Académique Documents
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Engine Textbook
Contents
1 Basic Structure of an Engine . . . . . . . . . . . . . . . . . . . . . . 1
6 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Fuel ( Gasoline ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Lubrication mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4-1
4-2
4-3
4-4
4-5
5 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6-1
6-2
6-3
6-4
6-5
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Three major elements and inhibitory elements of
the normal operation of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Troubleshooting and countermeasures . . . . . . . . . . . . . . . . . . . . . 10
3 Inspection and cleaning of components . . . . . . . . . . . . . . . . . . . . . 11
Spark plug
Cylinder
Combustion chamber
Choke
Carburetor
Air filter
Muffler
Fuel
tank
Piston
Scavenging port
Needle valve
Connecting rod
Float
Crankshaft
Crankcase
Scavenging
Compression
and intake
Compression
Explosion
Exhaust
Explosion
Exhaust
Air intake
Scavenging
Scavenging
Air filter
Fuel
Carburetor
Produces air-fuel
mixture (air-fuel ratio)
1 2 3
Crank chamber
Intakes air.
Scavenging
( Combustion chamber )
Spark-timing control
Spark plug
Compression
Explosion
Air
exhaust
Muffler
1. Fuel ( Gasoline )
Gasoline is made from the distillate fraction of crude oil, in the first stage of crude oil distillation, with a
boiling point range of 30 to 200 C. Gasoline is divided into premium gasoline of higher octane values
and regular gasoline of lower octane values.
For two-cycle engines, regular gasoline (octane value: 89 or higher) is used. Gasoline of a low boiling
point is highly combustible. The flammability of gasoline having a high boiling point is low and leaving
it as it is over time will allow the combustible contents of gasoline to vaporize and the nonflammable
contents to remain.
2. Engine oil
2-1. Effects of oil
1 Lubricating effect :
Oil enters conflicting surfaces between metal parts and supports the load
with oil membranes such that the metals do not touch each other directly.
2 Sealing effect :
Oil maintains the gaps between the cylinder, piston, and piston rings sealed
to prevent leakage of gas.
3 Cooling effect :
Oil reduces the heat generated on the cylinder, piston, bearing, etc.
by thermal propagation effect.
4 Cleaning effect :
Oil washes off carbon, deposit, sludge, etc. generated in the mechanism.
5 Rust-preventive effect : The oil film protects metal surfaces from rust.
Type of oil
Required performance
Cleaning effect
Dispersibility
Acid neutralizing property
Oxidative stability
Corrosion-resistant and rust preventive property
Combustibleness
Wear-resistant and seize-resistant property
>
3. Lubrication mechanism
The lubrication mechanisms of two-cycle gasoline engines are divided into mixed fuel methods in
which engine oil is mixed with fuel beforehand and separated lubrication methods in which engine oil
and fuel are supplied separately to be mixed subsequently.
Mixed gasoline
Carburetor
20 : 1=5%
25 : 1=4%
33 : 1=3%
50 : 1=2%
Mixture ratio
Gasoline: Oil
20
:
1
25
:
1
33
:
1
50
:
1
Oil
1
Gasoline
from 20 to 50
[Deteriorated gasoline]
3
4. Air-fuel mixture
4-1. Principle of the carburetor mechanism
1 The explosive combustion of fuel to expand the air volume
within the cylinder is necessary for the rotation of a
gasoline engine. Gasoline is not fed to the cylinder as it is;
it has to be atomized for efficient combustion.
[A]
[B]
[C]
Venturi tube ( A )
Throttle valve
Nozzle ( B )
Air
Air-fuel
mixture
Fuel ( C )
Fluid
level
Float arm
Float
chamber
Drain
Suction passage
Main nozzle
Diaphragm
Metering lever
Chamber
Drain
wire
Chamber
Flow-rate control
Throttle valve methods are available in butterfly type ( butterfly valve type ), piston valve type, or rotary
valve type.
