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Questions 1 to 32: Select the best answer to each question. FIGURE A-1—Use this illustration to answer Question 1.
1. In the photo shown in Figure A-1, a technician is doing something to an engine. What is the purpose of the item labeled with the letter X in the figure?
A. This item is used to install the flywheel onto the end of the crankshaft.
B. This item is used to install the flywheel key.
C. This item is used to hold the flywheel and the crankshaft in alignment.
D. This item is used to protect the threads of the crankshaft when the flywheel is being removed.
Questions 2 through 9 are based on the following information.
Imagine that you’re watching a technician rebuild a small, one-cylinder, gas-powered engine. The technician has just reached the point in the rebuilding process at which the intake and exhaust valves will be inspected and measured. The valve specifications for the engine being rebuilt are shown in Figure A-2. Look over the specifications in the chart, then proceed to answer Questions 2 through 9. Refer back to Figure A-2 as often as necessary to help you answer the questions.FIGURE A-2—Use the information in this chart to answer Questions 2 through 9.FIGURE A-3—Use this illustration to answer Question 2.(Courtesy of Kohler)2. In Figure A-3, the technician is performing a measurement on the engine’s intake valve with an outside micrometer. The micrometer reading the technician gets is shown in the figure. (Note that this micrometer has a 0-1 inch range.) Read the micrometer and compare the measurement to the valve specification listed in Figure A-2. Based on this comparison, which of the following statements is correct?
A. The micrometer reading is 0.3073 inch, which is higher than the maximum specification for this valve.
B. The micrometer reading is 0.0311 inch, which is lower than the minimum specification for this valve.
C. The micrometer reading is 0.3123 inch, which is within the specification range for this valve.
D. The micrometer reading is 0.3250 inch, which is higher than the maximum specification for this valve.
FIGURE A-4—Use this illustration to answer Question 3.3. The technician is now measuring the area indicated by the arrow on the intake valve shown in Figure A-4. According to the valve specifications in Figure A-2, what should this measurement be if the valve is in good condition?
A. The measurement should be between 1.370 inches and 1.380 inches.
B. The measurement should be between 0.037 inch and 0.045 inch.
C. The measurement should be between 1.120 inches and 1.130 inches.
D. The measurement should be between 0.312 inch and 0.313 inch.
FIGURE A-5—Use this illustration to answer Question 4.4. In the next step of the valve inspection process, the technician is measuring the area indicated by the arrow on the exhaust valve shown in Figure A-5. According to the valve specifications in Figure A-2, what should this measurement be if the valve is in good condition?
A. The measurement should be an angle of 45 degrees.
B. The measurement should be 0.031 inch.
C. The measurement should be an angle of 89 degrees.
D. The measurement should be between 0.037 inch and 0.045 inch.
FIGURE A-6—Use this illustration to answer Question 5.5. The technician is now performing the measurement shown in Figure A-6. According to the valve specifications in Figure A-2, what should this measurement be if the engine is in good condition?
A. The measurement should be an angle of 45 degrees.
B. The measurement should be between 0.037 inch and 0.045 inch.
C. The measurement should be between 0.3074 inch and 0.3081 inch.
D. The measurement should be 0.031 inch.
Customer reply 29 Mar 2018
FIGURE A-7—Use this illustration to answer Question 6.6. The technician is now measuring the area indicated on the exhaust valve shown in Figure A-7. According to the valve specifications in Figure A-2, what should this measurement be if the valve is in good condition?
A. The measurement should be between 0.3074 inch and 0.3081 inch.
B. The measurement should be an angle of 89 degrees.
C. The measurement should be a minimum of 0.031 inch.
D. The measurement should be between 1.370 inches and 1.380 inches.
FIGURE A-8—Use this illustration to answer Question 7.7. In the next step of the valve inspection process, the technician is measuring the area indicated on the exhaust valve shown in Figure A-8. According to the valve specifications in Figure A-2, what should this measurement be if the valve is in good condition?
