1 8.2 to 1
IGNITION SYSTEM Transistorized Magneto Ignition Transistorized Magneto Ignition Transistorized Magneto Ignition
SPARK PLUG NGK(BP6ES,BPR6ES) NGK(BP6ES,BPR6ES) NGK(BP6ES,BPR6ES)
CARBURETOR Float type, adjustable idle speed Float type with a fuel-shutoff solenoid,
Adjustable idle speed Float type with a fuel-shutoff solenoid,
Adjustable idle speed
AIR CLEANER StandardSemi-dry(foam),sidemount StandardSemi-dry(foam),sidemount StandardSemi-dry(foam),sidemount
LUBRICATING SYSTEM Splash Splash Splash
OIL CAPACITY 0.55qt.(520mL) 1.06qt.(1000mL) 1.11qt.(1100mL)
STARTING SYSTEM Recoil,2o’clockposition 18VElectricmotorandRecoil2o’clock
position 18 V Electric motor and Recoil 2 o’clock
position
STOPPING SYSTEM Ignition primary circuit ground Ignition primary circuit ground Ignition primary circuit ground
FUEL USED Regulargasoline(86octane) Regulargasoline(86octane) Regulargasoline(86octane)
P.T.O. SHAFT ROTATION Counterclockwise(fromP.T.O.side) Counterclockwise(fromP.T.O.side) Counterclockwise(fromP.T.O.side)
CRANKSHAFT PTO Ext. #5 per SAE J609a
(2.25"taperperfoot)
Ext.#6perSAEJ609a(2.25"taperperfoot)
GOVERNOR Mechanical, centrifugal flyweight type, 60 Hz fixed speed
FUEL LINE Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER Eitheringastankorinfuelline(earliermodels)
ON/OFF SWITCH Without Without Without
*Grosshorsepower(HP).Thishorsepowerratingrepresentsthemaximumoutputunderlaboratoryconditionsat3600RPMinaccordancewithSAE(SocietyofAutomotiveEngineers)
J1995 and should be used for comparison purposes only. Actual engine output will be lower and will vary depending on the application, speed and other variables including altitude
and temperature.
5
APPLICATION PRESSURE WASHERS
MODEL DW168F-2H DW177F-H DW188F-H
TYPE SingleCylinder,4Stroke,OHV,SparkIgnition,AirCooled
MAX. HORSEPOWER* 6.5 hp 9 hp 13 hp
TOTAL DISPLACEMENT 196 cc 270 cc 389 cc
BORE AND STROKE 68 x 54 mm 77 x 58 mm 88 x 64 mm
RATED SPEED 3400 rpm 3400 rpm 3600 rpm
MAX NO LOAD SPEED 3700 rpm 3700 rpm 3800 rpm
IDLE SPEED no idle control 2750 rpm 2750 rpm
DRY WEIGHT 37.5lbs.(17kg) 57.3lbs.(26kg) 70.5lbs.(32kg)
DIMENSIONS (L X W X H) IN (mm)15.7x13.0x13.4(400x330x340) 16.9x15.6x16.1(430x395x410) 18.7x17.3x17.1(475x440x435)
MOUNTING FLANGE Flange A per SAE J609a Flange B per SAE J609a Flange B per SAE J609a
COMPRESSION RATIO 8.5 to 1 8.2 to 1 8.2 to 1
IGNITION SYSTEM Transistorized Magneto Ignition Transistorized Magneto Ignition Transistorized Magneto Ignition
SPARK PLUG NGK(BP6ES,BPR6ES) NGK(BP6ES,BPR6ES) NGK(BP6ES,BPR6ES)
CARBURETOR Float type, adjustable idle speed Float type, adjustable idle speed Float type, adjustable idle speed
AIR CLEANER Standard Semi-dry (foam+paper), high
mount StandardSemi-dry(foam+paper),highmount StandardSemi-dry(foam+paper),highmount
LUBRICATING SYSTEM Splash Splash Splash
OIL CAPACITY 0.55qt.(520mL) 1.06qt(1000mL) 1.11qt(1100mL)
STARTING SYSTEM Recoil,10o'clockposition Recoil,10o'clockposition Recoil,10o'clockposition/Electricstart
STOPPING SYSTEM Ignition primary circuit ground Ignition primary circuit ground Ignition primary circuit ground
FUEL USED Regulargasoline(86octane,upto10%ethanol)
FUEL TANK CAPACITY 0.95gal(3.6L) 1.56gal(5.9L) 1.93gal(7.3L)
P.T.O. SHAFT ROTATION Counterclockwise(fromP.T.O.side) Counterclockwise(fromP.T.O.side) Counterclockwise(fromP.T.O.side)
CRANKSHAFT PTO Ext.#3perSAEJ609a(3/4"keywayPTO) Ext.#4perSAEJ609a(1"keywayPTO) Ext.#4perSAEJ609a(1"keywayPTO)
GOVERNOR Mechanical, centrifugal flyweight type, variable speed
FUEL LINE Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER Ingastankonly
ON/OFF SWITCH Equippedonrecoilbase Equippedonrecoilbase Equippedonrecoilbase
*Grosshorsepower(HP).Thishorsepowerratingrepresentsthemaximumoutputunderlaboratoryconditionsat3600RPMinaccordancewithSAE(SocietyofAutomotiveEngineers)
J1995 and should be used for comparison purposes only. Actual engine output will be lower and will vary depending on the application, speed and other variables including altitude
and temperature.