[ Butterfly type ]
Mixture ratio
Low-temperature startup
1:1
Excessive-density
combustible mixture
Low-speed idling
1:8
1 : 13
1 : 15
1 : 16 17
1 : 11
Low
density
density Extremely-low
combustible mixture
1 : 20
4 A considerably high density, such as 1:1, is required to increase the starting performance for the
mixture used for starting up a cold engine.
5. Valve mechanism
The cylinder ports and piston in a two-cycle engine serve as the valves in a four-cycle engine. The
timing of valve operation is determined by the positions of the ports.
Air-intake
port
Crankcase
4 This air flow stops when the piston reaches the top dead point. However, when the rpm exceeds
2,000 min-1 in actual engine operating conditions, the air flow continues even if the piston starts
descending after the top dead point until the air-intake port starts closing.
6. Ignition system
6-1. Types of ignition systems
A flywheel magnet consists of an ignition system including a magneto coil and an interrupting device,
and a flywheel. The ignition system is either a contact type, CDI or TCI, both of which are non-contact
types.
Ignition system
Current-interruption type
Contact type
Non-contact type
Capacity-interruption type
Non-contact type
Point type
TCI
CDI
( Old type )
Ignition coil
Ignition coil
Flywheel
Flywheel
6-2. Flywheel
A flywheel is provided with a cast magnet for power generation. The flywheel rotates around the fixed
coil to cause flux variation in the coil and generate electromotive force. Flywheels are divided into the
inner-magnet type and outer-magnet type depending on the position of the cast magnet.
Primary coil
Iron core
Secondary coil
[Ignition coil]
Ignition signal
Characteristics
Interruptor ( point )
Point type
( current Cam
interruption type ) Ignition coil
( Trigger coil )
CDI type
Electronic circuit of
( capacitythyristor and transistor
interruption type )
Ignition coil
1 A compact and light type with coils and unit integrated has been developed.
2 Ignition timing does not vary, requiring no adjustment.
3 The secondary voltage is high and the rise of the voltage is very quick,
resulting in an excellent ignition characteristic even when the spark plug is
stained and excellent acceleration and high-speed operation characteristics.
Terminal nut
Center electrode
Corrugation
Insulating
material
Gasket
Fixing screw
Gas volume
Air gap
0.6 0.7mm
Lateral electrode
Screw diameter: 14 mm
Standard hex screw
subtense size: 20.6 mm
Protrudedinsulation type
Small-size plug
( Bantam type )
With resistance
for noise prevention
Thermal value
Screw length:
11.2 mm
Special
specification
A
B
C
18mm
14mm
10mm
M Small-size plug
P Protruded type
R With resistance
Screw diameter
Screw diameter
No
indication
L
H
E
9.5mm
11.2mm
12.7mm
19.0mm
A Special specification
S Standard specification
V-grooved center
Y electrode (excellent
ignition characteristic)
4 Troubleshooting
1. Three major elements and inhibitory elements of
the normal operation of engines
Gasoline of poor quality
Clogged carburetor jet orifice or
the like
Inadequate aperture of adjusting needle
Hardened diaphragm
Clogged tank filter
Clogged tank air vent
Clogged cock or fuel tube
Air leakage
Overheated carburetor (due to
vapor lock)
Fuel
Proper air-fuel
mixture
Spark
Engine
Engine Starts
without Fail
Fail
Pressure
No pressure leakage
in the combustion
chamber and crank
chamber
Cause
No spark
No compression
Weak sparking
Engine starts but it Weak compression
does not continue
idling
Strong sparking and
good compression
Engine stalls
Engine starts but
acceleration is ...
Engine starts
but ...
Acceleration is not
smooth or rpm does
not rise
Rotation fluctuates
at a high speed
Fuel consumption is
too large
10
Countermeasure
Cleaning
Release of brake
Adjustment
Adjustment
Adjustment
Cleaning
Oil replenishment
Cleaning
Adjustment
Fuel filter
Air-intake
port
Screwdriver
Cleaner cover
Air Filter
11
Crank chamber
Fuel tank
Inlet valve
Idle port
Idling aperture
Low-speed fuel
adjusting screw
Intermediate aperture
Pump
diaphragm
Venturi tube
Throttle
valve
High-speed fuel
adjusting screw
Main nozzle
Idle port
Metering
diaphragm
12
Full aperture
Completely fastened?