A. The measurement should be between 1.370 inches and 1.380 inches.
B. The measurement should be between 0.3074 inch and 0.3081 inch.
C. The measurement should be between 1.120 inches and 1.130 inches.
D. The measurement should be between 0.312 inch and 0.313 inch.
FIGURE A-9—Use this illustration to answer Question 8.8. The technician is now measuring the inside diameter of the intake valve guide with a telescoping gage and an outside micrometer. Figure A-9 shows the technician measuring the telescoping gage with the micrometer. The micrometer reading the technician gets is also shown in the figure (note that this micrometer has a 0-1 inch range). Read the micrometer and compare the actual measurement to the valve specifications in Figure A-2. Based on this comparison, which of the following statements is correct?
A. The micrometer reading is 0.307 inch, which is higher than the maximum specification for this engine.
B. The micrometer reading is 0.312 inch, which is within the specification range for this engine.
C. The micrometer reading is 0.325 inch, which is higher than the maximum specification for this engine.
D. The micrometer reading is 0.313 inch, which is within the specification range for this engine.
FIGURE A-10—Use this photo to answer Question 9.9. The technician is now using a tool to recondition one area of the engine, as shown in Figure A-10. According to the valve specifications in Figure A-2, what should the measurement of this area be when the technician has finished reconditioning it?
A. The measurement should be between 0.312 inch and
0.313 inch.
B. The measurement should be an angle of 90 degrees.
C. The measurement should be between 0.037 inch and
0.045 inch.
D. The measurement should be an angle of 45 degrees.
FIGURE A-11—Use this illustration to answer Question 10.(Courtesy of Kohler)10. Figure A-11 shows a technician performing an engine reassembly task. What does the technician appear to be doing in the drawing?
A. Installing a piston pin and its retaining ring in a piston
B. Measuring the piston ring end gap
C. Installing a piston ring on a piston
D. Measuring the piston ring side clearance
FIGURE A-12—Use this photo to answer Question 11.
11. Three students are watching a technician disassemble an engine. In Figure A-12, the technician is removing a component from the engine. Student A says that the governor linkage and spring are connected to this component. Student B says that this component is used to control the flow of fuel from the fuel tank to the carburetor. Student C says that the kill switch wire is connected to this component. Which of the following statements is correct?
A. Only Student A is correct.
B. Student A and Student C are both correct.
C. Only Student B is correct.
D. None of the three students is correct.
Questions 12 through 30 are based on the following information.
Imagine that you’re watching a technician rebuild a small, one-cylinder, gas-powered engine. The engine has already been disassembled, and the technician is ready to perform the various measurements that are needed to make sure that the engine is in good condition. The specification chart for this particular engine is provided in Figure A-13. Look over the specification chart, then proceed to answer Questions 12 through 30. Refer back to Figure A-13 (and to your study units on rebuilding) as often as necessary to help you answer the questions.FIGURE A-13—Use this table to answer Questions 12 through 30.FIGURE A-14—Use this illustration to answer Question 12. (Courtesy of Kohler)
12. At this stage in the rebuild, the technician is measuring the outside diameter of the crankpin with an outside micrometer. He measures the diameter in opposite directions at each of three locations on the crankpin-the left, the middle, and the right. Thus, he takes a total of six measurements. The measurement locations are shown in Figure A-14, along with the measurements he records at each of the locations. Compare these measurements to the specification chart in Figure A-13. Note that the chart specifies an al
Customer reply 29 Mar 2018
13. The X and Y measurements that the technician recorded in Figure A-14 show the diameters in opposing directions at each of the three locations on the crankshaft (left, right, and middle). At this time, use the X and Y measurements to calculate whether the crankshaft is out-of-round at any of the three locations. (To do this, compare the X value to the Y value at each location. Subtract the smaller value from the larger value at each location to determine how much the crankshaft is out-of-round at that location.) Next, compare your three out-of-round calculations to the maximum allowable out-of-round specification in Figure A-13. Based on your calculations and the manufacturer’s specification, which of the following statements is correct?
