Newb assembling 1st minibike

[stargazer7467]

Picked up a frame from a local fabricator that sells on ebay since i wanted to put my engine to good use.

I have a Honda OHC 5hp engine GC160 model. Picked up this frame and looking to put a bike together for this summer.

Im having a hard time with the clutch setup on this engine, i have a MaxTorque clutch i bought from work for the 3/4" shaft that the engine had but went back to find out that the crank snout is stepped, about 1/2" from the crankcase the diameters steps up to 5/8". This puts the sprocket inline with the frame . Has anyone ran into this with these engine before?

Also looking for wheels, all i seem to find is go kart wheels with offset hubs.

Appreciate any help in advance

 

[Russ2251]

PTO may been designed to operate a power washer, generator, trash pump, snowthrower, etc.
A pic will give us a better idea of what you have and what can be done to get you running.

 

[porsche930dude]

are you running the chain inboard?

 

[stargazer7467]

yes the chain would be inboard, ill get some pics tomorrow of it.

 

[stargazer7467]

still looking for wheels thought

 

[B-Well]

still looking for wheels thought

10" pit bike wheels work killer with a little fab

check my thread

 

[stargazer7467]

heres what im dealing with on the crank snout.

 

[porsche930dude]

iv filed those down before. grab a nice wide file with the engine running and slowly file it down to match the rest of the shaft. If the keyway gives you trouble glue a key into it so you can file it smoothly without jumping. and pop it out when your done. just dont go too far be real carefull and keep checking as you get down to the size

 

[stargazer7467]

great idea! I didnt really want to pull the crank out and have it machined.

 

[stargazer7467]

well, i tried the file idea but only kinda tore it up , didnt hurt the crank but took very little off and grooved it a bit. Doing some looking around and found a jackshaft system might suit my needs a bit better. Looks like that would get the engine a little more centered and give options for gearing in teh future. Sound like a good bet?

 

[Russ2251]

If you decide that PTO is incorrect (which mine is) for your application, the correct crankshaft part #13310-ZL8-600 will work perfectly.Only $29 delivered...brand new Honda certified!!!

 

[stargazer7467]

well I ended up removing the crankshaft, and having it lathed down to 3/4". $25 later and done Saturday night by a local machinist. Just got the engine back together this evening. Thats a great find thought, didnt know you could buy different crankshafts.

It was kind of a pain to deal with and i could have bought a minibike already done for about $300, but i wanted to build it myself. Almost there lol.

 

[stargazer7467]

well its mostly together and runs, just have to figure out how to hook the throttle up to this honda engine and get a brake on it!

 

[Russ2251]

I'm planning on using my brand new Comet TAV 30 2 with the GC160.
I purchased the TAV about 3 years ago and had nothing to bolt it up to until now.
In order to get the engine bolted to frame, I had to get rid of the original carb, tank, and fuel pump assembly. It was just too bulky and presented some serious clearance issues.

 

[Doc Sprocket]

I had to get rid of the original carb, tank, and fuel pump assembly.

Not to jack the thread, but- your GC came with a fuel pump? What was it from?

 

[Russ2251]

Not to jack the thread, but- your GC came with a fuel pump? What was it from?

Engine came off of a power washer.
To my knowledge, all Honda GC160's (and 190's?)come with a fuel pump.
Center-line of tank is below carb which necessitates a pump.

 

[stargazer7467]

yes the one im using has a fuel pump as well, its from a roto-tiller. I kind off cool , you take the fuel cap off and you see the little return line dumping back into the tank lol.

 

[Russ2251]

It appears to be a tough little engine.
Rated at 5hp, is lighter than a Briggs 5hp L head.
I have 2 complaints about it though.

 

[Doc Sprocket]

I looked around, and it does appear that they all have pumps. Might be a cheap OEM-type option for folks wanting to set up a remote tank on another engine...

I have 2 complaints about it though.

Care to elaborate?

 

[Russ2251]

Care to elaborate?

1.) Exhaust is directed forward pointing directly to operator.
This is a problem in a kart application, but not for a mini bike.
Easily remedied with some plumbing.

2.) Engine is assembled using an RTV type of sealant. The GX's are put together the same way. Sloppy.
Makes engine more difficult to disassemble and reassemble and looks like crap when it is assembled, even when new. Stuff oozes out all over the place (see pic above).
I have lapped the case halves so that I can use an anaerobic sealant such as LocTite 515. Will look professional when reassembled.
Valve cover also uses the RTV and will be replaced with a neoprene gasket.