6
APPLICATION COMPRESSOR
MODEL DW168F-2E DW177FD-E
TYPE SingleCylinder,4Stroke,OHV,SparkIgnition,AirCooled
MAX. HORSEPOWER* 6.5 hp 9 hp
TOTAL DISPLACEMENT 196 cc 270 cc
BORE AND STROKE 68 x 54 mm 77 x 58 mm
RATED SPEED 3400 rpm 3400 rpm
MAX NO LOAD SPEED 3600 rpm 3600 rpm
IDLE SPEED 2400 rpm 2400 rpm
DRY WEIGHT 33lbs.(15kg) 57.3lbs.(26kg)
DIMENSIONS (L X W X H) IN (mm)15.7x13.0x13.4(400x330x340) 16.9x15.6x16.1(430x395x410)
MOUNTING FLANGE Flange A per SAE J609a Flange B per SAE J609a
COMPRESSION RATIO 8.5 to 1 8.2 to 1
IGNITION SYSTEM Transistorized Magneto Ignition Transistorized Magneto Ignition
SPARK PLUG NGK(BP6ES,BPR6ES) NGK(BP6ES,BPR6ES)
CARBURETOR Float type, adjustable idle speed Float type, adjustable idle speed
AIR CLEANER StandardSemi-dry(foam+paper),highmount StandardSemi-dry(foam+paper),highmount
LUBRICATING SYSTEM Splash Splash
OIL CAPACITY .507qt(480mL) 1.06qt(1000mL)
STARTING SYSTEM Recoil,10o'clockposition 18 V Electric motor and
recoilstarter10o'clockposition
STOPPING SYSTEM Ignition primary circuit ground Ignition primary circuit ground
FUEL USED Regulargasoline(86octane,upto10%ethanol)
FUEL TANK CAPACITY 0.95gal(3.6L) 1.56gal(5.9L)
P.T.O. SHAFT ROTATION Counterclockwise(fromP.T.O.side) Counterclockwise(fromP.T.O.side)
CRANKSHAFT PTO Ext.#3perSAEJ609a(3/4"keywayPTO) Ext.#4perSAEJ609a(1"keywayPTO)
GOVERNOR Mechanical, centrifugal flyweight type, variable speed
FUEL LINE Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER Ingastankonly
ON/OFF SWITCH Equippedonrecoilbase Equippedonrecoilbase
*Grosshorsepower(HP).Thishorsepowerratingrepresentsthemaximumoutputunderlaboratoryconditionsat3600RPMinaccordancewithSAE
(SocietyofAutomotiveEngineers)J1995andshouldbeusedforcomparisonpurposesonly.Actualengineoutputwillbelowerandwillvarydepending
on the application, speed and other variables including altitude and temperature.
7
8
9
10
NOTE: All dimensions in mm unless noted otherwise
6.5 HP
9-13 HP
6.5 HP
.313-24
19.02
9-13 HP
25.4
.313-24
11
Bl
Bl/W
W
BAT
ST
IG
M
Y/G Y/G E
DIODE
COMBINATION SWITCH
COMBINATION WIRE
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
STARTER
BATTERY
CHARGE
COIL
Br
Br
R
Y Y
Bl
Bl
Bl
Y
W
W
Bl
Bl/W
G
RedR
Y/ G
W
Yellow Green
White
Bl
Y
Br
Bl/W
Black
Yellow
Brown
Black White
IG E ST BAT
OFF
ON
START
ENGINE SWITCH
FUSE 5A
Bl IG
Y/G Y/G E
COMBINATION SWITCH
COMBINATION WIRE
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
Y Y
Bl
Bl
Bl
Y
Bl
Bl
Y
Black
Yellow IG E ST BAT
OFF
ON
ENGINE SWITCH
Y/G Yellow /Green
G
Green
Bl
Bl/W
W
BAT
ST
IG
M
Y/G Y/G E
DIODE
COMBINATION SWITCH
COMBINATION WIRE
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
STARTER
BATTERY
CHARGE
COIL
Br
Br
R
Y Y
Bl
Bl
Bl
Y
W
W
Bl
Bl/W
G
RedR
Y/ G
W
Yellow Green
White
Bl
Y
Br
Bl/W
Black
Yellow
Brown
Black White
IG E ST BAT
OFF
ON
START
ENGINE SWITCH
FUSE 5A
Bl IG
Y/G Y/G E
COMBINATION SWITCH
COMBINATION WIRE
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
Y Y
Bl
Bl
Bl
Y
Bl
Bl
Y
Black
Yellow IG E ST BAT
OFF
ON
ENGINE SWITCH
Y/G Yellow /Green
G
Green
12
MaIntenanCe stanDaRDs
PART ITEM
DW168 DW177 DW188
*STANDARD (MM) *SERVICE LIMIT
(MM) *STANDARD (MM) *SERVICE LIMIT
(MM) *STANDARD (MM) *SERVICE
LIMIT(MM)
ENGINE Cylinder compression 50 – 90 psi -60 – 100 psi -60 – 100 psi -
CYLINDER Sleeve I.D. 68.015~68.025 68.156 77.02~77.03 77.179 88.015~88.025 88.195
CYLINDER HEAD Warpage 00.10 00.10 00.10
PISTON Skirt O.D. 67.975~67.985 67.85 76.970~76.980 76.85 87.970~87.980 87.85
Piston-to-cylinder
clearance 0.030~0.050 0.12 0.040~0.060 0.1 0.045~0.065 0.1
Piston-to-piston pin
bore clearance 0.004~0.016 0.08 0.004~0.016 0.08 0.004~0.016 0.08
Piston Pin bore I.D. 18.002~18.008 18.042 18.002~18.008 18.042 20.002~20.008 20.042
Pin O.D. 17.992~17.998 17.94 17.992~17.998 17.95 19.992~19.998 19.94
PISTON RINGS Ring side clearance
Ring,Top 0.08~0.12 0.10 0.02~0.06 0.15 0.02~0.06 0.15
Ring, Compression 0.07~0.11 0.10 0.02~0.06 0.15 0.02~0.06 0.15
Ring Assy, Oil 0.02~0.16 0.15 0.02~0.16 0.15 0.04~0.19 0.15
Ring end gap 0.15~0.35 1.0 0.20~0.35 1.0 0.20~0.40 1.0
Ring width
Ring,Top 1.420~1.440 1.3 1.97~1.99 1.75 1.97~1.99 1.75
Ring, Compression 1.420~1.440 1.3 1.97~1.99 1.75 1.97~1.99 1.75
Ring Assy, Oil 2.37~2.49 2.3 2.77~2.79 2.5 2.65~2.78 2.5
CONNECTING ROD Small end I.D. 18.011~18.022 18.06 18.011~18.022 18.06 20.011~20.022 20.06
Big end I.D. 30.02~30.03 30.06 33.02~33.03 33.06 36.02~36.03 36.06
Big end oil clearance 0.030~0.055 0.1 0.029~0.055 0.1 0.029~0.064 0.1
Big end side clearance 0.95~1.45 1.85 0.55~1.25 1.65 0.55~1.25 1.65
CRANKSHAFT Crankshaft O.D. 29.975~29.990 29.92 32.975~32.991 32.92 35.966~35.991 35.92
VALVES Valve clearance
IN 0.10~0.15 -0.10~0.15 -0.10~0.15 -
EX 0.20~0.25 -0.20~0.25 -0.20~0.25 -
Stem O.D.