A. The out-of-round measurement at the left of the crankshaft is higher than the maximum allowable measurement.
B. The out-of-round measurement at the middle of the crankshaft is higher than the maximum allowable measurement.
C. The out-of-round measurement at the right of the crankshaft is higher than the maximum allowable measurement.
D. None of the three out-of-round measurements is higher than the maximum allowable measurement.
14. Next, determine whether the crankshaft is tapered. To do this, compare the three X measurements in Figure A-14 to each other. Subtract the smallest X measurement from the largest X measurement to calculate the taper at X. Then, compare the three Y measurements to each other. Subtract the smallest Y measurement from the largest Y measurement to calculate the taper at Y.
Next, compare your two taper calculations to the maximum allowable taper specification in Figure A-13. Based on your calculations and the manufacturer’s specification, which of the following statements is correct?
A. The crank is tapered more than the maximum allowable amount at X.
B. The crank is tapered more than the maximum allowable amount at Y.
C. The crank is tapered more than the maximum allowable amount at both X and Y.
D. The crank isn’t tapered more than the maximum allowable amount at either X or Y.
FIGURE A-15—Use this illustration to answer Question 15. (Courtesy of Kohler)15. The technician has completed the crankshaft measurements and is now ready to proceed to the cylinder bore. He measures the inside diameter of the cylinder bore by using a telescoping gage and an outside micrometer. He measures the inside diameter in opposite directions at each of three locations in the cylinder bore-the top, the middle, and the bottom. Thus, he takes a total of six measurements. The measurement locations are shown in Figure A-15, along with the measurements you record at each of the locations. Compare these measurements to the maximum wear limit specification in Figure A-13. Based on this information, which of the following statements is correct?
A. The X diameter at the top of the cylinder bore is larger than the allowable limit.
B. The Y diameter at the middle of the cylinder bore is larger than the allowable limit.
C. The X diameter at the bottom of the cylinder bore is larger than the allowable limit.
D. The inside diameter measurements at all three locations are larger than the specified limit.
16. The X and Y measurements that the technician recorded in Figure A-15 show the diameters in opposing directions at each of the three locations in the cylinder bore (top, middle, and bottom). At this time, use the X and Y measurements to calculate whether the cylinder bore is out-of-round at any of the three locations. (To do this, compare the X value to the Y value at each location. Subtract the smaller value from the larger value at each location to determine how much the bore is out-of-round at that location.) Next, compare your three out-of-round calculations to the maximum allowable out-of-round specification in Figure A-13. Based on your calculations and the manufacturer’s specification, which of the following statements is correct?
A. The out-of-round measurement at the top of the cylinder bore is higher than the maximum allowable measurement.
B. The out-of-round measurement at the middle of the cylinder bore is higher than the maximum allowable measurement.
C. The out-of-round measurement at the bottom of the cylinder bore is higher than the maximum allowable measurement.
D. None of the three out-of-round measurements is higher than the maximum allowable measurement.
17. Next, determine whether the cylinder bore is tapered. To do this, compare the three X measurements in Figure A-15 to each other. Subtract the smallest X measurement from the largest X measurement to calculate the taper at X. Then, compare the three Y measurements to each other. Subtract the smallest Y measurement from the largest Y measurement to calculate the taper at Y. Next, compare your two taper calculations to the maximum allowable taper specification in Figure A-13. Based on your calculations and the manufacturer’s specification, which of the
Customer reply 29 Mar 2018
following statements is correct?
