Course Syllabus
Small Engines
Mr. Sullivan Instructor
Course: Small Engines, CTE
Hours: 2ND Hour
Room: Tech Lab 122/Woods Lab
E-mail: msullivan2@lisle202.org
Office phone Hogue Tech: (630)-493-8368
Course Description:
This course covers theory of operation, disassembly, inspection, assembly, and
troubleshooting of small gasoline fueled engines. Emphasis will be placed on
understanding the universal principles of induction, efficiency, compression, exhaust,
camshafts, valve-train, lubrication and ignition that are common to all internal combustion
engines. Demonstrations will be performed to show you how the engine will be
disassembled and reassembled prior to the start of class
Small engines can be used to learn all of the techniques and skills for directional learning,
and engine rebuilding that are necessary for any size engine. Working with small engines
saves storage space, student dollars, consumables, and most importantly longevity of
purchased small engine products. Machining and measuring techniques will be learned
and combined with proper application they can be applied the hand crank generator unit!
Cleanliness, precision, “doing it the right way” will be stressed in order to disassemble
rebuild and start your engines. Twenty five percent of the grade is asserted to restarting
your engines and getting them to run. Take your time follow the directions and pay
attention to the rebuilding process!
Safety Tool Boxes and Consumables
It is required that all students either wear their own prescription eyeglasses or safety
glasses during demonstrations and laboratory work. Safety glasses will be provided to
yourself from the instructor that become your responsibility you will need to lock your
lockers and keep your glasses in your assigned locker! As well students will be assigned a
tool box with tools that they are responsible for each tool. You are responibile for all tools
in the tool box and all tools in the toolbox will be required to be turned as a text book all
tools/tool boxes not turned in you will be charged for as a text book fee. Locks and
Lockers you are also responsible for any lost locks will be charged as a $5.00 locker fee,
make sure your locks are locked after each lab day so tools and safety glasses are not
stolen or lost!
Any student found not wearing safety glasses, will need to complete a book work
assignment by the sink to receive credit for the lab assignment or take a zero for that days
lab work.

The Power Tech Lab provides an extensive set of tools, however, specialty
or a good set of hand tools may make your day much smoother. Secure
storage is available for student use.

Each student must provide their own supply of:
o Shop towels (Al’s, Car Quest, NAPA…)
o Shop apron, coveralls, or shop coat (used from Autozone, Car Quest!)
o Small containers for parts and pieces (boxes, bags, reused cans…)

