Runs with muffler off but not on

Lochlin

Guys, hoping to get some advice. I have this "new to me" '85 that I am trying to resurrect. Compression is good at a bit over 100 psi.

Cart runs fine with the muffler off. It won't run with the muffler on other than an occasional sputter. I swapped mufflers with my running '85 with the same result so it's not a muffler issue.

When I got this cart, there was a ton of that gasket-goo stuff where the cylinder base gasket goes. I got that all cleaned up and inspected this area. Everything looks ok with regard to no giant gouges or anything on the engine or the cylnder base. I installed a new base gasket which didn't help. I then installed another base gasket (so there are now two of them). Still no change. When I get some time I might put a bit of permatex in there too just to see if that helps. The way a previous owner had all of the gasket-goo there makes me wonder if this could be a problem area.

It's really tough to tell but when the motor runs with with muffler off it looks like there might be just a touch of smoke at the points / fan area but with the muffler off it's really tough to say for sure. This would be where that front crank seal is (called oil seal in manual as we learned from a previous post).

I am going to go ahead and order that front seal but does anyone have any other thoughts?

BGW

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teecro

What is new spec on compression? While it can vary from one engine type to another but 100 PSI does not sound very good to me. Adding a 2nd base gasket increased the overall height of the cylinder and thus lowered your compression ratio. It sounds to me that your engine is just too weak to run through the restriction caused by the mufflers...

Lochlin

Compression spec is 80-100. Mine is 105-110 and it holds there when the engine isn't turning. We should be ok there.

I have to ponder the "double gasket" theory. I wouldn't think less than a millimeter or so would matter much but who knows. Either way, single gasket didn't work either.