Adjusted correctly?
(See pgs. 15 and 16.)
No damage, looseness,
or hardening?
No damage or leakage?
(See p. 20)
Positioned correctly
without deformation?
Overflow.
No fuel flows out.
Adjusted correctly?
(See pgs. 15
and 16.)
Insufficient acceleration.
Unstable at low speeds.
Unstable at high speeds.
No damage,
looseness, or
hardening?
No damage or
leakage?
Completely
fastened
13
Standard
Adjusting method
Operate the following three types of screws for the adjustment of the carburetor.
Idling adjusting screw
The procedure to "rotate the screw backward 1 and 1/8 turns from the fully-closed position" in the
standard setting for the high-speed fuel adjusting screw and low-speed fuel adjusting screw refers to a
position of each screw which is to be reached finally for the setting by rotating the screw backward 1
and 1/8 turns from the extreme position reached first by rotating the adjusting screw clockwise slowly.
Idling adjusting
screw (T)
High-speed fuel
adjusting screw
(H)
14
Too
thin
Too
thick
A. Idling adjustment
1 The rpm is adjusted with the idling adjusting screw
so that the engine can rotate steadily without the
rotation of the blade. If the rpm is not obtained,
standard setting with the low-speed fuel adjusting
screw shall be performed.
Clockwise
2 The position at which the engine reaches the highest rpm shall be determined by rotating the
low-speed fuel adjusting screw clockwise or counterclockwise.
3 The set position shall be at a position reached by rotating the low-speed fuel adjusting screw
counterclockwise by 1/8 to 1/4 turns from the position determined in the step 2 above ( the engine
rpm is reduced by 200 to 300 min-1 as a result ).
4 Operate the idling adjusting screw so that the idling rpm reaches 2,700 to 3,500 min-1.
B. High-speed adjustment
Rotate the high-speed adjusting screw, in the same manner as with the low-speed adjusting screw,
clockwise or counterclockwise to find a position where the engine reaches the highest rpm. The set
position shall be at a position reached by rotating the high-speed fuel adjusting screw counterclockwise by 1/8 to 1/4 turns from the position determined above. If the highest rpm does not result from
this procedure, use the standard setting. Fuel that is too thin may cause seizure and fuel that is too
thick may cause carbon clogging. ( The setting is usually made for the same effect as with the
low-speed fuel adjusting screw. )
C. Height of metering lever
1 Bend the metering lever in the carburetor slightly so that
the height of the metering level is 1.65 mm as shown in
the figure on the right.
The height varies with the model.
Metering lever
1.65mm
Carburetor body
Clever suggestion
Operate the low-speed fuel adjustment first and return the high-speed fuel adjusting
screw to the same position obtained by the low-speed fuel adjustment ( by the same
number of screw turns ) for quick adjustment.
15
Primer pump
Check valve
Metering chamber
Fuel tank
Choke
valve
Air
Metering chamber
Idling negative
pressure adjusting
groove
Throttle
valve
Needle jet
Jet needle
Idling aperture
16
Intermediate aperture
Full aperture
4 - 2 - 1. Inspection points
E-ring
Jet needle
Gasket
Carburetor body
Inspect the fuel passage for
clogging with dirt, corrosion, or wear. Clean or
repair it as necessary.
Pump gasket
Inspect it for damage or
leakage.
Pump cover
Inspect the fuel passage
for clogging with dirt or
damage.
Gasket
Needle valve
Inspect it for wear or dirt.
Air tightness test
Valve-opening pressure:
0.14 Mpa
Valve-closing pressure:
0.049 Mpa or more
Metering lever
Priming pump
Inspect it for cracks, damage, or leakage.
Diaphragm gasket
Inspect it for damage
or leakage.
Metering diaphragm
Inspect it for damage,
hardening, or warpage.
