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Gene Davis (Ga.
04-24-2004 22:57:11
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I have a GX160 horizontal shaft,5.5hp engine that is going to drive me nuts I think! Here's the story. I went to visit my daughter and on the way to see her house I noticed a theme park style fiber-glass bodied go-kart under a tree. Short story is that it became mine over the telephone, and when she came to visit she brought it to me.Unloaded it off her truck and was suprised to see that I had captured not 1, but 2 Honda GX160's with the reduction gear/clutch set ups. Both were off the chassis and he had them inside the building. Took a look at both of them, one was almost new, but somehow one mounting ear got broken off, but not into the sump, so it still holds oil ok so I'll refer to it as #1. The other one was a little more used, but was missing carburetor and air cleaner assembly, so I'll refer to it as #2. No sweat there, for there is everything I need on the other one. That's why the guy had 2 engines she said. First I crank the one with the broken mount hole and it runs like a new one should all the way from idle to full throttle and in between, but it has a broken clutch spring. SO... I took the carburetor, insulator block, and air filter assembly off this one and put it on the older engine. Interestingly they are just alike, only a few numbers different in the serial numbers. This engine runs good also, so I mount it on the chassis and turn the grandchildern loose with it. Have to say it is light years ahead of the 5hp briggs on the other kart they have, not faster, just easier to keep running. I taped all the int.ports and muffler closed on, drain gas tank and line on the broken mount engine(#1), and sit it under my bench, and diligently look for a carb./airfilter assembly. Takes a while, but I run a cross one person who deals in a lot of used Honda engines and parts. So we strike up a deal, and he sends me a carburetor,carburetor insulator block,/air filter assembly off a properly running GX160 engine. I install it on engine with broken mount hole with gaskets carefully lining up all holes in them,and when I crank it up it has an awful case of nervous governor hunting. Stopped and adjusted governor as book instructs. Runs o.k. at low idle. It also has to have the choke almost closed to run above 1/4 throttle. O.k. heres's the rest of the story:Checked the carb. and it looked clean inside and no restrictions in the main orfice, blew air through all passages I could with out disassembling any thing but the bowl and the needle and seat/float assembly. float is about level when you invert the carb. The cranking speed compression is 100psi, book says 85-120#, valve clearences cold are;Int .005(book calls for .006+or-.001), exh is .009, book calls for .008 +or-.001)Spark plugs(3different ones) gapped at reccomended .030. Tried different ffuel tank, line and cleaned the sediment bowl and shut off passageways also. It will run long as you want it to below 1/4 throttle. It cranks on the first or second pull and needs very little choke after it gets warm. I can crank it up and let it run at just above low idle, and take an oil can and squirt oil around all gasket sealing surfaces, does not change running characteristics or suck in the oil as if sealing air leak. Then I take a propane torch,(not lit of course!), and hold it to all gasket joints , and still no difference. When I take the torch and add the propane to the air stream to enrichen the mixture, it almost cures the problem. When you look in the carburetor throat you can see the gasoline being discharged from the main nozzle, but not in a steady stream, it comes out in what looks like slugs. This carburetor has a bowl vent that is vented through a hole in the mounting gasket then to a circular slot milled into the insulating block that allows the overflow to go off below the carb. It also has a couple of what I assume to be the high and low speed nozzle air bleeds or what ever that are in the front of the carb. throat and the butterfly is notched for them where it closes. Does anyone have any suggestions, or answers? I have ran wires through all the carb passages I could get to, and this set up ran fine on the other guys engine, I want to cure it before I pull all my hair out and go mad. There are no Honda dealers within about 75-100 miles of me, and haven't found anybody wanting to sell service manuals. Most people think that a Honda is a car or motorcycle! What about it? Anybody got any experience on these, or ideas? I know Rusty Jones is going to give me a horse laugh on this one for sure now!! Gene Davis
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