Gasoline Engine 7 & 16 hp with Electric Start www.mud-skipper.com (844) MUD-SKIP
FUEL AND ENGINE OIL 3 PRE-OPERATION INSPECTION 5 STARTING AND STOPPING THE ENGINE 6 INSPECTION AND MAINTENANCE 8 STORAGE OF ENGINE 11 CLEANING THE CARBURETOR FUEL JET 14 PRE SEASON CHECK LIST 15 TROUBLESHOOTING 16 INSTALLING A KILL SWITCH 18 STARTER WIRING 19 ENGINE BASE DIMENSIONS LT210 7hp 20 ENGINE BASE DIMENSIONS LT420 16hp 21 ENGINE PTO DIMENSIONS LT420 16hp 22 ENGINE PTO DIMENSIONS LT210 7hp 23 SPARE PARTS & SPECIFICATIONS 24 INSTALLING A MUD-SKIPPER OUTBOARD KIT 25 Page 1
Thank you for purchasing the Mud-Skipper Gasoline engine. This OPERATION MANUAL tells you how to operate and service your gasoline engine. Please read it before using the engine to ensure proper handling and operating. Follow the instructions carefully to keep your engine in the best running condition. Do not run the engine indoors or where ventilation is poor. Keep explosive and flammables at least 1 m (3ft) away from the engine. Do not smoke when adding fuel Do not run the engine when gasoline has split, clean the overflowing fuel and fuel spillage. Do not remove the fuel tank cap or add fuel while the engine is running or hot.(add fuel after the engine has cooled by waiting 2 or more minutes after engine is stopped.) Do not run the engine without the muffler or air cleaner installed. Do not touch the muffler, muffler cover or engine body while the engine is running or hot. Place protective covers over the rotating parts. If rotating parts, such as the drive shaft, pulley, belt, etc, are exposed, they are potentially hazardous. To prevent injury, equip them with protective covers or shrouds. If you have any questions concerning this manual, or any suggestions, please contact Mud-Skipper at 1-844-MUD-SKIP. Page 2
FUEL AND ENGINE OIL Use clean, fresh, unleaded ETHANOL FREE gasoline. wherever possible. Do not mix oil into the gasoline Page 3
Engine Oil Use the engine oil grade depending on ambient temperature using the table below Note: Recommended engine oil: SAE 5W-40 mineral oil use only Do not add commercial additives to the oil. Do not mix gasoline into the oil Before starting, be sure to conduct an oil check. Place the engine on a level surface when adding oil and conducting inspections; WARNING: Engine is shipped without oil. If using the engine on a Longtail, or Twister, the engine will be operated on an angle, not level. Consequently, the oil sensor must be disabled. It is installed for applications where the engine is operated on a level plane) YOU MUST CHECK THE OIL LEVEL EVERY TIME YOU OPERATE YOUR ENGINE. WE WILL NOT ACCEPT RETURNS FOR SEIZED ENGINES DUE TO LACK OF OIL. Page 4
PRE-OPERATION INSPECTION Fuel Inspection Is there fresh gasoline in the tank? Is old gasoline being used? If so, remove it and replace with fresh gasoline Is the fuel tank cap closed correctly? WARNING: Air-cleaner Inspection Foam filters should be washed in detergent, dried and lightly impregnated with oil. Paper filters should be replaced. Engine Oil Inspection Check the engine filled with the recommended engine oil, and the oil is clean If not, replace it. You should replace it every season. Inspect the Tightness of all Fastener Screws Check the screws used to fasten the muffler (Do this when the muffler is cold) Fuel and Oil Leaks Inspection Check for oil and fuel leaks and make the necessary repairs. Page 5
STARTING AND STOPPING THE ENGINE Starting the Engine OPEN the fuel cock Turn the engine switch to "ON" position Completely CLOSE the choke valve Move throttle lever a little to OPEN THESE ENGINES START BY CHOKING THE CARBURETOR, REGARDLESS OF WHETHER THE ENGINE IS HOT OR COLD. Page 6
Due to EPA regulations, there is no fuel/air mix adjustment on these engines as the carburetor is preset. Recoil start: Hold the starter handle and pull it slightly until the compression position is reached, and then pull it swiftly from this position; Slowly return the starter handle to its original position after the engine starts. Electric start; Turn the key switch to "START" position; and keep it there until the engine starts. If engine does not start after running the electric starter for 5 sec, wait 10 sec before trying again. After engine starts, release the key switch, it will return to "ON"(or "RUN") position. After engine starts, gradually turn the choke lever to the full "OPEN" position, and set the throttle lever in the Max. position. Before placing under load, warm up the engine for about 3 min. To switch off, turn the fuel cock off first, then use the on/off switch. Don t switch off the engine under load at high speed. It could cause damage. Page 7