IN 5.468~5.48 5.318 6.568~6.580 6.44 6.568~6.580 6.44
EX 5.418~5.44 5.275 6.545~6.560 6.40 6.545~6.560 6.40
Guide I.D. IN/EX 5.500~5.512 5.572 6.600~6.615 6.66 6.600~6.615 6.66
Stem clearance
IN 0.020~0.044 0.1 0.020~0.070 0.11 0.020~0.070 0.11
EX 0.060~0.084 0.12 0.040~0.070 0.15 0.020~0.070 0.15
Seat width 0.7~0.9 2.0 0.8~1.0 2.0 0.7~0.9 2.0
Spring free length 30~31 29.0 38.5~39.5 37.5 38.5~39.5 37.5
* unless otherwise noted
13
PART ITEM
DW168 DW177 DW188
*STANDARD (MM) *SERVICE LIMIT
(MM) *STANDARD (MM) *SERVICE LIMIT
(MM) *STANDARD (MM) *SERVICE
LIMIT(MM)
CAMSHAFT CAM height
IN 27.700 27.45 31.716 31.35 32.585 32.25
EX 27.747 27.50 31.754 31.35 32.068 31.80
Camshaft O.D. 13.966~13.984 13.916 15.966~15.984 15.92 15.966~15.984 15.92
CRANKCASE COVER Camshaft holder I.D. 14.000~14.018 14.05 16.000~16.018 16.05 16.000~16.018 16.05
SPARK PLUG Gap 0.7 ~ 0.8 -0.7 ~ 0.8 -0.7 ~ 0.8 -
SPARK PLUG BOOT Resistance 10k 7.5–10.5k 10k 7.5–10.5k 10k 7.5–10.5k
IGNITION COIL Resistance
Primary 1.3Ω±0.2Ω-1.3Ω±0.2Ω-1.3Ω±0.2Ω-
Secondary 6.4kΩ±1kΩ-6.4kΩ±1kΩ-6.4kΩ±1kΩ-
Air gap 0.4±0.2 -0.4±0.2 -0.4±0.2 -
STARTER MOTOR Brush length 10 5.5 10 5.5 10 5.5
* unless otherwise noted
toRQUe taBLe
ITEM TORQUE
168 (N– M) 177/188 (N– M) 168 (FT–LB) 177/188 (FT–LB)
CONNECTING ROD BOLT 12–14 14–16 10 12
CYLINDER HEAD BOLT 32–35 50–55 26 41
FLYWHEEL NUT 80–90 90–115 66 85
ROCKER ARM PIVOT BOLT 28–32 28–32 24 24
CRANKCASE COVER BOLT 27–30 27–30 22 22
OIL LEVEL SWITCH JOINT NUT 6–8 6–8 6 6
FUEL FILTER, JOIN NUT 6–8 6–8 6 6
MUFFLER MOUNTING NUT 27–30 27–30 22 22
AIR CLEANER WING NUT 8–12 8–12 9 9
OIL DRAIN BOLT 20–25 25–30 18 18
FUEL TANK BOLT, NUT 8–10 8–10 7 7
AIR CLEANER MOUNTING NUT 1–2 1–2 1 1
UNSPECIFIED TORQUE VALUES
BOLT, NUT 5–7 5–7 5 5
6MM BOLT, NUT 8–12 8–12 9 9
8MM BOLT, NUT 24–28 24–28 21 21
10MM BOLT, NUT 50–55 50–55 41 41
GOVERNOR ARM RETAINER BOLT 7–9 7–9 5.2–6.6 5.2–6.6
14
MaIntenanCe
Procedure Daily 50 hours
or weekly
(whichever
comes first)
100 hours 150 hours
or monthly
(whichever
comes first)
500 Hours
Clean engine exterior
X
Cleanbatterypackand
charger
X
Checkoillevel
X
Change oil *
X(1)
Clean air filter
X(1)
Cleansparkplugs
X
Checkfuelline,hoseclamps
andfueltank
X
Oilleakinspection
X
Sparkarrestor
X
Sediment cup
X
Clean inline fuel filter
X
Checkforunusual
noise/vibration
X
Checkandadjustvalve
clearance(.15mmintake,
.2mmexhaust)
X
Prepare unit for Storage
Prepare unit for storage if it is to remain idle for more then 30
days
* The engine oil must be changed after the first 20 hours or operation. Thereafter change oil every
100 hours of operation or monthly, whichever comes first.
