Honda GX160 technical regulations
Contents
1. If the output shaft keyway and throw of the crankshaft are mis aligned then the location tool cannot be used and in this instance the engine must be positioned at TDC using piston stop or DTi method and the ABkC marked template tool used as above 20 Ignition coil The ignition coil including ignition lead will be the standard unmodified unit and is interchangeable between all engine types The coil mounting bolts must be standard unmodified and use the original mounting positions 21 Camshaft The standard unmodified camshaft must be used the service limits are 27 65mm for the exhaust and 27 60mm for the inlet lobes T1 and 27 45mm for both lobes T2 The K E and T1 engine can only use the T1 camshaft the T2 engine can only use the T2 camshaft The inlet profiles are different between T1 and T2 with the T2 having a longer duration The difference is easily identifiable with profile gauges or by measuring the open period 22 Push rods The steel push rods of the T1 have been replaced with thicker aluminium units for the T2 The pushrods are not interchangeable between T1 and T2 23 Crankcase The crankcase can only be modified by the removal of the governor mechanism and in all other respects must be standard unmodified If completely removed the hole in the crankcase must be sealed to prevent j oil leakage unless a suitable pulse take off is used The crankcase bearings and seals must be standard unmodified The bore2. must be standard only service limit 68 165mm E at all points of the bore No sleeving s Honda GX160 technical regulations Version 9 Jan 2014 Page 6 of 9 or surface material change to the cylinder bore is allowed but honing is permitted The cylinder mating face must always have the manufacturer s original finishing marks visible The deck height must be 45 20mm 0 3mm read between the cylinder mating face and the cast face of the t piston in line with the piston pin with the piston at BDC Carbon removal is allowed as describe previously See drawing 2 amp 3 in Appendix 1 When measuring a K type engine 1 3mm should be added to the obtained reading to accommodate the dish in the piston A welded repair is allowed to the engine mounting area at the crankcase base only 24 Crankcase side cover must be standard unmodified and positioned with both standard unmodified dowels in place T1 and T2 side covers are interchangeable 25 Gaskets All gaskets must be standard unmodified Where there is any doubt about the eligibility or suitability of a particular gasket it should be compared with a new item from the manufacturer 26 Clutch A dry air cooled centrifugal clutch of Noram Horstman Magnum Maxtorque 1600 or 4000 series type or any other clutch subsequently introduced which satisfies the same criteria must be used to transmit the drive The clutch should be in standard form as supplied be incapable
3. of adjustment in position and have a maximum engagement speed of no more than 2 500 rpm engine speed The ABkC reserves the right to make amendments at any time during the year in order to equalise performance between the T1 and T2 engines or to otherwise adjust the performance of either or both engine types Any new regulation will come into force one month after the publication of updated regulations subject to MSA approval NOTES Unless otherwise stated T1 component on left T2 on right Measurements marked are nominal and only for guidance in determining differences between engine types Other dimensions are absolute for scrutineering purposes Honda GX160 technical regulations Version 9 Jan 2014 Page 7 of 9 Appendix 1 PN 16166 ZH8 W50 PN 16166 ZH8 810 PN 16166 Z4M 921 Drawing 1 head gasket face Valve seat Drawing 4 valve guide Official ABkC restrictor plate Drawing 3 Note 1 In all the carbs the bore is cast not machined and therefore can be a little out of true If measuring this bore it is safest to use a semi circular gauge rather than a flat plate gauge Honda GX160 technical regulations Version 9 Jan 2014 Page 8 of 9 Appendix 2 The original manufacturer s finish The inspected engine might not be as bright or so distinct but the patterning must be apparent over the complete machined area These lines might flow in different directions from engine
4. to engine or appear to originate or rotate from different points Note 2 The finish will always look like this in a new engine engines with age should be observed accordingly This finish will never wear away on its own Honda GX160 technical regulations Version 9 Jan 2014 Page 9 of 9
