Brushcutter Mechanic Course

Lesson 1 • Workshop Safety and Tool Organisation

Establishes safe workshop layout, fire prevention, and tool storage practices. Ensures learners maintain a hazard-free environment for all diagnostic and repair tasks.

Lesson 2 • Personal Protective Equipment

Specifies required PPE for brushcutter operation and mechanical work. Connects proper protection habits to injury prevention before learners handle any equipment.

Lesson 3 • Major Components and Assemblies

Identifies engine, drive shaft, gearhead, harness, and cutting attachment as integrated systems. Provides the anatomical map learners reference throughout the entire course.

Lesson 1 • Engine Cooling and Thermal Management

Describes air-cooling fin design, shroud airflow paths, and overheating consequences. Learners recognise cooling system deficiencies as a root cause of premature engine wear.

Lesson 2 • Crankshaft and Bearings

Covers crankshaft construction, main bearing types, and connecting rod big-end bearings. Learners assess bearing condition and understand how failures propagate through the engine.

Lesson 3 • Lubrication in Two-Stroke Engines

Explains premix and oil-injection lubrication methods and correct oil-to-fuel ratios. Directly links improper lubrication to the bearing and piston failures studied in prior sections.

Lesson 4 • Engine Block and Cylinder Assembly

Details cylinder bore, piston, rings, and wrist pin as a matched assembly. Learners connect component wear patterns to combustion efficiency losses.

Lesson 1 • Diaphragm Carburettor Construction

Identifies metering diaphragm, pump diaphragm, check valves, and needle-and-seat assembly. Provides the structural knowledge required for accurate carburettor fault diagnosis.

Lesson 2 • Carburettor Adjustment Procedures

Teaches high-speed, low-speed, and idle mixture screw adjustment using tachometer feedback. Learners achieve factory-specified RPM ranges without over-richening or leaning the mixture.

Lesson 3 • Air Filter Service and Intake Sealing

Covers foam and felt filter cleaning, replacement intervals, and intake boot seal inspection. Connects air filter condition directly to carburettor contamination and mixture accuracy.

Lesson 4 • Carburettor Overhaul and Cleaning

Details disassembly sequence, solvent cleaning, diaphragm inspection, and reassembly torque specs. Learners complete a full overhaul restoring carburettor function to manufacturer standards.

Lesson 1 • Spark Plug Diagnosis and Selection

Interprets spark plug electrode colour, deposits, and erosion as combustion condition indicators. Learners select correct plug heat range and gap for the engine being serviced.

Lesson 2 • Flywheel Inspection and Service

Covers flywheel magnet strength, key shear diagnosis, and safe flywheel removal techniques. Learners identify timing-related faults caused by flywheel key damage or magnet degradation.

Lesson 3 • Ignition Module Testing and Air Gap

Teaches resistance testing of the ignition module and precise air gap setting with feeler gauges. Correct air gap directly determines spark energy and timing consistency.

Lesson 1 • Bottom-End Disassembly and Inspection

Details crankcase splitting, crankshaft removal, and bearing and seal extraction procedures. Learners assess crankshaft runout and bearing condition to determine reuse or replacement.

Lesson 2 • Break-In Procedure and Post-Overhaul Testing

Establishes a structured break-in run sequence and post-overhaul performance verification checks. Learners confirm the rebuilt engine meets compression, RPM, and temperature specifications.

Lesson 3 • Engine Reassembly and Torque Sequence

Specifies bearing installation temperatures, seal orientation, piston ring gap positioning, and torque sequences. Learners assemble the engine to eliminate leaks and achieve correct compression.

Lesson 4 • Top-End Disassembly and Measurement

Covers cylinder head removal, piston extraction, and bore measurement with inside micrometers. Learners determine whether to hone, re-bore, or replace the cylinder based on measurements.

Lesson 1 • Gearhead Disassembly and Inspection

Details bevel gear removal, bearing extraction, and housing inspection for wear and cracks. Learners document gear contact patterns to assess mesh quality before reassembly.

Lesson 2 • Drive Shaft Inspection and Replacement

Covers shaft straightness, spline wear, and flexible-core condition checks using visual and tactile methods. Learners replace worn shafts and re-grease correctly to prevent premature failure.

Lesson 3 • Drive Shaft Types and Construction

Distinguishes solid, flexible, and split-shaft designs and their respective bearing and coupling arrangements. Learners match service procedures to shaft type before disassembly.

Lesson 1 • Blade Mounting and Torque Procedures

Details correct blade washer stack, thread direction, and torque values for secure blade retention. Incorrect mounting is the leading cause of blade ejection injuries.

Lesson 2 • Blade Types and Selection Criteria

Compares two-tooth, three-tooth, multi-tooth, and brush-knife blades by material and application. Learners select the correct blade to maximise cutting efficiency and minimise operator fatigue.

Lesson 3 • Blade Sharpening Techniques

Teaches file and bench-grinder sharpening methods while maintaining original bevel angle and balance. Proper sharpening restores cutting efficiency and reduces engine load.

Lesson 4 • Trimmer Head Service

Covers bump-feed, fixed-line, and pre-wound head disassembly, line replacement, and spring inspection. Learners restore reliable line feed to eliminate operator downtime during use.

Lesson 1 • Overheating and Fuel Consumption Faults

Diagnoses lean mixture, cooling restriction, and ignition timing errors as overheating root causes. Learners also identify abnormal fuel consumption patterns linked to specific system failures.

Lesson 2 • Performance and Power-Loss Diagnosis

Diagnoses rich/lean conditions, partial blockages, and mechanical wear causing power loss under load. Learners use tachometer data and plug readings to pinpoint the defective system.

Lesson 3 • No-Start and Hard-Start Diagnosis

Applies a spark-compression-fuel sequence to isolate no-start causes across ignition, fuel, and mechanical systems. Learners resolve no-start faults without unnecessary component replacement.

Lesson 4 • Vibration and Noise Fault Diagnosis

Isolates vibration and abnormal noise to drive shaft, gearhead, cutting attachment, or engine sources. Learners use isolation techniques to confirm the origin before disassembly.