(1)Performmorefrequentlyindustyorhumidconditions
SPARK PLUG CONDITION CHECK
• Removethesparkplugforinspection
• AlwaysuserecommendedplugseeSpecifications
• Setgaptospecification,seeSpark Plug under Maintenance Standards.
1. Normal Plug – Slightly rounded electrodes with light coat of ashy brown deposits indi-
cate normal wear and a healthy engine.
2. Oil Fouling –Wetoilyfilmwillpreventtheplugfromsparking.Thisconditionsignals
worn valves or piston rings. This condition can be caused by running the engine in
thechokeposition.Checkvalvesandpistonrings,overhaulifneeded.Replacespark
plug.
3. Carbon Fouling–Blackdrysootcoveringtheelectrodesindicatesincompletecom-
bustion.Thiscanbearesultofweakignitionorarichmixture.
a.Checkcarburetoradjustment,adjustspeedifneeded.
b.Checkairfilter,cleanifneeded.
4. Gap Bridging – A combustion particle lodged between the electrodes carries current
across the gap. This does not normally signal engine problems elsewhere.
5. Whitened Electrodes – This is evidence combustion is too hot and there is overheat-
ing. This can result from too lean fuel mixture.
a.Make sure spark plug is correct type, see Spark Plug under Maintenance
Standards.
b. Ignition timing malfunction. Set ignition air coil gap, see the Flywheel Ignition
Adjustment section.
6. Excessive Wear – Plug worn to the point of having encrusted deposits and thin
rounded out electrodes. Replace plug.
WARNING: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do not
touch. Allow engine to cool prior to servicing.
A dirty air cleaner will restrict airflow to the carburetor. To prevent carburetor malfunction,
service the air filter regularly. Service more frequently when operating the generator in
extremely dusty areas.
WARNING: Using gasoline or flammable solvent to clean the filter element can cause a
fire or explosion.
WARNING: Risk of fire. Do not operate without air filter.
TO CLEAN THE ELEMENTS
(DW168F-2E, DW177F-E, DW168F-2H, DW177F-H)
1. Remove the wing nut and the air filter cover.
2. Remove the second wing nut and remove the filter.
3. Remove the foam-type pre-filter from the filter.
4. Inspect foam and paper elements. Replace them if damaged.
TO CLEAN THE ELEMENTS
Foam element: Wash element in warm, soapy
water. Then saturate it in clean engine oil.
Squeezetheelementtoremoveexcessoil.
Paper element: Clean element by tapping
gently to remove dust. Use compressed air to
blow off dust.
WARNING: When using compressed air, user
always must wear eye protection that conforms to
ANSI Z87.1. (CAN/CSA Z94.3).
Never use oil. Always blow the element from the
inside.Ifusingcompressedairkeeptheairpressurelessthan30psi.
Place the foam pre-filter over the paper element and reinstall it onto the engine.
(DW168F-2F, DW177FD-F, DW188F)
1. Unsnap the air filter cover clips and remove
the air cleaner cover.
2. Remove the elements from air filter.
3. Wash elements in warm soapy water and
rinse thoroughly. Allow the elements to dry
thoroughly.
4.Soak the elements in clean engine oil and
squeezeouttheexcessoil.NOTE: Theenginewillsmokeduringinitialstart-upiftoo
much oil is left in the elements.
5. Reinstall the air filter elements and snap air filter cover in place.
WARNING: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do
not touch. Allow engine to cool prior to servicing.
TO CHECK OIL
1. Place unit on a flat level surface.
15
2.Removeoilfill/dipstickandwipeclean.
3.Reinsertoilfill/dipstickfullyintooilfillport PATTERNS
PATTERNS
and tighten. Allow oil to collect on the
dipstickforafewseconds.
4.Removeoilfill/dipstick toreadoillevel. If
oil falls below top of pattern on dipstick,
add oil.
NOTE: When filling the crankcase, allow
theoiltoflowveryslowly.Iftheoilisaddedtooquickly,itwilloverflowandappeartobe
full.
5.Replacedipstickandtightensecurely.
TO CHANGE OIL
NOTE: Engine oil contains substances that are regulated and must be disposed of in
accordance with local, state, provincial and federal laws and regulations.
1.Disconnectsparkplugwire.
2.Locateasuitablecontainerunderoildrainplug(Q9).
3.Removetheoilfill/dipstick(J9)fromcrankcase.
J9
Q9
4. Remove the oil drain plug.
5. Allow ample time for all oil to drain out.
6. Install the oil drain plug and tighten securely.
7. Fill with recommended oil. Refer to the Viscosity-
Ambient Temperature Chart for recommended oil.
NOTE: Synthetic oil is NOT recommended.
˚F -20 0 20 40 60 80 100
˚C -28.8 -17.7 -6.6 4.4 15.5 26.6 37.7
5W-30
10W-30
30
VISCOSITY-AMBIENT TEMPERATURE CHART
8.Replacedipstickandtightensecurely.
9.Reconnectsparkplugwire.
10. Dispose of oil according to local, state, provincial and federal laws and regulations.
Userecommendedsparkplugs,seeSparkPlugCrossReferenceforcorrectsparkplug.
Toensureproperengineoperation,thesparkplugmustbeproperly gappedandfreeof
deposits.
WARNING: If the engine has been running, the muffler and spark plug will be very hot.
To reduce the risk of injury, allow cooling before proceeding.
WARNING:
Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA
Z94.3) with side shields.
SPARK PLUG CROSS REFERENCE
BRAND PART NUMBER
NGK BP6ES, BPR6ES
AUTOLITE 63
AC DELCO R41XL,R42XLS, R43FS,R43XL, R43XLS, R44XLS, R45XLS
CHAMPION RJ14YC
1.Removethesparkplugboot.