A. The cylinder bore is tapered more than the maximum allowable amount at X.
B. The cylinder bore is tapered more than the maximum allowable amount at Y.
C. The cylinder bore is tapered more than the maximum allowable amount at both X and Y.
D. The cylinder bore isn’t tapered more than the maximum allowable amount at either X or Y.
Customer reply 29 Mar 2018
FIGURE A-16—Use this illustration to answer Question 18.18. At this time, the technician is measuring the thrust face outside diameter of the piston with an outside micrometer. The micrometer has a range of 3 to 4 inches. The micrometer reading the technician gets is shown in Figure A-16. Read the micrometer, then compare the measurement to the specification chart in Figure A-13. Based on this information, which of the following statements is correct?
A. The micrometer reading is 3.515 inches, which is within the specification range for this piston.
B. The micrometer reading is 3.015 inches, which is lower than the minimum specification for this piston.
C. The micrometer reading is 3.365 inches, which is within the specification range for this piston.
D. The micrometer reading is 3.315 inches, which is lower than the minimum specification for this piston.
19. You learned the outside diameter of the piston in Question 18 and the inside diameter of the cylinder bore in Question 15. Now that you know both of these measurements, you can calculate the piston-to-bore clearance. To do this, subtract the measured outside diameter of the piston from the largest cylinder bore diameter measurement that the technician recorded in Figure A-15.
Next, compare the actual piston-to-bore clearance of this engine to the allowable clearance range listed in the specification chart in Figure A-13. Based on your calculation and the information in the specification chart, which of the following statements is correct?
A. The piston-to-bore clearance in this engine is 0.005, which is smaller than the minimum specification for this engine.
B. The piston-to-bore clearance in this engine is 0.009, which is within the specified range for this engine.
C. The piston-to-bore clearance in this engine is 0.013, which is larger than the maximum specification for this engine.
D. The piston-to-bore clearance in this engine is 0.014, which is larger than the maximum specification for this engine.
Customer reply 29 Mar 2018
FIGURE A-17—Use this illustration to answer Question 20.20. The technician is now performing the piston measurement shown in Figure A-17. Identify what measurement is being performed in this illustration, then check the chart in Figure A-13 to see what the correct specification should be for this engine. According to the specification chart, what should this measurement be?
A. A maximum of 0.006 inch
B. Between 0.007 inch and 0.010 inch
C. Between 0.010 inch and 0.020 inch
D. A maximum of 0.030 inch
Customer reply 29 Mar 2018
FIGURE A-18—Use this illustration to answer Question 21.
21. In the next step of the rebuild process, the technician is measuring the outside diameter of the piston pin with an outside micrometer. The micrometer reading the technician gets is shown in Figure A-18. (The micrometer has a range of 0 to 1 inch.) Read the micrometer, then compare the measurement to the piston pin specification in Figure A-13. Based on this information, which of the following statements is correct?
A. The micrometer reading is 0.506 inch, which is lower than the minimum specification for this piston pin.
B. The micrometer reading is 0.516 inch, which is within the specification range for this piston pin.
C. The micrometer reading is 0.525 inches, which is lower than the minimum specification for this piston pin.
D. The micrometer reading is 0.531 inch, which is within the specification range for this piston pin.
Customer reply 29 Mar 2018
FIGURE A-19—Use this illustration to answer Question 22. (Courtesy of Kohler)22. In Figure A-19, the technician is performing a measurement on the engine’s exhaust valve with an outside micrometer. The micrometer reading the technician gets is shown. (Note that this micrometer has a 0-1 inch range.) Read the micrometer and compare the measurement to the specification listed on the chart in Figure A-13. Based on this comparison, which of the following statements is correct?
A. The micrometer reading is 0.039 inch, which is the correct specification for this valve.
B. The micrometer reading is 0.3071 inch, which is the correct specification for this valve.
C. The micrometer reading is 0.3079 inch, which is the correct specification for this valve.
D. The micrometer reading is 0.3123 inch, which is the correct specification for this valve.23. The technician has just finished measuring the valve-to-tappet clearance for the exhaust valve and the intake valve. He gets a clearance measurement of 0.009 inch for the intake valve and a clearance measurement of 0.017 inch for the exhaust valve. Compare these measurements to the specification chart in Figure A-13. According to the information in the chart, which of the following statements is correct?
