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SMALL ENGINE TROUBLESHOOTING GUIDE 

 

Table of Contents

  1. Engine will not start
  2. Engine hard to start
  3. Engine kicks back while starting
  4. Engine starts but dies
  5. Engine runs but quits when hot
  6. Engine runs rough at idle
  7. Engine runs rough under load
  8. Engine smokes blue ( oil burning )
  9. Engine smokes black ( rich fuel mixture )
  10. Engine surges
  11. Engine runs too fast
  12. Engine runs too slow
  13. Engine lacks power
  14. Engine backfires through carburetor
  15. Engine backfires through exhaust
  16. Engine uses excessive fuel
  17. Fuel in the crankcase
  18. Loud pop when engine stops
  19. Engine runs too hot
  20. Engine leaks oil
  21. Excessive vibration
  22. One cylinder misfiring or not firing on twin cylinder engines

ENGINE WILL NOT START

CAUSE

SOLUTION

REPAIR DETAILS

No fuel

Put fuel in fuel tank

 

Bad fuel

Drain fuel tank and carburetor and refill

 

No fuel delivery

Inspect fuel lines, carburetor and fuel pump

*

Choke \ primer faulty

Adjust choke or replace primer

*

Faulty ignition

Repair ignition system

*

Plugged air filter

Replace air filter

 

Low compression

Repair engine

*

Low cranking speed

Charge \ replace battery or repair electrical system

*

Improper timing

Correct ignition timing

*

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ENGINE HARD TO START

CAUSE

SOLUTION

REPAIR DETAILS

Bad fuel

Drain fuel tank and carburetor and refill

 

Faulty ignition

Repair ignition system

*

Plugged air filter

Replace air filter

 

Low compression

Repair engine

*

Low cranking speed

Charge \ replace battery or repair electrical system

*

Improper timing

Correct ignition timing

*

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ENGINE KICKS BACK WHILE STARTING

CAUSE

SOLUTION

REPAIR DETAILS

Improper timing

Correct ignition timing

*

Cutting blade removed

Install cutting blade

Common on push mowers

Faulty compression release

Repair compression release

 

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ENGINE STARTS BUT DIES

CAUSE

SOLUTION

REPAIR DETAILS

Bad fuel

Drain fuel tank and carburetor and refill

 

Air leak

Reseal carburetor mounting

 

Fuel vent plugged

Clean / replace fuel cap

 

Main jet partially plugged

Clean carburetor

*

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ENGINE RUNS BUT QUITS WHEN HOT

CAUSE

SOLUTION

REPAIR DETAILS

Vapor Lock

Reroute fuel line

*

Defective ignition components

Repair ignition system

*

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ENGINE RUNS ROUGH AT IDLE

CAUSE

SOLUTION

REPAIR DETAILS

Dirty air filter

Change air filter

 

Weak spark

Repair Ignition system

*

Fouled Spark plug

Change spark plug

 

Improper fuel mixture

Correct fuel mixture

*

Improper valve sealing

Adjust or reseal valves

*

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ENGINE RUNS ROUGH UNDER LOAD

CAUSE

SOLUTION

REPAIR DETAILS

Dirty air filter

Change air filter

 

Weak spark

Repair Ignition system

*

Fouled Spark plug

Change spark plug

 

Improper fuel mixture

Correct fuel mixture

*

Improper valve sealing

Adjust or reseal valves

*

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ENGINE SMOKES BLUE (oil burning)

CAUSE

SOLUTION

REPAIR DETAILS

Engine oil overfilled

Drain oil and refill correctly

 

Engine oil contaminated

Drain oil and refill correctly

 

Contaminated fuel

Drain fuel and carburetor

 

Faulty breather

Replace breather

 

Faulty head gasket

Replace head gasket

*

Worn valve guides

Replace valves and guides

*

Worn piston rings / cylinder

Replace piston and rings

*

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ENGINE SMOKES BLACK (rich fuel mixture)

CAUSE

SOLUTION

REPAIR DETAILS

Dirty air filter

Replace air filter

 

Fouled spark plug

Replace spark plug

 

Improper carburetor adjustment

Adjust carburetor

*

Improper choke adjustment

Adjust choke control

*

Weak ignition spark

Repair ignition system

*

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ENGINE SURGES

CAUSE

SOLUTION

REPAIR DETAILS

Dirty air filter

Replace air filter

 

Contaminated fuel

Drain fuel and carburetor

 