2.Cleananydirtfromaroundthesparkplugbase.
3.Useasparkplugwrench(notsupplied)toremovethesparkplug.
4.Visuallyinspectthesparkplug.Replaceitiftheinsulatoriscrackedorchipped.Clean
thesparkplugwithawirebrushifitisgoingtobereused.
5. Measure the plug gap with the feeler gauge. Correct as necessary by
carefully bending the side electrode. The gap should be: 0.70-0.80 mm
(0.028-0.031in).
6.Makesurethespark plugwasherisingoodcondition.Thread thespark
plug in by hand to prevent cross threading.
7.Afterthesparkplugisseated,tightenwithasparkplugwrenchtocompress
thewasher.Ifinstallinganewsparkplug,tightenthesparkplug1/2turn
after it seats to compress the washer. If reinstalling a used spark plug,
tighten1/8–1/4turnafterthesparkplugseatstocompressthewasher.Do
not overtighten.
NOTE: The spark plug must be securely tightened. An improperly tightened spark plug
canbecomeveryhotandcoulddamagetheengine.Neverusesparkplugswhichhavean
improperheatrange.Useonlytherecommendedsparkplugsorequivalent.
WARNING: DO NOT operate engine without muffler cover or spark arrestor.
WARNING: If the engine has been running, the muffler will be very hot. To reduce the
risk of injury, allow engine to cool before proceeding.
WARNING:
Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA
Z94.3) with side shields when removing carbon deposits.
NOTE:Thesparkarrestermustbeservicedevery100hourstomaintainitsefficiency.
R12
CC
1.Removethesparkarrestorscrews(R12)andremovethesparkarrestor(CC).
2.Usebrushtoremovecarbondepositsfromthesparkarresterscreen.Inspectthespark
arresterscreenforholesortears.Replacethesparkarresterifnecessary.
WARNING: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do not
touch. Allow engine to cool prior to servicing.
NOTE: Enginemustbecoldtocheckthevalveclearance.
1. Remove the cylinder head cover.
16
2.Set the piston in the top dead center position of its compression stroke.
NOTE:bothrockerarms(P7,K8) will have the largest gap with each valve (U7,V7,P8,Q8).
3.Insertafeelergaugebetweentherockerarmandvalvetomeasurevalveclearance.
R7, M8
S7, N8
P7, K8
R10
U7, V7, P8, Q8
Standard
(mm)
Service
Limit
(mm)
VALVE
CLEARANCE
IN 0.10~0.15 -
EX 0.20~0.25 -
4.Adjust rocker armpivot(R7,M8) by looseningtherocker armlocknut (S7,N8)and
adjustthepivotlocknut(R10)untiltheclearanceiscorrect.Whenclearanceiscorrect
tightentherockerarmlocknut.
5.Checktheclearanceagainwithnutstightened.
IMPORTANT: If the engine does not start, is hard to start or is performing poorly ensure
fuelsystemiscleanandfueltankcontainsfreshgasolinebeforetroubleshooting.
WARNING: Risk of explosion.
Spilled gasoline and it’s vapors can become ignited from
sparks from smoking products, electrical arcing, exhaust, flame, gases and hot engine com-
ponents such as the muffler.
Make sure there are no sources of ignition, such as smoking
products near servicing location. Wipe any fuel spillage from engine.
WARNING: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do
not touch. Allow engine to cool prior to servicing.
DRAIN CARBURETOR
1.Placethefuelshutoffvalve(A,ifequipped) A
B2, K2,
F3
in the closed (horizontal) position as
shown.
2. Place an
OSHA-approved container
suitable for fuel under the carburetor
bowl.
NOTE:
Using a funnel will allow
the fuel to flow into the container with
less spillage.
3. Remove the carburetor bowl drain bolt (B2,K2,F3).
4. Fuel will drain from carburetor bowl.
5. Remove the carburetor bowl and clean it in nonflammable
or high flash point solvent.
CLEANING DEBRIS SCREEN (IF EQUIPPED)
1. Remove fuel cap.
2. Remove debris screen.
3.
Clean debris screen. Use compressed air to blow off
debris.
WARNING: When using compressed air, user always must wear eye protection that
conforms to ANSI Z87.1. (CAN/CSA Z94.3).
FUEL SEDIMENT CUP CLEANING (IF EQUIPPED)
1.Place the fuel shut off valve (A, if equipped) in the closed (horizontal) position as
shown.
A
B
A
C
D
A
2.Removethesedimentcup(D)fromthefuelvalveonthebottomofthetank.
3.Cleanthesedimentcup,screen(C)andO-ring(B)innonflammableorhighflashpoint
solvent.
4.Drainandremovegastank,flushuntilclean.
5.Replaceorcleanfuelfilter.Fuelfiltermaybeinsidegastankwherefuelexitsoran
in line fuel filter may be on the fuel line. See
Service Bulletin
(SB06109)
REASSEMBLE
1. Reinstall O-ring, sediment cup, carburetor bowl, carburetor bowl drain bolt, debris
screen and fuel cap
2.Replaceinlinefilter(ifequipped).
3.Turnthefuelshut-offvalve(A,ifequipped)totheopen(vertical)positionandcheckfor
fuelleaks.
High Altitude Modification should only be made to engines operating at above
5,000ft.(1524m)foranextendedperiodasmanufacturedenginesaresuitableforopera-
tionupto5,000ft.(1524m)abovesealevel.NOTE: Reset to factory setting immediately
whenengineismovedtooperatebelow5,000ft.(1524m).Toreset,replacehighaltitude
main jet with low altitude main jet. If the engine is used at low altitudes after a carburetor
modification, the carburetor may cause the engine to overheat and result in serious engine
damage.