A. The exhaust valve clearance is within the specification range, but the intake valve clearance is not.
B. The intake valve clearance is within the specification range, but the exhaust valve clearance is not.
C. The intake valve clearance and the exhaust valve clearance are both within their specification ranges.
D. Neither the intake valve clearance nor the exhaust valve clearance are within their specification ra
Customer reply 29 Mar 2018
FIGURE A-20—Use this illustration to answer Question 24.
24. At this time, the technician has just finished measuring the inside diameter of the intake valve guide by using a telescoping gage and an outside micrometer. Figure A-20 shows the technician measuring the telescoping gage with the micrometer. The micrometer reading is also shown in the figure (note that this micrometer has a 0-1 inch range). Read the micrometer and compare the actual measurement to the specification chart in Figure A-13. Based on this comparison, which of the following statements is correct?
A. The micrometer reading is 0.3079 inch, which is lower than the specification for this engine.
B. The micrometer reading is 0.3129 inch, which is the correct specification for this engine.
C. The micrometer reading is 0.3259 inch, which is higher than the specification for this engine.
D. The micrometer reading is 0.3629 inch, which is higher than the specification for this engine.
Customer reply 29 Mar 2018
FIGURE A-21—Use this illustration to answer Question 25.(Courtesy of Kohler)25. The technician is now performing a measurement on the engine component shown in Figure A-21. Identify what measurement is being performed in this illustration. Then, check the chart in Figure A-13 to see what the correct specification should be for this component. According to the specification chart, what should this measurement be?
A. A maximum of 0.003 inch
B. Exactly 260 inch-pounds
C. A minimum of 0.020 inch
D. Exactly 15 foot-pounds
Customer reply 29 Mar 2018
FIGURE A-22—Use this illustration to answer Question 26.(Courtesy of Kohler)26. At this point, the technician is performing a measurement on the engine component shown in Figure A-22. Identify what measurement is being performed in Figure A-22, then check the chart in Figure A-13 to see what the correct specification should be for this component. According to the specification chart, what should this measurement be?
A. A minimum of 0.002 inch
B. A maximum of 0.0025 inch
C. A maximum of 0.005 inch
D. A minimum of 0.016 inch
Customer reply 29 Mar 2018
FIGURE A-23—Use this illustration to answer Question 27.(Courtesy of Kohler)27. The technician is now performing a measurement on the engine component shown in Figure A-23. Identify what measurement is being performed in this illustration, then check the chart in Figure A-13 to see what the correct specification should be for this component. According to the specification chart, what should this measurement be?
A. A maximum of 0.006 inch
B. Between 0.007 inch and 0.010 inch
C. A maximum of 0.030 inch
D. Between 0.0531 inch and 0.533 inch
Customer reply 29 Mar 2018
FIGURE A-24—Use this illustration to answer Question 28.(Courtesy of Homelite, Inc., Subsidiary of John Deere & Co.)28. Next, the technician is performing the measurement shown in Figure A-24. Identify what measurement is being performed in this illustration, then check the chart in Figure A-13 to see what the correct specification should be for this engine. According to the specification chart, what should this measurement be?
A. A minimum of 0.003 inch
B. Between 0.007 inch and 0.010 inch
C. Between 0.012 inch and 0.016 inch
D. A maximum of 0.025 inch
Customer reply 29 Mar 2018
FIGURE A-25—Use this illustration to answer Question 29.29. The technician is now performing a measurement on the engine component shown in Figure A-25. Identify what measurement is being performed in this illustration, then check the chart in Figure A-13 to see what the correct specification should be for this component. According to the specification chart, what should this measurement be?