INSPECTION AND MAINTENANCE Daily and Regular Inspection Daily and regular inspections are important to assure safe, proper and long-term operation of the engine. Refer to this inspection table when conducting inspections and maintenance. Regular Inspection Table: Page 8
CLEANING THE AIR FILTER Page 9
Cleaning the spark plug Remove the carbon attached to the electrode Polish the electrode with emery paper or wire brush Adjust the electrode gap Clean the fuel filter Remove the filter from fuel tank neck Clean it in solvent Clean the fuel cock deposit cup Remove the cup from fuel cock Clean the cup Replace the cup - use a new 2-ring Page 10
STORAGE OF ENGINE Should the engine be stored for a long period, please do as follows: Drain off the fuel in tank and oil in crankcase Remove the spark plug, add about 2-3 cc. Engine oil into the cylinder, and reinstall the spark plug. Pull the recoil until feeling the compression. At this time, both the inlet and exhaust valve are closed to prevent the engine chamber from rusting. Clean the surface of the engine with clean cotton cloth. Store the engine in dry and dust free area. Electric starter: Disconnect the battery, charge the battery once every month. TROUBLE SHOOTING Starting failure: Is the engine switch turned to "ON" position? Remove the spark plug, if it is soiled, clean or replace it. Is the compression sufficient? Confirm by pulling the starter handle six times slowly. When compression is insufficient - Check whether the spark plug is firmly tightened. Is fuel cock open? Is fuel sucked into the combustion chamber? Close choke lever, pull the starter handle several times, then remove the spark plug. When the tip of spark plug is wet, it is OK. When fuel is not sucked in, check fuel strainer for blockages. When engine does not start even though fuel is present, replace fuel with new. If fuel is not being drawn into the engine carburetor, remove the bowl, undo the Jet Retainer, remove the jet and check all holes are clear. Page 11
Is there fresh fuel in the tank? Is the fuel tank tap open? Is the kill switch open? Is the battery charged? Is the HT Lead firmly fixed to the spark plug? Is the gas tank cap vent hole plugged up? Is there sufficient oil in the engine? Is the Oil Sensor still connected? Check Your Fuel Is the fuel tank tap open and fuel is flowing? Remove the fuel tube to check for flow. Remove all old fuel and flush the tank. Look for particulate in the old fuel. If there is rust, you must consider lining the tank with Caswell Gas Tank Sealer. If you used ethanol based fuel, you have probably gummed up the carburetor and worse, it forms varnish goop on almost everything if left too long. Ethanol also attracts moisture, so you may have water in the bottom of the tank, if you over wintered with ethanol fuel. The gas tank cap has a small vent hole in it, and rainwater etc. can enter via this route. Ethanol rots plastic, rubber seals and causes rust. Why are you putting this in your engine? Check for a Spark! It s worth changing the spark plug every season. Check the spark plug gap and adjust if necessary. Check for a spark using a spark tester, removing the plug, re-attaching the HT lead and placing the plug on the engine body (on bare metal). Pull the recoil cord and observe the spark on the plug. It s best to do this in a darkened room or at Page 12
night. You should see a bright blue spark. If there is a yellow or weak spark, change the spark plug. Check the HT lead, (This is the thicker lead that fits onto the spark plug.) Damage can occur to this, causing a short and grounding out the power to the plug. look for cracks and perished rubber Check the Ignition Coil Using an ohmmeter, check the resistance between the side terminals of the coil. Do this with all of the wires to the coil disconnected. It should read 0.75 to 0.81 ohms. Then check the resistance between either side terminal and the center high tension terminal. https://youtu.be/m3zc9q33ex8 If the coil fails these tests, replace it. Starter Fluid Walmart sell an inexpensive Engine Starter Fluid for less than $3. Simply spray a jet for 3-4 seconds into the air intake (where the air filter is). Then start the engine. As long as you have a spark, the engine should fire up, and it will draw the fuel in from the tank. Page 13