1. Set the fuel valve in the off position. Remove the carburetor drain bolt (B2,K2,F3) from
the carburetor bowl (E3,J2) and allow fuel to drain into a suitable container.
2. Remove the fuel cutoff solenoid (D3, if equipped) from the carburetor bowl using a
Phillips screwdriver.
B2,
K2, F3 V3, L2
X2
D3 I4
E3, J2
3. Remove the carburetor bowl (E3,J2)andretainingbolt(V3,L2)witha14mmsocket.
17
4. Remove the main jet (I4) and e-tube (X2),with a flat head screwdriver.
5. Replace the main jet with the main jet specified for high altitude service. This high
altitude main jet comes in a high altitude carburetor adjustment package with new
carburetor bowl and fuel shut-off solenoid O-rings.
6. Reassemble carburetor in reverse order. Replace carburetor bowl O-ring and solenoid
O-ring if necessary.
7.Turnonfuelvalveandinspectforfuelleak.
NOTE: Makesuretheenginehasagoodgroundbeforetroubleshooting.
STARTING PROBLEM
PROBLEM POSSIBLE CAUSE SOLUTION
Engine will
not start,
stay running
or only runs
whenchoked
1. On/Off switch in
OFF position Place On/Off switch in ON position.
2. Low or no fuel Add fuel.
3. Fuel valve in
OFF position Place fuel valve in ON position.
4. Low oil or no oil Add oil.
5. Chokeinwrong
position Forcoldstarts,chokemustbeinCLOSEDposition.
Onpullringchokes,pullringallthewayout.
Onleverchokes,moveleverallthewayindirection
of arrow.
If in doubt, remove air cleaner and visually verify
thatchokeplateisclosedandcompletelyblocking
entrance.
6. Checkfuel
condition Ensure fuel is clean and fresh. If problem continues
refer to Fuel System under Maintenance.
7. Sparkplugwire
(is loose on plug Ensurethatsparkplugwireistightlyconnectedto
sparkplug
8. Low oil shutdown
(LOS)
Makesureoillevelisuptofullmark,refertoOil
under Maintenance. If problem continues refer to
Inspection/Oil Level Switch under Governor/Low
Oil Shutoff.
9. Checkforspark Perform Ignition Test under Perform Test Checks.
10.Examinespark
plug condition Perform Spark Plug Condition Check under
Maintenance.
11.Improper valve
clearance Reset valve clearances (see Maintenance
Standards)
12.Cap not venting After performing Fuel Check, if problem still contin-
ues:
Run engine with gas cap loose or removed to see
if engine still stalls. If it does not stall, gas cap is
not venting. NOTE: California models of generators
and pressure washers have non-venting gas caps
for emissions. Venting air is supplied from carbon
canister.
If gas cap is not venting properly the fuel filter
couldbedirtyorblocked,sedimentcupfullof
debris or fuel valve could be clogged.
PROBLEM POSSIBLE CAUSE SOLUTION
Engine will
not start,
stay running
or only runs
whenchoked
(continued)
13.Gastank/fuel
filter does not
allow flow of gas
because it is dirty
orblocked
Thereare2typesofgastank/fuelfilterdesigns
used:
Onerequiresanin-linefilterlocatedinthefuelline
between the fuel valve and the carburetor. The other
has a tube shaped filter above the fuel valve inside
thegastank.Thisseconddesigndoesnotrequire
an in-line filter.
Tocheckthegastank/fuelfilter,placefuelvalve
leverintheclosed(horizontal)position,removefuel
line from fuel valve and place fuel valve lever in the
on(vertical)positiontocheckflowtoacatchpan.
If there is flow and the engine has only the internal
tankfilter,thefilterisnottheproblem.
If there is no flow, , place fuel valve lever in the
closed(horizontal)position,removefuelvalveto
accesstubefilter,cleanitandreassemble.Tocheck
in line filter disconnect fuel line from carburetor and
placefuelvalveleverintheon(vertical)position
tocheckforfuelflow.Ifnofloworweak,replace
fuel filter. See Service Bulletin SB06109 regarding
filters. NOTE: Air Compressors and Pressure
Washers have a fuel valve in the carburetor. On
these remove drain screw on carburetor bowl to
verify flow.
14.Sediment cup
full of debris (fuel
valve)
Placethefuelvalveleverintheclosed(horizontal)
position, remove fuel line from fuel valve and
placefuelvalveleverintheon(vertical)positionto
checkflowtoacatchpan.Ifnofloworweak,clean
sediment cup, refer to Fuel System to clean the
sediment cup. With sediment cup removed from fuel
valve, place fuel valve lever in the ON position to
verify flow from cup area into a catch pan. This will
confirm fuel valve itself is not clogged.
15.Fuel valve
clogged Removevalvefromgeneratortankandwithvalve
in the OPEN position use compressed air to blow it
cleanorsoakitinsolvent.Orreplacevalve.
16.Evaporative
system not
venting fresh air
totanktoreplace
gas as being
used. (California
Units)
Ensurenoobstructions,kinksorblockagesarein
evaporative system hose connected to bottom of
gastankandtocharcoalcanisteronlowerframe.
Disconnecthosefromcanisterthatgoestotank.
With gas gap removed, blow through hose. Air
should flow freely. If not find obstruction and correct.
NOTE: On California versions of pressure washers,
evaporativesystemhoseexitsfromtopofgastank.
18
PROBLEM POSSIBLE CAUSE SOLUTION
Engine will
not start,
stay running
or only runs
whenchoked
(continued)
17.Vacuumleakat
carburetor Ensure the evaporative system hose from the
charcoal canister is connected firmly to port
behind carburetor and other evaporative hoses
are connected firmly. Ensure carburetor is tightly
secured to engine by the two mounting nuts inside
air cleaner
18.No or low
compression Refer to Compression Test under Perform Test
Checks.
