Troybilt Pony Muffler Smoking/Overheating (melting spark plug wire)

[Kmh72412]

I have a troybilt Pony riding mower that my mom bought that is having some issues.

It is overheating to the point that the muffler smokes and the spark plug wire/boot melts.

The muffler is not blowing smoke but smoking itself and just after 20-30 seconds of running. No smoke is coming out of muffler but again, the muffler is literally smoking.

It is not turning red or anything like I have heard some individuals say they experience.

The carb was changed recently due to surging and the surging stopped but now the muffler smokes and the spark plug wire melts if mower runs for longer than a minute or so.

I have checked the oil, changed it, rechecked it, changed the fuel filter, fuel lines, carb, and air filter.

I have tried adjusting carb but no luck. I checked cooling fins, no debris or blockage.

Any ideas? I'd really appreciate any help. I have really come to a halt in this fix and figured I'd reach out for some help. Thanks in advance.

 

[sgkent]

put an infrared gun on the head to see how hot it is. How does it idle? Best guess is that it is jetted too lean.

 

[Kmh72412]

put an infrared gun on the head to see how hot it is. How does it idle? Best guess is that it is jetted too lean.

It idles great. Since changing the carb the surging went away but it's still getting so hot the spark plug wire keeps melting.

I'll definitely try that. Do you know about how hot would be normal and excessive?

Thanks for your response and help.

 

[StarTech]

Also check for loose muffler to engine connection or blown exhaust gasket. Either will the exhaust at the head run so hot even the exhaust valve seat can come out of place.

 

[Kmh72412]

Also check for loose muffler to engine connection or blown exhaust gasket. Either will the exhaust at the head run so hot even the exhaust valve seat can come out of place.

Thank you, I hadn't thought of that. I forgot to mention the muffler is new and I did notice the gasket was a little old (and I didn't replace it).

I'll have to take it off and recheck it. I really appreciate your insight and help StarTech.

 

[ILENGINE]

Thank you, I hadn't thought of that. I forgot to mention the muffler is new and I did notice the gasket was a little old (and I didn't replace it).

I'll have to take it off and recheck it. I really appreciate your insight and help StarTech.

A new muffler will smoke until the paint anticorrosive coating burns off. And the exhaust gasket could be leaking blowing hot exhaust in the spark plug boot.

 

[Kmh72412]

A new muffler will smoke until the paint anticorrosive coating burns off. And the exhaust gasket could be leaking blowing hot exhaust in the spark plug boot.

Thanks ILENGINE I really appreciate that insight and information. I didn't know that about the anticorrosive coating.

That last point makes perfect sense as well. I really appreciate all the help from everyone.

 

[sgkent]

"but it's still getting so hot'

do you care to explain that statement? It appears from your statement the overheating problem began before the carb was replaced. Also - did you replace the coil, and if so under what circumstances?

 

[Kmh72412]

do you care to explain that statement? It appears from your statement the overheating problem began before the carb was replaced. Also - did you replace the coil, and if so under what circumstances?

Yes, the overheating was an issue before the carb change. The carb was changed due to surging (which was fixed with new carb) but overheating persisted.

The coil was replaced because the wire melted due to overheating.

The muffler was changed last due to the muffler making a rattling sound when removed and shaken.

 

[sgkent]

what problem came first?

How much use had the engine seen without that problem before it happened?

engine model number and serial and/or at least Pony model number and serial.

What spark plug number are you running in it?