Hustler Engine Problems

[tmore22]

Hello everyone. Wanted to start by saying that you all have a wonderful website! The boards, gallery, etc., etc. is amazing and there seems to be some extremely knowledgeable members too.

I am somewhat new to the world of ATV’s. I was given a 1974 Cushman Trackster and a 1980 Hustler. I had the Trackster running 6 or 7 years ago but due to a job relocation, etc. I wasn’t able to tinker with it anymore. It hadn’t run in over 20 years, so working on it was a challenge, but the fun I had on it certainly made it worthwhile. Hopefully once I get the Hustler running properly, I'll get the Trackster primed and running once again.

Most recently I have been playing around with the Hustler, but am having a very difficult time getting it to run properly. I need your help! The Hustler was parked in about 1983 and never messed with until last year. It has the 16 Hp K341 Kohler engine. To date, I have replaced:

• Fuel line and filter
• Fuel pump
• Carburetor
• Coil, points, condenser, spark plug, & plug wire

It will start and run all day long, but as soon as I attempt to rev it up, it “falls all over its face” and attempts to die unless I let off the gas. I’ve adjusted and readjusted the new carburetor (the old one would only run full choke, but the new one runs w/ the choke wide open) but it still seems to be running somewhat rich. The plug is also pretty black after running it. Obviously I don’t know a great deal about small engines, but it seems to be a timing problem to me. I believe I’ve set the points correctly (assuming TDC is when the piston is at its highest position when viewed through the spark plug hole...again, I'm no mechanic), but am not sure if there is some other sort of timing method I should use. It also has a slight knock when revving it up, so I’m not sure if it’s more serious than I think. Does anyone have any suggestions for me???! I'd like to repair it myself in lieu of taking it to a shop, although my wife would probably appreciate me giving into my temptations and just have someone else fix it for me!

I appreciate the help and once again, great site!

[Amphiman1]

Welcome!

Welcome to the site! Good luck on your new Hobby!
I wonder if it is the woodruff/ key , in flywheel?

[mudbug3]

tmore22

Welcome to the amphibious forum. I,m sorry I can,t offer you any help with your mechanical problems , but I,m sure some forum members will soon answer your post , and offer help in solving your engine problems.

[ygmir]

revving and dying seem to indicate to lean........and, if you say the old carb needed full choke to run......again, lean.
seems maybe an air/vacuum leak?

I see the new carb runs normally, but, still, when throttling up, and, it dies, it seems that it's starving for fuel.

the black plug my be to cold, dunno.

when you say runs all day, you mean driving it around? or idling?

do you mean it dies when revved really high?
moving or idling?

there are more details that would help diagnose.......

anyway, those are a couple of my thoughts, random as they may be.......

good luck

[turvuren]

Kohler trouble

Sounds like maybe your engine is tired. Assuming you have fresh,clean fuel to carb, a good starting point is to let it idle for at least 5 minutes then pull spark plug and do a compression check. Your nearest auto mechanic should have a gauge you can borrow

[tmore22]

Thanks for the replies!

Where might a good starting place for a vacuum leak be? I don't see too many hoses around except for the one that connects into the air filter housing (which I haven't re-installed since I'm still adjusting).

I was thinking the same thing about the fuel so I replaced the fuel line with 5/16" hose. I hope the new fuel pump is working properly and not starving the carb.

I might try a hotter plug, but don't want to over do it.

When I say revving, I mean almost anything past idle...like moving the throttle on the carb about 1/4 inch. I can't get it revving high enough to kick the clutches in and get the transmission spinning.

What would the symptons of a broken woodruff key be?

Thanks so much for the help!

[racerone3]

i don't know the particulars of your engine by the model #, but i'm assuming 2 stroke? a few thoughts on it... when you replaced the carb, did you match all the jets? some carbs came with different jetting to be used on various engines, or at different altitudes. a while back i fought with a tiller for months after a carb rebuild, only to find that i was way out of range on the jetting. if your unsure, take the main jets out of the old carb, soak in acetone to clean them and then put the old jets in the new carb.
2 stokes usually pump fuel by crank case pressure. if the crank seals are bad, it won't pump properly, and will starve for fuel when you try to rev it. i check for this by gravity feeding fuel directly to the carb (no pump). i have the gas tank from an old riding mower on a stand. just run a line down to the carb and see if it will run that way. you may be fighting 2 problems... if it's flooding at idle (hence the wet plugs) then starving for fuel. if your running an electric pump, it could be too strong. it might overcome thee float, and cause the engine to run way too rich.
also if the plugs are wet, they might already be fouled. did you replace them before the carb?
a broken flywheel key will change your timing. it can allow the flywheel to spin on the crankshaft. symptoms can be all over the board... just depends how far the timing gets out.
good luck getting it up and running, and keep us posted on your progress

[jerseybigfoot]

Kohler 16 Problems

tmore22; Here is a link for your engine manual.

http://www.kohlerengines.com/common/resources/tp_2379.pdf

Make sure you have a nice hot spark. I suspect if you have a poor spark. if you are uncertain as the condition of the points they are probably old and need replacing. My Hustler had the same engine and was about the same year. Once I gave it a tune up with points, condenser, carb, sparkplug, aircleaner it ran real strong. These engines have lots of torque.

[tmore22]

i don't know the particulars of your engine by the model #, but i'm assuming 2 stroke? a few thoughts on it... when you replaced the carb, did you match all the jets? some carbs came with different jetting to be used on various engines, or at different altitudes. a while back i fought with a tiller for months after a carb rebuild, only to find that i was way out of range on the jetting. if your unsure, take the main jets out of the old carb, soak in acetone to clean them and then put the old jets in the new carb.
2 stokes usually pump fuel by crank case pressure. if the crank seals are bad, it won't pump properly, and will starve for fuel when you try to rev it. i check for this by gravity feeding fuel directly to the carb (no pump). i have the gas tank from an old riding mower on a stand. just run a line down to the carb and see if it will run that way. you may be fighting 2 problems... if it's flooding at idle (hence the wet plugs) then starving for fuel. if your running an electric pump, it could be too strong. it might overcome thee float, and cause the engine to run way too rich.
also if the plugs are wet, they might already be fouled. did you replace them before the carb?
a broken flywheel key will change your timing. it can allow the flywheel to spin on the crankshaft. symptoms can be all over the board... just depends how far the timing gets out.
good luck getting it up and running, and keep us posted on your progress

The Kohler engine is a 4 stroke. When I changed carbs, the only one I could find available was made by a different manufacturer than the original (new is a Walbro, original was a Kohler) so mix-matching the jets won't be a possibility because the design is slightly different.

I'll try the trick of bypassing the fuel pump and coming directly out of a fuel container and see if I have any luck.

I've only been cleaning the plug with carb cleaner and drying it out before reinstalling it. I'll try replacing the plug with a hotter one and see if I have any luck.

I'll attempt to figure out how to check the flywheel key and see what it looks like.

Thanks so much for the help!

[tmore22]

tmore22; Here is a link for your engine manual.

http://www.kohlerengines.com/common/resources/tp_2379.pdf

Make sure you have a nice hot spark. I suspect if you have a poor spark. if you are uncertain as the condition of the points they are probably old and need replacing. My Hustler had the same engine and was about the same year. Once I gave it a tune up with points, condenser, carb, sparkplug, aircleaner it ran real strong. These engines have lots of torque.

I replaced the points before attempting to start the engine after it set for years. I've replaced everything you have listed and will attempt a hotter plug.

Thanks!