19.Dirty air filter Ensureaircleaneriscleanandnotblockingairfrom
entering carburetor. Clean if necessary.
Engine will
not turn
over, engine
seized
1. Battery is dead
(Electricstart)
Tryfullychargedbattery.Replacebatterypackif
needed.
2. Recoil pull
starter rope
broken
Replace pull start rope. Refer to Recoil Starter/
Assemble Recoil Starter under Breakdowns.
3. Recoil pull start
not engaging
engine
Remove recoil assembly. Repair or replace as nec-
essary. Refer to Recoil Starter/Assemble Recoil
Starter under Breakdowns.
4. Cylinder filled
with gas. Removesparkplugandtipenginemomentarily.If
gas pours out hole, carburetor float bowl needle is
stuckopen.Cleanorreplacecarburetor.Referto
Carburetor under Breakdowns for cleaning instruc-
tions.
NOTE: When transporting unit fuel valve must be in
OFF position, if not flooding will occur."
5. Electric starter
motor faulty Refer to Start Mechanism under Perform Test
Checks and Starter Motor under Breakdowns for
checks.
6. Excessive
carbon buildup
in head. Engine
was possibly run
withchokein
closed or partially
closed position
instead of open.
Ensurechokemechanismoperates
correctly.
Withthechokeinthefullyopenpositionandthe
enginerunning,thechokeplateatentranceofthe
carburetor should be fully open.
Onleverchokesmovetheleverallthewaytothe
right
Replacechokemechanismifchokedoesnot
operate in this way or is damaged. Test and verify
compression is correct. Refer to Compression Test
under Perform Test Checks.
7. Internal part
failure Withsparkplugremoved,rotateengineshaftby
handtoseeifitrotatessmoothly.Ifstilllockedup,
removecrankcasecoveranddeterminecause.
Poor
performance,
low power,
running
too fast,
Backfiring
often
1. Fuelquality
issue or
restriction
Refer to Engine will not start, stay running or
only runs when choked steps 5,6,12 & 13 under
Starting Problem/Engine under Troubleshooting.
PROBLEM POSSIBLE CAUSE SOLUTION
Poor
performance,
low power,
running
too fast,
Backfiring
often
(continued)
2. Sparkarrestor
dirty or clogged Cleansparkarrestor,refertoSpark Arrestor under
Maintenance.Runenginebrieflywithoutspark
arrestor to verify that was the cause. Reassemble
sparkarrestortomuffler.Ifscreenisdamaged
replacesparkarrestorifscreenisdamaged.
IMPORTANT:Theseproductsareequippedwith
spark-arrestingmufflers.Itislegallyrequiredin
the state of California. It is a violation of California
statutes section 130050 and/or sections 4442 and
4443 of the California Public Resources Code,
unlesstheengineisequippedwithasparkarrester,
as defined in section 4442, and maintained in effec-
tiveworkingorder.Sparkarrestersarealsorequired
on some U.S. Forest Service land and may also be
legallyrequiredunderotherstatutesandordinanc-
es.
3. Worn governor
arm rivet joint
Worn carburetor
throttle actuator,
Governor arm
slipping on shaft,
Throttlelinkages
bent
High speed
screw has been
tampered with
Ifengineisrunningover4000rpm(67Hz),first
ensurealllinkagescontrollingthethrottleposition
actuate freely without binding over full travel. NOTE:
Comparingtheoldgovernorlinkagetoanew
replacementgovernorlinkagemayhelptodeter-
mine if the components in the system are worn or
damaged.
• The riveted joint in governor arm must pivot
freely but not be loose and sloppy.
• Ifthehighspeedadjustingscrewhasbeentam-
pered with it can be readjusted, refer to Speed/
Governor Adjustments under Perform Test
Checks.HOWEVER, if the root cause of the high
speed is due to the governor arm slipping on the
governor shaft, adjusting the speed will give a
false indication of being correct. The speed will
beokuntilputunderaload,theenginewilldroop
or bog down. After adjusting the speed, the
unitmustbetestedusingaloadbanktesterby
gradually applying full rated load. If speed drops
more that 3 Hz, the governor arm has slipped on
the shaft and needs to be reset. To reset gover-
nor arm, refer to Speed/Governor Adjustments
under Perform Test Checks.
4. Backfiringoften
or air filter
melted, Ignition
coil could be
faulty
Replace ignition coil. NOTE: Coil resistance can
measureokandstillbefaulty.Itisbesttoreplace
coil in this case.
19
PROBLEM POSSIBLE CAUSE SOLUTION
Engine
surges,
hunts or runs
unevenly
Fuel level too low,
running out of gas
can cause speed
variation(hunting)
for a while before
enginequits
Checkfuellevel,addfuelifneeded.
Fuelqualityissueor
restriction Refer to Engine will not start, stay running or
only runs when choked steps 5,6,12 & 13 under
Starting Problem/Engine under Troubleshooting.
Sparkarrestordirty
or clogged Cleansparkarrestor,refertoSpark Arrestor under
Maintenance.Runenginebrieflywithoutspark
arrestor to verify that was the cause. Reassemble
sparkarrestortomuffler.Ifscreenisdamaged
replacesparkarrestorifscreenisdamaged.
IMPORTANT:Theseproductsareequippedwith
spark-arrestingmufflers.Itislegallyrequiredin
the state of California. It is a violation of California
statutes section 130050 and/or sections 4442 and
4443 of the California Public Resources Code,
unlesstheengineisequippedwithasparkarrester,
as defined in section 4442, and maintained in effec-
tiveworkingorder.Sparkarrestersarealsorequired
on some U.S. Forest Service land and may also be
legallyrequiredunderotherstatutesandordinanc-
es.