Replace it with a new
one if found defective.
Combination valve
Metering lever pin
Check valve
Inspect it for damage, hardening,
or warpage.
17
Adjusting screw
Main adjusting
screw
Adjusting screw
The standard setting of the main adjusting screw is completed by rotating the screw clockwise
slowly to its extreme end and then returning the screw counterclockwise.
5 The jet needle of the throttle valve is fixed in position with an E-ring. Changing the position of the
E-ring varies the gap between the jet needle and needle jet; thus changing the fuel flow rate and
adjusting the air-fuel ratio.
Attaching the E-ring to the upper groove of the clip
reduces the flow rate ( thin mixture ).
Standard position of
the clip (middle level)
Attaching the E-ring to the lower groove of the clip
Fuel is thinner.
increases the flow rate ( thick mixture ).
6 When the jet needle is worn to result in an excessive
amount of fuel after using the equipment for a long
time or if the fuel consumption is excessive by the
use in a cold region, change the position of the clip
for adjustment.
E-ring
Fuel is thicker.
Jet needle
18
Stepped
wear
Dirt
8 The standard height of the control lever is 2.1 to 2.4 mm from the surface of the packing. The level is
satisfactory as long as the lever is flush with the plate surface. Adjust the control lever height,
checking with a rule or other similar tool.
Control lever
2.1 to 2.4 mm
Packing surface
Control lever
Plate
Plate
19
Inspection of the
primary coil
Inspection of the
secondary coil
Resistance of
the secondary coil
K
Model
Resistance of
the secondary coil
K
CS35EC
CG24E
CS35ED
CG22ED
CS40ED
CG24ED
CS35EC2 (S)
CG26ED
12 13 ( TCI )
CS35ED2 (S)
CG26EF
12 13 ( TCI )
CS35ED2
FCG21E
CS40ED2
FCG23E
CS40EF
FCG25E
12 13 ( TCI )
CS45EF
E12
10 20% ( TCI )
E20SA
10 20% ( TCI )
E26SA
10 20% ( TCI )
Model
Ignition coil
Hexagon socket
head screw
Gap
0.3 to 0.4 mm
20
Electrode gap
( 0.6 to 0.7 mm )
Electrode
Spark plug
(2) Insert the spark plug in the plug cap and make the electrode touch the metal part of the engine. Then, turn the
switch to "ON" and pull the starter handle lightly.
High-voltage wire
(3) If the setting is in good condition, the spark plug electrode will spark with a pop.
[ Defective conditions ]
0.8mm
0.6mm
Smoldering
Flashover
Expanded gap
due to friction
Bridge
21
2. Storage of the engine for a long time ( more than one month )
1 Drain the fuel tank completely.
2 In the case of an engine with a primer pump, remove the fuel from the carburetor fuel chamber by
the primer pump.
3 Start the engine to consume the fuel in the carburetor passage completely.
4 Remove the spark plug and supply a few drops of two-cycle engine oil through the plug mount hole.
Then, pull the starter several times so that oil film is formed over the surfaces of the piston and
cylinder wall (rust prevention measure).
5 Set the piston at a level about 10 to 15 mm below the top dead point. (This is to prevent insects
from entering via this air-intake port or air-exhaust port.)
6 Attach the spark plug in place and put the engine in a dry and well-ventilated location.
22
6 References
1. Spark plug
Plug with a resistor element
Resistor
element
Cross-sectional view
Green plug
A green plug is provided with a V-groove on the center
electrode.
Features :
Flame kernel
(source of spark)
Anti-inflammatory action by the
center electrode
is minimized for
the machined
90-degree Vgroove.
Center
electrode
Outer
electrode
NGK
DENSO
L86C
B6HS
W20FS
Standard type
CJ8
BM6A
W20M
Insulator-discharging type
CJ8Y
BPM6A
W20MP-U
Insulator-discharging type
CJ7Y
BPM7A
W22MP-U
RCJ8Y
BPMR6A
W20MPR-U
BPM7Y
Green plug
23
Stroke
Bore
Bottom dead
point
Bottom
dead
point
V=
D2LN
Compression ratio
Top
dead
point
VC
L
Bottom
dead
point
Compression ratio =
24
2. Excellent durability
1 The engine employs a suction-thrust structure in which the piston is pressed against the air-intake side
when the piston moves downward from the top dead point.