A. 0.025 inch
B. Between 0.012 inch and 0.016 inch
C. 0.030 inch
D. A minimum of 0.016 inch
Customer reply 29 Mar 2018
FIGURE A-26—Use this troubleshooting chart to answer Questions 30, 31, and 32.30. A customer brings a garden tiller into your shop and complains that the engine won’t start. After checking the condition of the engine yourself, you determine that the engine will crank but won’t start. At this point, you know that the internal engine components aren’t seized, since the crankshaft will turn. Not wanting to overlook any obvious causes, you check the fuel tank and the spark plug connection. You find that the fuel tank is half-full and that the spark plug wire is connected. Upon checking the key switch and the kill switch, you find that they’re both in their correct ON positions. Therefore, you remove the spark plug and perform a spark test. When you hold the spark plug wire close to the engine block and crank the engine, you observe a bright blue spark jump from the wire to the engine block. You then repeat the test with the spark plug connected to the wire. A bright blue spark appears in this test, too, so the spark plug appears to be in good condition. According to the troubleshooting chart in Figure A-26, what should be your next troubleshooting step?
A. Check the fuel shutoff valve, the fuel line, and the quality of the fuel.
B. Disassemble the engine to check the condition of the piston rings, cylinder bore, and valves.
C. Check the grass screen, cooling fins, and shroud for obstructions.
D. Remove the flywheel and check the condition of the flywheel key.31. A customer brings a riding lawn mower into your shop and explains that it won’t start. After checking the machine yourself, you determine that the engine won’t crank at all. While you’re testing the mower, you double-check the position of the transmission and the safety interlock switches to make sure that all are in the correct starting positions. The transmission is in neutral, the blade is disengaged, and the clutch pedal is down and locked, which are the correct starting positions of the switches. When you question the customer to get a little more information about the problem, she tells you that the mower was running fine the last time she used it. From the customer’s answers, you determine that when she last used the mower, there didn’t appear to be any signs of overheating or other conditions that would have seized up the engine. Next, you perform tests on the battery, the key switch, the ignition switch, and the starter. All appear to be in good condition. According to the troubleshooting chart in Figure A-26, what would be your next troubleshooting step?
A. Check the condition of the cylinder head gasket.
B. Test the spark plug and measure its gap.
C. Check for loose wires and faulty connections.
D. Disassemble the engine and measure the valve-to-tappet clearance.32. A customer brings a lawn mower into your shop and complains that the engine is using a lot of oil. After briefly checking the engine, you determine that the oil level appears to be correct and that the breather system is properly assembled and free of obstructions. You then ask the customer what type of oil he’s using in the engine. You can tell from the customer’s answer that the type of oil being used in the engine is the correct type recommended by the manufacturer. According to the troubleshooting chart in Figure A-26, what would be your next troubleshooting step?
A. Check the carburetor’s idle speed and idle fuel settings.
B. Check the piston rings, cylinder bore, and valves.
C. Check to see whether the kill switch or key switch is in the OFF position.
D. Drain the fuel from the tank to determine if it contains dirt or water.
Customer reply 29 Mar 2018
Question 12 got cut off reposting it
FIGURE A-14—Use this illustration to answer Question 12. (Courtesy of Kohler)
12. At this stage in the rebuild, the technician is measuring the outside diameter of the crankpin with an outside micrometer. He measures the diameter in opposite directions at each of three locations on the crankpin-the left, the middle, and the right. Thus, he takes a total of six measurements. The measurement locations are shown in Figure A-14, along with the measurements he records at each of the locations. Compare these measurements to the specification chart in Figure A-13. Note that the chart specifies an allowable range for the outside diameter of the crankpin. Based on this information, which of the following statements is correct?
A. The X diameter at the left of the crankpin is smaller than the specified range.
B. The Y diameter at the middle of the crankpin is smaller than the specified range.
C. The X and Y diameters at the right of the crankpin are smaller than the specified range.
D. The outside diameter measurements at all three locations are within the specified range.

Exam #08903600