Found a Honda G200 engine ...

landuse · Nov 2, 2015

Nice paint job!!

NewbCarter · Nov 2, 2015

Lucky7 said:
Is there a screw to adjust the fuel to air ratio?

Il take a photo of it tho there are two screws

One is the idle adjust (moves throttle lever) the other one is i suppose the mixture adjust one..

OzFab · Nov 2, 2015

NewbCarter said:
Seems to be running lean ... bigger jet needed since the flow is much less restrictive ?

Remember that, without the air filter, air flow will be more than with the air filter on; once the air filter is fitted, air flow will be restricted which will make the mixture richer...

NewbCarter · Nov 5, 2015

Well , good news and bad news :

Good news is that i found a exhaust shop that will let me use their machinery ( hydraulic bender and MiG welder ) to fab my own exhaust ... tho im yet to determine the dimensions ..

Bad news is that the engine went from lean , to flooded . Literally , tried to fire up the motor , and it sputtered along , and i noticed choke or not it made no difference ... so i knew something is going on . Also if i tried to apply throttle it just dies .

So il need to order the filter adapter , jets and a new carb ...

Tho pics of the exhaust work soon ...

NewbCarter · Nov 7, 2015

Well fixed the carburetor issue... the float thingy got stuck by a piece of metal that somehow found its way into the carb ...

Anyways , also fabricated my own intake header for a pod filter i had laying around ... isnt the prettiest thing , but works great .

NewbCarter · Nov 7, 2015

Some more ...

Exhaust is the last thing .... will do that throughout the next week ... alot of work for that

mckutzy · Nov 7, 2015

One thing I found out with a homemade intake, is keeping the flanges flat.
I had a number of problems originally on my bike with my intake adapters I made.
Found out the weren't entirely flat against the carb. Even with the gaskets it didn't help, air was seeping in.
Check with a straight edge and file or sand down the high spots.
In this case every little thing helps.

NewbCarter · Nov 7, 2015

mckutzy said:
One thing I found out with a homemade intake, is keeping the flanges flat.
I had a number of problems originally on my bike with my intake adapters I made.
Found out the weren't entirely flat against the carb. Even with the gaskets it didn't help, air was seeping in.
Check with a straight edge and file or sand down the high spots.
In this case every little thing helps.

The actual header is an exhaust from a generator set ... i used fine sandpaper to get the rust / dirt from it , and then used it against a flat surface to straighten it out ...

It works nice , right now im waiting for the video to upload , i think ul be surprised by how good it runs .. with a DIY intake

---------- Post added at 01:35 PM ---------- Previous post was at 01:26 PM ----------

https://www.youtube.com/watch?v=Ub2mzJL3spA Here it is running ... this wasnt beyond 1/3 throttle ... gonna order a tach soon so i can keep an eye on them revs ..

OzFab · Nov 7, 2015

Sounds great but, I'm a little confused; how is the filter attached to the intake?

NewbCarter · Nov 8, 2015

Fabroman said:
Sounds great but, I'm a little confused; how is the filter attached to the intake?

You can see in pics i cut out a circle with the outer diameter of the filter out of a steel plate , thick enough it supports the filter , but thin enough that i dont need heavy machinery to drill it / cut it .

Then i used the same steel plate and cut 2x0.5cm strips (3 pieces ) , and bent them into small L profiles . I used rivets and secured those L profiles to the circle thingy , and then bent them a bit inwards .

Then i simply put the filter on , and drilled the holes to hold it thru it into the L profiles . Put some self-tapping screws and done .

NewbCarter · Nov 13, 2015

https://www.youtube.com/watch?v=Y105p0duHS4ž After some work , i elongated the exhaust .

Its hillbilly style , yes , but should do for now , till i get the other parts to start a build .

Wasnt pulling maybe 1/3 of the throttle , and its angry when you jank it xD

What would your guys estimate on the power be ? Or RPM for that matter ... im blind till i get the tach hooked up.

briggsandstratton123 · Nov 15, 2015

i use an atv muffler for 4 stroke engines

NewbCarter · Nov 18, 2015

If i do find one , il try to use it , but for now , i guess this will do .

Anyways , a question :

Im planning to use this chassis : http://www.njuskalo.hr/moto-dijelovi-ostali/karting-bez-masine-rama-swiss-hutless-oglas-16608358

Tho that is IF i get the needed money .

So , if it weighs under 120-130kg ( driver included ) , what kind of gear ratio am i looking for , keeping in mind the engine is probably making around 6-7hp , and without the governor ?

(I understand that a simple chain , sprocket and centrifugal clutch is the simplest way , but if i do find a suitable gearbox , il use that . )

karte_m0lim · Nov 18, 2015

U should wrap it in 100 euros bills and throw it in mine back yard...

OzFab · Nov 18, 2015

Be aware that using that chassis means you will need to use a jackshaft as the engine sprocket will be on the left of the engine (next to the seat) & the axle sprocket cannot run inside the axle bearing...

With such small tyres, you can safely start at around 5:1...

landuse · Nov 18, 2015

Fabroman said:
Be aware that using that chassis means you will need to use a jackshaft as the engine sprocket will be on the left of the engine (next to the seat) & the axle sprocket cannot run inside the axle bearing...

With such small tyres, you can safely start at around 5:1...

I agree. You cannot run without a jackshaft unless you try and move the engine to the other side

NewbCarter · Nov 28, 2015

Well , il see about that once the chassis arrives , and/or the gearbox .

Till then , some more work . Also thinking of giving the whole exhaust a paint-job in gloss black . Thermopaint of course.

NewbCarter · Nov 28, 2015

And here it is running with the muffler :
https://www.youtube.com/watch?v=FnuwszwpDxs

NewbCarter · Dec 3, 2015

Well a question ... :

I have bought a tachometer or the engine off alliexpress ( http://www.aliexpress.com/item/Hot-...archweb201560_9&spm=2114.01020208.3.74.jlvpG2)

It arrived , looks awesome but ... there are a few issues .

First - i am not really certain of where should i hook it up . I tried wrapping the signal wire around the sparkplug wire and it didnt work . I tried hooking it up to the killswitch wire , which did work ( read 2. ) , but not great . I also tried hooking it directly onto the sparkplug , which seemed to work but the engine would shut down ( ground shorted.. )

So it did seem to work when hooked up to the killswitch wire , but the tachometer lagged behind alot , and read 3000 RPM idle ... and it barely responded to the throttle ...

What would be the "correct" way to hook it up to the engine ?

NewbCarter · Dec 5, 2015

Dismiss the upper post guys .. got the tach wired up today , and grew a pair to move the throttle lever past 1/2 open ...

The last reading i saw on the tach was around 6100RPM before shutting it down due to a rattle noise coming from the flywheel area ... Turns out the key somehow made got loose in the keyway between the crank and flywheel and thats what caused the rattle ...

So realigned it , put some loctite compund on the flywheel nut , and ran it again , everything is fine .... Until i shut it down and it wont startup again , no spark ! ...

Note : just because the tach read 6100RPM doesnt mean its correct , so just a note ... to me it did sound like 6000+ but ...

Found a Honda G200 engine ...

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