CLEANING THE CARBURETOR FUEL JET Place a tray underneath the engine if you intend to do this job on the boat, but we recommend removing the engine and doing this work in a workshop. These parts are small and easily lost. To gain access to the Fuel Jet, undo the retainer screw at the base of the carburetor bowl and pull off the bowl. Up inside the screw hole, there is a brass retainer. Using a small screwdriver, undo the retainer. The jet will drop out. Wash the retainer, jet, float and pin with carburetor cleaner, then hold the jet up to the light to inspect it. There are several very small holes in the shank of the brass tube, so make sure these are all clear of debris. Squirt carburetor cleaner up into the chamber where the jets resides and into all orifices in the carburetor and reinstall the jet and retainer screw. Be careful when replacing the carburetor bowl. There is a thin rubber gasket around the lip which is easily reinstalled incorrectly, resulting in fuel leakage. It is best to install the gasket onto the lip of the bowl, and secure it with a couple of dabs of silicon rubber or gasket maker adhesive prior to replacing the bowl. Page 14
PRE SEASON CHECK LIST Oil Drain the sump and replace the oil at the beginning of every season, or every 25 hours use. Air Filter Remove the air filter. If foam, wash in detergent with warm water, and dry. Then rub in a small amount of light oil, say a teaspoon full. This aids the filter to trap dust particles. Spark Plug It s worth changing the plug every season. Check the spark plug gap and adjust if necessary. Check for a spark using a spark tester, removing the plug, re-attaching the HT lead and placing the plug on the engine body (on bare metal). Pull the recoil cord and observe the spark on the plug. It s best to do this in a darkened room or at night. You should see a bright blue spark. If there is a yellow or weak spark, change the spark plug. Fuel The engine should have been stored without fuel in the tank or carburetor. Use only ethanol free fuel for your engine. Ethanol will clog up ports in your carburetor and rot out rubber and plastic seals and hoses. Carburetor Check the choke butterfly is operating correctly. Apply a light coat of WD40 to ensure free movement.if you stored your engine with ethanol based fuel in it, you may need to strip down the carburetor and thoroughly clean it. Use a commercial Carburetor Cleaner. Linkages There are numerous springs and rods connected to the carburetor and throttle lever. These will vary from each sized engine, so it is a good idea to take a photo of these as a reference, then check them every season for loss or damage. Take the filter cover off to get a better view of these parts. Dirty linkages can cause problems, so keep them as clean as possible. One way to remove dirt and light oil is to spray with electrical contact cleaner. It s worth changing the plug every season. Page 15
TROUBLESHOOTING Smoking Engine Black smoke Black smoke is an indicator of too much gas being burnt. Blue or white smoke problem Smoking engines indicates burning oil, probably caused by: Over filling the crankcase with oil Incorrect oil grades Defective or obstructed crankcase breather Crankcase air leak Blown head gasket Worn cylinder and/or rings Turning/tilting the engine on its side Surging Engine When an engine surges or pants, it sounds as if the engine reaches full speed, only to decelerate quickly. Engines rely on a precise volume of gasoline and air to operate correctly.. Check the Air Filter Clean foam filters with dish washer detergent and then apply a light coat of oil, squeezing it into the foam. Paper filters must be replaced. An air filter is a quick fix that should be your first remedy for a surging engine. Problems in the Fuel System Check and clean out the small vent hole in the gas tank cap for good ventilation. Old gasoline, especially ethanol based, should be removed, the tank flushed and replaced with fresh ethanol free fuel. Check for rust in the tank, and consider lining the tank with Caswell Gas Tank Sealer. Do not store your engine with ethanol based fuel in the tank. Run the engine until out of gas and drain the tank. Spray tank and carburetor with a light coat of WD40. Ethanol is your enemy. Avoid it whenever possible. Page 16
