Small Engine

Disassembly
A Visual Guide

Objectives:

Learn operational theory through disassembly of a

small engine.
Become familiar with the internal mechanisms of
an internal combustion engine.
Reinforce lecture-based theoretical discussions.

Procedure Notes:

Take notes and make sketches as you disassemble

the engine.

This will assist you during the reassembly process.

Your engine may not be exactly like the engine in

this presentation..

Steps 1 & 2:

Drain engine oil into appropriate container.

Drain gasoline from engine into appropriate
container.

Step 3: Disconnect the Spark

Plug Cable and Remove Spark
Plug

Step 4: Remove Air Cleaner &

Mounting Plate if Equipped

Step 5: Remove Blower

Housing

Step 6: Remove Vane Governor,

Carburetor Linkage, and
Armature

Step 6: Remove Vane Governor,

Carburetor Linkage, and Armature

Reminder: Sketch a picture of the linkage assembly to the

left of this page for reassembly purposes. 5hp models will
not have a vane governor or linkage that attaches to it.

Step 7: Remove Carburetor

and Fuel Tank
BoltPoints

Reminder: Do not remove carburetor from tank. Some models

require step 8 before this step. On 5hp models DO NOT loosen or
remove the mechanical governor bar. Remove the linkage only.

Step 8: Remove Muffler

Step 9: Remove Flywheel

Screen & Starter Clutch ORCrankshaft Nut, Bell Housing,
& Flywheel Screen

Step 10: Remove Flywheel

Reminder: Keep track of the flywheel key.

Note: If the engine you are

working on is equipped with a
Magnetron Ignition System,
disregard steps 11-13.
*Sketch the points &
condenser assembly to the left
of this page for reassembly

Steps 11 - 13:

11. Remove Breaker Point Cover

12. Remove Breaker Points and

Condenser

13. Remove the Armature Wire if

Still Attached

Step 14: Remove Cylinder

Head

Reminder: Sketch or note cylinder head bolt differences &

locations.

Step 14: Remove Cylinder Head

Note:Turnthecrankshaftandviewthefourstrokecycle.

Step 15: Remove the Crankcase

Cover

Tapoilfillspoutstoloosen

Step 15: Remove the Crankcase

Cover & Gasket

Reminder: Use caution not to tear the gasket. Oil may still be in the
crankcase.

Step 16: Remove the Camshaft

Tappetsmayfallout.
Reminder: Sketch the position of the timing marks.

Step 17: Remove the

Tappets/Lifters

(may fall out when cam was removed)

Step 18: Unbolt the Connecting

Rod from the Crankshaft

Reminder: Use a 6 point socket only! Sketch

the orientation of the cap.

Step 19: Remove the Piston

Note:RollthepistonandcranktoTDC.Next,rollthecrankto
BDCleavingthepistonatTDC.Usingyourfingers,gentlypushthe
pistonoutofthecylinder.Donotallowthepistontoflyintotheair.

Step 19: Remove the Piston

Xtoenginefront.
NippletowardX

Reminder: Note the orientation of the piston when removed from the
cylinder. Create a sketch that will be used for reassembly.

Step 20: Remove the Rings and

the Connecting Rod from the
Piston

Note:Useapistonringexpander.Sketch the piston ring orientation if

differences exist. Sketch the orientation of the connecting rod to

Step 20: Remove the Rings and the

Connecting Rod from the Piston

Note:RemoveGClipswithneedlenosepliersandusea1/4nutdriver
togentlytapthewristpinoutofthebosses

Step 21: Remove the

Crankshaft

Reminder: Note the differences in the ends of the cranks

Step 22: Remove the Valve

Cover Plate

Step 23: Remove the Valve

Springs and Valves

Reminder: Note possible differences in the valve springs. Some engines m

have different valve keepers. See lab instructor for removal procedures

Disassembly Completion

Upon Completion, do the following:

Place all parts in your assigned tub

Place a piece of tape on your tub that has your
name on it.
Cover your engine parts with paper towel
Place your tub in the assigned area.