(It is strongly recommended that any student working on a typical “small
engine” also purchase the appropriate manual for that engine (Honda,
Tecumseh, Kohler, Onan, Wisconsin, Kawasaki, etc.) The Power Lab is only
equipped to handle Briggs and Stratton engines. As a side note horizontal
shaft engines are preferred to vertical shaft designs, but this is to be taken as
a recommendation not a requirement.)
Course Topical Outline:
1) General Principles of internal combustion Engine Operation
i) Stroke vs. Cycles
2)
3)
4)
5)
ii) Thermal principles
iii) Bore, Stroke
iv) Volumetric Efficiency
Nomenclature
i) Piston
ii) Connecting Rod
iii) Rings
iv) Camshaft
v) Crankshaft
vi) Magneto
vii) Lifters
viii)Rocker arms and followers
ix) Valves
x) Valve springs
xi) Valve retainers
xii) Valve guides
xiii)Valve retainers
xiv) Flywheel
xv) Timing gears, chain or belts
System Functions
i) Fuel
ii) Pressure systems
iii) Lubrication
iv) Ignition
v) Cooling
(Precision Measurements)
i) Valve Lift/Lashing
ii) Combustion chamber volume
iii) Armature clearance
iv) Ring side clearance
v) Runout and out of round
vi) Fasteners
Carburetor Competency Checklist
a) Show the choke
b) Show idle speed screw adj.
c) Show high speed screw
d) Trace air flow path
e) Explain action of float/needle assembly
Show the throttle
Show idle mixture screw
Show high speed jet (main)
Show fuel paths
Show main and idle fuel flow paths
Course Objectives:
At the conclusion of the course the students will be able to:
1. Define the concepts of bore, stroke, cycles, compression ratio, volumetric efficiency,
displacement, thermal efficiency.
2. Disassemble, and reassemble a small gasoline engine such that; (a) all parts are
assembled correctly, (b) all fasteners are torqued correctly, (c) no threads are
stripped, and (d) the engine runs and accelerates without hesitation.
3. Operate the following hand tools; combination wrenches, sockets, ratchets, torque
wrench, ridge reamers, ring expanders and compressor, valve spring compressor,
valve seat cutter
4. Operate the following precision measurement instruments; feeler gage, wire gage,
dial indicator, telescope gage, small hole gages, dial calipers, micrometers.
5. Operate the following diagnostic and test equipment; compression tester, and spark
tester
6. Explain correlation concepts such as reciprocating and rotating motions that
correspond to ignition, exhaust, intake, valve timing, and balancing
7. Identify correctly 20 parts of a small gasoline engine.
8. Tune and adjust the idle, low speed, and high speed circuits of the carburetor.
9. Detect runout, out of round, and calculate the clearance between shaft and plain
bearing.
Course Assignments:
Written Examinations—3 @ 20% seniors A 4 exams for all else
Engine Restoration—60%
Participation — 20%
Students following the labs working on their engines will receive all participation points for
that day each day a l
This will be done as per the Task Completion Record. All tasks will be completed in line
with the Mastery Learning approach, where 100% mastery must be achieved by each
student. The student should have his/her own engine(if you decide that you want to
rebuild or fix an old engine that does not run). The workspace should be clean and
organized, operations will need to be scheduled, and storage systems of new and used
parts will be developed by each student. If you complete all tasks early, you are free to
work with others to allow them to achieve mastery of the designed objectives listed above!
Grading Evaluation:
This course is designed around a value system for each assignment. Each learning
assignment has been weighted and assigned a certain percentage portion based on: the
amount of work required/creativity required/importance to professional
development/relative value of cognitive vs. psychomotor vs. affective domains. Missed
labs and participation due to absences can be made up after school before school or by
completing book work!
Grading Procedure:
1.
All assignments will be turned in on the day designated during class time for the
course.
2.
All written work will be evaluated on the following criteria:
a. content quality
b. completeness
c. clarity
3.
Please ask questions if assignments are unclear. The final responsibility for
misunderstandings and late work rests with the student.
4.
Points will be assigned for each student’s work. The total points obtained
throughout the course will then be evaluated according to the following chart:
A
100-93%
B
92-85%
C
84-80%
D
74-67%
5.
Missing class is not “OK”. Discussion questions, safety instruction, and instruction
on equipment and instruments are all valuable and should not be missed.
Absences cause expensive wear and tear on equipment, supplies and facility.
Demonstrations on equipment and technique are difficult to be given over.
6.
Appointments can be directly made with the instructor or E-Mail.
7.
Grades will be determined by attendance patterns, completion of labs, participation
and performance on written and constructive projects that demonstrate learning
Absences: If you are absent from class, you need to turn in your CLASSWORK when you
return. Any new assignments that were made during your absence will be due the following day
(one day for each absence). If you know that you will be gone in advance, please make up your
work ahead of time. It is your responsibility to check with me at the beginning of class if you will
be/have been absent from class. You will be granted an extra day for each day absent that will not
count against your grade.
Late Work
Students who have late assignments are expected to finish the assignments one
week after the due date. I understand that you may have miss a due date but want to see you
complete the assignment as each assignment is purposeful to the class. I would not assign
something that does not need to be completed. Therefore a student has up to one week to
complete the assignment for full credit and after one week the student can submit the assignment
for 80% of the total grade possible. You will be assessed as you would on the same rubric for
each assignment so you are expected to complete work with the same expectations as all of the
other students.
ADA:
Students who have special needs or disabilities that may affect their ability to
access information and / or material presented in this course are encouraged to
contact the instructor or the special education department
Small Engines
Course Reading / Assignment Schedule
(Keyed to Small Gas Engine Repair, Paul Dempsey)
Week #
Topic
Assignments Due
1
Safety Unit and Hand Tools
2
Engine Theory 4 Stroke
3
4
Engine Theory 4 Stroke
4 stroke Small Engine
disassembly
5
4 stroke Small Engine
disassembly
6
8
9
4 stroke Small Engine
reassembly
4 stroke Small Engine
reassembly
Key Train
2 Stroke Theory
Tools Test
Guided W.S.
Reading Activities
Short answer questions
Test
“
Ignition systems Reading
Valve Timing Reading
Disassembly Labs
Ignition systems Reading
Valve Timing Reading
Disassembly Labs
Rebuilding Labs
10
2-stroke Disassembly
11
2-stroke Reassembly
12
13
2stroke engine start
Electricity Unit
14
Electricity Unit
7
Rebuilding Labs
Start & Run engines
Key Train
2-Stroke reading activities
2-stroke written activities
2-stroke Test
2-stroke labs
2-stroke written
assignments
2-stroke labs
2-stroke written
assignments
Start 2-stroke engines
Bread Boards
Electricity flow
Measuring electricity
AC vs DC Reading
Bread Boards
Electricity flow
Measuring electricity
AC vs DC Reading
15
Build Hand crank generators
in the lab
16
Build Hand crank generators
in the lab
17
Wind Generators
18
Wind Generators
Assembly of hand crank
generators, mechanical
features
Assembly of hand cranks
generators, mechanical
features. And assembly of
electrical, trouble shooting
Build wind generators to
charge small devices
Build wind generators to
charge small devices
Guardian Signature ______________________________________________
Student Signiture ________________________________________________