Problems with Carburetor Unbolt the carburetor bowl and thoroughly clean in fresh gasoline or carburetor cleaner. (Remember to reinstall the thin rubber gasket correctly) Check the float for free movement Check all ports and vents for blockages, particularly the bolt that hold the bowl on. It has port holes that tend to block. Check the gaskets for tears or damage and replace if required. Problems with Air or Vacuum Leaks Check all nuts and bolts holding carburetor to the engine. Change gaskets or use a liquid gasket to ensure a good seal.. Permatex Form- A-Gasket No.1 Sealant. A loose carburetor sucks air in through gaps where it attaches to the engine block, altering the air/gasoline mix ratio. There is insufficient vacuum to pull gasoline into the carburetor from the tank. Post Season Check List This check list is the most important thing you can do to make your start-up next season go easily. To prevent corrosion inside the engine cylinder- Remove the spark plug, and squirt a teaspoon of light oil through the plug hole. Pull the recoil until you feel compression. At this time, both the inlet and exhaust valve are closed, and this prevents the engine chamber from rusting; Drain all fuel from the tank and run the engine to remove fuel from carburetor bowl. Check the fuel tank for corrosion. If present, remove the tank and treat it with Caswell Gas Tank Sealer. Drain the oil from the engine. Spray WD 40 inside the fuel tank, to reduce rusting. Replace the gas tank cap. Disconnect the battery, charge the battery once every month. Store under cover, in the dry. Page 17
INSTALLING A KILL SWITCH Locate the Kill switch on a suitable position on the steering handle or somewhere on the boat near the operator s position, and run a twin flex wire to the engine. Follow the diagram for wiring the actual switch from the enclosed Kill Switch instructions. Connect one wire to the same bolt you used as the ground for the black battery wire. Connect the other wire to the joining two wires #3 and #11. You may snip off the connectors of #3 & #11 and add the Kill Switch wire to them, using a wire nut. Alternatively, find another male plug and add #3 and the Kill wire together and crimp the plug onto both. Then plug into #11. Run the engine and test the switch. Kill switches are designed to be used. Make sure you do! Page 18
STARTER WIRING Wire 1 To Terminal 10 (Positive lead from battery also to Terminal 10) Wire 2 (Yellow) To Wire 7 (Black) Wire 3 (Short Black) To Wire 6 (Black Leading From Under Engine) Wire 4 (Thick Black) To Wire 9 (Long Red) Wire 5 (Short Brown) To Wire 8 (Short Red) To Include A Kill Switch: Note- longer leads for kill switch, to mount switch at preferred location, are not included. Wire Red Wire from Kill Switch To Wire 3 (Short Black), then reconnect to Wire 6. You may clip the connectors off the wires and use a wire nut to connect, or attach new crimp connectors. Black Wire from Kill Switch attaches to any ground on the engine. To Start Engine: Ensure engine has oil and gasoline Connect positive terminal on 12V battery to Terminal 10. Connect negative terminal on 12V battery to any ground on the engine Set choke to full - even when engine is still hot. Set throttle to idle. Turn key to start or use recoil pull start. Page 19
ENGINE BASE DIMENSIONS LT210 7hp Page 20
ENGINE BASE DIMENSIONS LT420 16hp 20 196 90 20 2-Ø12 0.022 0 深 12 Ø11 通孔 10 103 17 132 56 58'34" 7.5 Page 21
ENGINE PTO DIMENSIONS LT420 16hp Page 22
ENGINE PTO DIMENSIONS LT210 7hp Page 23
SPARE PARTS & SPECIFICATIONS Page 24
INSTALLING A MUD-SKIPPER OUTBOARD KIT Before installing the PTO coupler, remove the bolt in the end of the shaft. This has been left in place for customers who wish to use the engine for other applications where an attachment needs to be bolted onto the shaft. Failure to remove this bolt will result in damage to the shaft bearing seals and will void any warranties. For Longtail couplers (right), the square key is not required. Simply slide the coupler over the shaft and tighten the three bolts so they protrude into the keyway slot. Do not over torque. PTO Housings will vary depending on the model and kit size. Slide the unit over the PTO Coupler and bolt to the engine using 5/16-24 UNF bolts and shake proof washers. Page 25
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