Stretched or miss-
ing governor spring
(small)
Replace spring, refer to Governor Linkage under
Breakdowns.
Governor spring
(large)isconnected
to wrong hole in
governor arm
Try different connection holes in governor arm.
Refer to Governor Linkage under Breakdowns.
Gasleaks Gasisleakingfrom
fuel valve Fuel valve may be loose, tighten securing nut while
holding valve in proper orientation. If valve still
leaks,valvemaybefaulty,replace.
Gasisleakingfrom
fuel line Ensuretherearenosplitsorwearmarksongas
line and ends are securely attached to fittings.
Gasisleakingfrom
carburetor the float
needle may be
stuckopen
Remove float bowl and clean thoroughly. Remove
float needle and clean needle and bore where
itlocates.Reassembleandcheck.Ifstillleaks,
replace carburetor. Refer to Carburetor under
Breakdowns.
Carburetor floods
while transporting Fuel valve must always be placed into the OFF
position when transporting.
Gascapleakswhen
transporting Gas should not be above shoulders of debris
screen,refertoengineinstructionmanual)Non-
Californiaenginesareequippedwithventedcaps,
asmallamountofgaswillleakifunitistippedata
steep angle and held there. If a large amount of gas
leaks,ensuretherubbergasketundercapispres-
entandthematingsurfaceofthetankissmooth
and flat. If >0.1 mm feeler gauge can fit under
straightedgeatanypoint,replacetank.
PROBLEM POSSIBLE CAUSE SOLUTION
Gasleaks
(continued)
Gasleakswhen
removing gas cap
and pressure can
be heard escaping
as cap is removed
(non-California
enginesonly)
Gas cap is not venting properly. Replace gas cap.
High oil
consumption
and/or oil
dripping from
air cleaner
orsparkplug
fouled with
carbon
Breather valve miss-
ing or damaged Removecylinderheadcoverandlookfordiscvalve
just inside of breather hose. This disc must be free
toopenorcloseoffopening.Ifstuckinoneposition
or completely missing, replace cylinder head cover
assembly.
PERFORMANCE PROBLEM
PROBLEM CHECK RESULT SOLUTION
Engine:
Lackspower
Overheats
Surges or runs
unevenly
Vibration or noise
level is excessive
Testsparkplugfiring Nospark See Ignition Test.
Sparksinconsistently See Speed/
Governor
Adjustment.
Examinesparkplug
condition Sparkplugisdry See Carburetor/fuel
delivery trouble-
shooting.
Sparkplugiswet: Checkcompression
Compression Poor compression See Compression
Test.
Good Compression Checkfuelcondition
Checkfuelcondition Poor fuel See Fuel System
under Maintenance.
AdequateFuel See Oil Alert Test.
RECOIL STARTER
PROBLEM CAUSE SOLUTION
Engine does not turn
over correctly Starter cord cut Disassemble and replace
starter cord
Returnspringbroken Replace or realign return
spring.
Ratchet assembly
malfunctioning Replace ratchet
20
PROBLEM CAUSE SOLUTION
Debrisislockingupflywheel Disassemble and clear any
debris from recoil base
and recoil assembly. See
Flywheel Ignition under
Breakdown.
BATTERY STARTER/BATTERY FAILURE
PROBLEM CAUSE SOLUTION
Battery does not
supply electricity to
starter
Battery leads faulty Checkfordebrisblocking
connections
If worn, replace battery
Battery is dead Charge and replace battery
pack.
BATTERY STARTER/STARTER MOTOR FAILURE
PROBLEM CAUSE SOLUTION
Starter motor fails Pinion gear not engaged with
flywheel Remove starter motor and
makesurethepiniongear
slides freely on helix
Solenoid faulty Makesuregearteethhave
not been stripped
Starter motor damaged Repair or replace starter
motor
Electrical relay fails Starter toggle switch faulty Checkforcontinuityonstarter
toggle switch in the ON posi-
tion.SeeFanCoverbreak-
down section.
STARTING PROBLEM
PROBLEM CAUSE SOLUTION
Poor compression Leaking/stuckvalves Valve job/replacement
Headgasketburned Replaceheadgasket
Worn piston rings Service/replace rings or piston
orcrankcase
Worn cylinder bore See Compression Test.
Warped/crackedcylinderhead Replace cylinder head
PERFORMANCE PROBLEM
PROBLEM CAUSE SOLUTION
Engine overheats Cooling fins obstructed Clear fins of debris
Excessive load Clean combustion chamber
Carbon in combustion
chamber Clean combustion chamber
Low oil Add oil
Set at wrong idle speed See Speed/Governor
Adjustment under Perform
Test Checks.
Low power Cloggedsparkarrestor Remove, clean and replace.
Valvesleaking Perform valve job,
see Inspection under
Breakdowns: Cylinder Head
Valves.
Intakeexhaustmanifolds
clogged Clean manifolds
Carbon build up Clean combustion chamber
Blackexhaust
smoke
Carbon in combustion
chamber Clean combustion chamber
Valvesleaking/stuck Checkvalves/seats.
Recondition if necessary.
Checkvalvetovalveguide
fit up.
Blueexhaustsmoke Piston rings/cylinder bore
worn and passing oil Replace rings and piston/
honecylinder/checkairfilter.
Can not handle load Improper valve clearance Check/adjustvalveclearance
or perform valve job, see
Inspection under Cylinder
Head Valves Breakdowns.
Weakvalvespring Perform valve job, see
Inspection under Cylinder
Head Valves Breakdown.
Valve/valve seats worn or
damaged Perform valve job, see
Inspection under Cylinder
Head Valves Breakdown.
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