2 The air-intake side of the piston where the temperature is lowest in the cylinder serves as the sliding
surface in this structure; therefore, durability against seizure is increased. A horizontal engine employs
an exhaust and scavenging-thrust structure in which the piston is pressed against the exhaust and
scavenging side ( high in temperature ).
3 With the piston speed reduced, durability against seizure is increased.
4. Engine oil
Role of engine oil
Engine oil is indispensable as it lubricates the major rotating elements of the engine such as the piston,
piston rings, and crank shaft.
Friction-reducing effect
Sealing effect
Cooling effect
Cleaning effect
Product name
Flash point
200L
21 to 70C
1,000L
2,000L
Designated regulation volume: In accordance with Articles 30 and 9-3 of Chapter 4, Section 1 Standards for Storage
and Handling of Hazardous Substances of Amounts Lower Than the Designated Regulation Volume under the Fire
Prevention Ordinance General Standards, handling and storage of hazardous substances of amounts lower than the
regulation volume stipulated under the government decrees concerning the regulation of hazardous substances
(referred to as Designated regulation volume hereinafter) must comply with the technical standards specified
independently.
Throttle: Idling
Throttle: Half-opened
Choke: Open
Choke: Open
Choke: Closed
Choke knob
26
CO
Typical sources include automobiles, especially during idling of engines. It is a major product of the
incomplete combustion of carbon and carbon-containing compounds.
NOx
HC
CARB (USA)
EPA (USA)
(All states except for
the State of California)
EC
(EU member nations)
Japan: Voluntary
regulation
(Japan Land
Engine Manufacturers
Association)
Total
volume
control
Individual
regulation
Total
volume
control
95
96
97
98
Tier 1
THC + Nox : 246
CO
: 805
99
00
01
02
03
04
05
(g/kWh)
06
07
08
09
10
11
12
13
14
Tier 3
THC + Nox : 50
CO : 536, PM : 2
Tier 2
THC + Nox : 72
CO : 536, PM : 2
Phase 1
THC + Nox : 246
CO
: 805
Stepped regulation
THC + Nox :
246 50
CO : 805
Stage 1
THC + Nox : 246
CO
: 805
Phase 2
THC + Nox : 50
CO
: 805
From
February
2008
Primary phase
THC + Nox : 246
CO
: 805
Stage 2
THC + Nox : 50
CO
: 805
Secondary phase
THC + Nox : 50
CO
: 805
THC
NOx
CO
PM
: Total hydrocarbon
: Nitrogen oxide
: Carbon monoxide
: Particulate matter
27
8. Principle of the new starter system, "Karugaru Start ( Quick and Easy Start )"
When the rope reel rotates with the starter handle pulled, the complete spring rotates via the ratchet.
When the complete spring rotates, the cam plate connected with the startup spring housed in the
complete spring rotates. The torque is transmitted to the crank shaft as the cam plate is engaged
with the starter pulley.
Since the compressive force of the cylinder is large, the crank shaft does not rotate. Only the startup
spring is rotated to accumulate the force.
With the starter handle returned in place, the rope reel is wound back by the spiral spring. However,
the complete spring is not wound back by ratchet B; the force in the startup spring remains
unchanged.
Then, with the starter handle pulled again, the startup spring is wound back further to increase the
accumulated force. When this force becomes larger than the compressive force of the cylinder, the
accumulated force in the startup spring is released all at once, to finally rotate the crank shaft and
start the engine operation.
Compressive force
Starter housing
Starter
handle
Spiral
spring
Crank shaft
Rope reel
Complete spring
Ratchet
Ratchet B
Startup spring
Cam plate
Starter pulley
3
4
* The arrows in the figure show the respective
directions of rotation and activation order
28
5
6
Crank shaft