Faulty ignition system

Repair ignition system

*

Improper carburetor adjustment

Adjust carburetor

*

Carburetor dirty

Clean carburetor

*

Malfunctioning governor

Adjust / repair governor

*

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ENGINE RUNS TOO FAST

CAUSE

SOLUTION

REPAIR DETAILS

Improper throttle control adjustment

Make sure the throttle control moves smoothly throughout its entire range

 

Throttle linkage bent or stuck

Make sure the throttle linkage can move freely through its entire range

 

Throttle plate loose

Tighten the screws securing the throttle plate

 

Governor malfunctioning

Adjust / repair governor

*

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ENGINE RUNS TOO SLOW

CAUSE

SOLUTION

REPAIR DETAILS

Improper throttle control adjustment

Make sure the throttle control moves smoothly throughout its entire range

 

Governor malfunctioning

Adjust / repair governor

*

Improper fuel mixture

Clean and/or adjust carburetor

 

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ENGINE LACKS POWER

CAUSE

SOLUTION

REPAIR DETAILS

Improper carburetor adjustment

Clean and / or adjust carburetor

 

Engine in need of a tune up

Perform seasonal maintenance

*

Improper valve adjustment

Adjust valves

*

Carbon build up on piston

Clean carbon from piston

*

Exhaust system obstructed

Clear blockage from exhaust system

 

Internal components worn

Repair / replace mechanical components

*

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ENGINE BACKFIRES THROUGH CARBURETOR

CAUSE

SOLUTION

REPAIR DETAILS

Improper ignition timing

Set ignition timing

*

Improper valve clearance

Adjust valve clearance

*

Intake valve not seating

Reseat / replace intake valve

*

Lean fuel mixture

Adjust or reseal carburetor

*

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ENGINE BACKFIRES THROUGH EXHAUST

CAUSE

SOLUTION

REPAIR DETAILS

Exhaust leak

Repair exhaust leaks

 

Bad spark plug

Replace spark plug

 

Exhaust valve not seating

Adjust / replace exhaust valve

*

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ENGINE USES EXCESSIVE FUEL

CAUSE

SOLUTION

REPAIR DETAILS

Tune up needed

Perform seasonal maintenance

*

Improper carburetor adjustment

Adjust carburetor

*

Improper choke adjustment

Adjust / repair choke

*

Improper timing adjustment

Adjust timing

*

Mechanical restriction in engine

Correct the mechanical drag

*

Mechanical restriction of machine engine is running

Repair / replace the source of the mechanical resistance

 

Carburetor leaking fuel

Repair carburetor

*

External fuel leak

Repair tank, fuel lines, or connections as required

 

Fuel leaking past float needle

Repair carburetor

*

Fuel leaking at fuel pump diaphragm

Repair / replace fuel pump

*

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FUEL IN CRANKCASE

CAUSE

SOLUTION

REPAIR DETAILS

Fuel leaking past float needle

Repair carburetor

*

Fuel leaking at fuel pump diaphragm

Repair / replace fuel pump

*

Fuel entering during transport

Shut off fuel before transport

 

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LOUD POP WHEN ENGINE STOPS

CAUSE

SOLUTION

REPAIR DETAILS

Rich fuel mixture

Adjust carburetor

*

Engine running hot

See “engine runs too hot” section

 

Engine running too fast when shut off

Idle engine before shutting off ignition

 

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ENGINE RUNS TOO HOT

CAUSE

SOLUTION

REPAIR DETAILS

Improper ignition timing

Set ignition timing

*

Engine overloaded

Make sure engine is of proper size for equipment and there are no mechanical restrictions

 

Plugged cooling fins

Remove engine shrouds and clean contamination from cooling fins

 

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ENGINE LEAKS OIL

CAUSE

SOLUTION

REPAIR DETAILS

Defective gaskets or seals

Replace components as required

 

Excessive compression leakage

Diagnose and repair internal components

*

Engine oil overfilled

Drain and refill to proper level

*

Engine oil contaminated

Drain and refill to proper level

*

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EXCESSIVE VIBRATION

CAUSE

SOLUTION

REPAIR DETAILS

Bent or imbalanced equipment attached to engine

Replace blade or blade adaptor as required

*

Cylinder misfiring

See “cylinder misfiring” section

 

Damaged flywheel

Replace flywheel – DO NOT ATTEMPT TO REPAIR

*

Loose engine mounting bolts

Tighten engine mounting bolts

 

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ONE CYLINDER MISFIRING OR NOT FIRING ON TWIN CYLINDER ENGINES

CAUSE

SOLUTION

REPAIR DETAILS

Ignition system faulty

Repair ignition system

*

Mechanical components worn or broken

Repair internal components

*

Leaking head gasket

Replace head gasket

*

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* = Detailed repair guides to come soon.