review of Harbor Freight 2.5 hp engine for a safer kids' bike

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robbie

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I did a speed test yesterday with my son riding the mini bike and me following in the pickup truck. I was impressed enough that I thought I should post my results here, for whatever it's worth. I know most folks who are inclined to buy a new engine at Harbor Freight will probably get the 6.5 for only a small amount of extra money. I can see myself doing that in the future, but there are 2 good reasons why you may want a 2.5 instead.

The first reason is that maybe you are putting an engine in a small bike frame that doesn't have enough room for a larger engine. Remove the tank and muffler, and the 2.5 has a very low profile. It's less than 10 inches from the mounting plate to the top of the spark plug. This was a pretty important factor on our bike. The 2.5 wouldn't fit with the tank and muffler, so I'm pretty sure a bigger engine wouldn't fit at all.

The other reason you may want a 2.5 is for a kid's bike. Conventional wisdom says that for a kid you get a big engine and gear it down to go slow at first, then change sprockets for higher speed after experience is gained. The disadvantage to a big engine with slower gearing is that it also increases the torque at the wheel, resulting in death by wheelie for an inexperienced little kid. A 2.5 geared correctly will give good performance, but no chance of unwanted wheelies or sudden loss of traction due to peeling out unexpectedly.

So, here's the review with the bad first and then the good part. I've discovered four unfavorable points about the 2.5:

1. The fuel tank is junk. The bolts unscrew themselves, the tank vibrates, the tabs break loose and cause cracks, then the gasoline runs out. Use a separate tank.

2. The air cleaner is junk. Metal nuts mounted in plastic will pull through easily. The design inhibits flow and I don't think it cleans the air as well as it should.

3. The stock exhaust is too restrictive, and none too quiet. I built a 2 foot 7/8" ID pipe with an 8HP Briggs muffler on the end. It's not much louder, and it increases performance noticeably.

4. The carburetor gets fouled sometimes. I think it got fouled by my dirty used fuel lines, and again by my dirty junkyard gas tank. Sometimes it just gets a bad attitude and I have to take the bowl off and clean it. Between two engines I've had to do a bowl-cleaning maybe 3 or 4 times since early summer.

Now here's the good part. Once you set it up correctly, this engine really goes. I clocked my kid at 20mph on a gravel driveway. That's a 1/3 mile driveway with a slight hill. I clocked him uphill and downhill, then took an average. Also, we went about 1/4 mile on the flat gravel road outside our driveway. The result was consistently 20 mph, which is almost too fast for 11 inch tires on gravel. It feels more like 40. But it's just right for teaching kids to handle a bike.

With a gear ratio of 9.18:1 and 11 inch tires, the engine had to be going around 5500 rpm to go 20 mph. A tachometer would be better, just to make sure the numbers are accurate. I don't have a tach, but Santa Claus might bring us a radar gun this year.

I think that's pretty impressive for an engine with no upgrades other than a better air cleaner and exhaust, and the governor removed. I don't have any regrets at all after buying 2 of these. You can't beat the price.
 

sideways

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Nice review, even though I'l never buy one of those engines I'l thank you for it. :thumbsup:

You've made a lot of great contributions to the forum, this is one of them, keep the good work going mate! :thumbsup:

Thanks

Hayden
 

redsox985

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Did you pull the gov. off of his engine? Otherwise it stopped at about 3600 +- a bit.
 

robbie

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I removed all external governor linkage, leaving only the stem sticking out of the block. The throttle cable is attached directly to the arm on the carburetor.
 

redsox985

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Did you put a throttle stop of some sort on there because, I personally, would be nervous of him revving it too high. But this is a great, informative thread.
 

robbie

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Thanks for saying that. I thought it was pretty useful information, because this engine is in the same general class as a 49cc 2 stroke, and the price is similar, but it allows you to use bigger chain and a wider variety of accessories. Unfortunately it doesn't come with a clutch the way a 49cc does. I thought it was a good idea to post some of the other pros and cons. This engine is a good option for a lot of small projects, and you don't have to mix your gasoline.

I didn't use a throttle stop. How fast do you think would be too fast? We generally don't rev to full power for long periods. We tend to use the throttle in spurts.
 

redsox985

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My thought was that if he over revs it for too long, when the valves are floating, the motor can have some catastrophic failures, especially fully stock. The stock valve springs and what not are made for 3600 rpm, not the ~5000+ it can reach.
 

robbie

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Good. I don't know why anybody even makes interference engines.

So, if the piston isn't going to hit the valves, what exactly is the danger of revving to 5k? Maybe the rod will fly apart? So far, so good.
 

bajagokart

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i had my 13 hp clone without a governor and it never had a valve float. maybe because the valve springs are 32 lb (pretty sure at least) but ive always heard on 6.5 hp you have to change out to 18lb valve springs
 

redsox985

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It's not bad insurance on a kid's bike. Although, I wouldn't have pulled his gov. personally.
 

devino246

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Good. I don't know why anybody even makes interference engines.

So, if the piston isn't going to hit the valves, what exactly is the danger of revving to 5k? Maybe the rod will fly apart? So far, so good.

In an interference engine, the valves stick out far enough when completely open that they would hit the piston at TDC. There is a legit reason for interference engines though. I dont feel like explaining it now :p

Valve float will act as a governor and prevent the engine from over-over revving. I believe around 4800rpm if I remember correctly.
 

redsox985

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Floating the valves for too long is not good though, it just acts as an warning to back off.
 

robbie

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In an interference engine, the valves stick out far enough when completely open that they would hit the piston at TDC. There is a legit reason for interference engines though. I dont feel like explaining it now :p

Valve float will act as a governor and prevent the engine from over-over revving. I believe around 4800rpm if I remember correctly.

Yeah, I know they design the engines this way for a reason, but I would make a slight performance sacrifice in favor of an engine that would never experience a valve strike. I think building an interference engine for a car and driving the camshaft with a rubber belt is inexcusable. But of course they do it all the time....

Regarding the HF 2.5, I'm not sure why it's a problem to rev to 5k if there's no possibility of a valve strike.
 

Russ2251

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Valve float will not hurt. As stated above by redsox985 devino246, this "built in" action prevents engine from over revving to the point where it tears itself apart.
NO contact with piston crown is possible with a stock engine.
Valve float can often times be misconstrued as a high speed lean-out.
Most 4 cycle engines will operate past 5k rpm before floating valves.
 
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