5. 5mm The T2 engine will use one off part number 12251 ZLO N 003 which when measured at the sealing ring must have a minimum dimension of 0 28mm 16 Piston The dished piston must only be used with the cylinder head from the K type engine The flat top pistons are interchangeable between the E and T1 type engines only and must not be used in the K type engine or with the K type head Piston rings will be standard unmodified Honda GX160 technical regulations Version 9 Jan 2014 Page 4 of 9 Only standard size rings marked 1R R T NT 1N T or N on top ring can be used Either the single or three piece oil control ring can be used on all engine types The rings must always be free in their grooves to function as designed T1 and T2 pistons are not interchangeable The T2 piston is shorter and has an additional curve under the oil ring The top two piston rings are visually similar to the T1 but the oil control ring is thinner 2mm as against 2 5mm on the T1 and the ring groove in the piston is correspondingly smaller Er ii Early T1 Late T1 17 Connecting Rod The standard unmodified unit is interchangeable between K E and T1 engine types The connecting rod from the T2 engine must also remain standard unmodified but will not fit other engine types on its own but see also section 18 158gr Piston weight 140gr 43gr piston pin weight 419 23 5mm piston height 21 4mm 84mm con rod length 86mm 119gr con rod weight 123
6. Honda GX 160 Technical Regulations 1 GENERAL The scrutineer will pay special attention to ensure that the finish of all components match those of the standard unit and reserves the right to compare any part from competitors engines directly with a standard part as supplied by Honda UK Unless competitors have gone out of their way to source alternative parts their engines should automatically comply with this rule Furthermore competitors should note that the term standard refers not only to the components used but also to AL G OME the number used and the manner in which the engines are assembled Please remember that save for the changes specifically mentioned in these regulations the engines must be completely standard unmodified and that all components will remain in place unless this document specifically states that they are allowed to be removed No specific coating procedures are allowed on any internal or external surface of the engine Carbon or gasket residue removal must be achieved by use of chemical agents only to preserve original finishes which must be apparent over the complete machined area see Appendix 2 The fasteners on the engines may be drilled for the purposes of lock wiring Replacement of external fasteners with non Honda fasteners is only permitted when the replacement fastener improves safety or when the standard Honda fastener is not readily available A thread recovery procedure is acceptable prov
7. U 10 Bodywork ducting All of the engine bodywork and ducting must be standard unmodified except for the drilling of a small hole to accept one end of a throttle return spring or security fixing The pull cord mechanism must be standard unmodified although the pull cord starter may be rotated on its standard mounting holes All or any of the bodywork ducting can be painted or chromed 11 Rocker cover Rocker cover must be standard unmodified although it may be painted or chromed Its valve must be present and in working order The breather pipe must be in position and intact of suitable length that it is securely fixed in both the rocker cover and the outlet of the airbox and have no perforations or leakage points Cover interchangeable between all engine types 12 Valve Gear The valve rocker studs must be standard unmodified On the T1 engine only the inlet valve collet PN 14771 ZE1 000 may be replaced with an exhaust valve collet PN 14773 ZE1 000 and an exhaust valve rotator PN 14781 ZE1 000 If this modification is performed to the inlet valve it is permissible to fit one 8mm washer between the cylinder head and the base of the valve rocker post to raise the post and ensure that the adjuster locknut sits on a full thread The valve spring used must offer no mechanical advantage over a standard GX140 valve spring PN14751 ZE1 000 i e a force of 5 kg will compress the spring to less than 25mm overall length or a spring which o
8. com en welcome html shaded area denotes text amended from previous version COMPONENT BY COMPONENT 3 The fuel tank It is strongly urged that the engine s integral fuel tank be removed If this is done then the engine must be fitted with a suitable cover A standard centrally mounted fuel tank should then be used unmodified and this tank and its mounting must be in accordance with manufacturer s instructions The capacity of this tank must not exceed 7 5 litres if used for endurance events Ballast may be added to the tank in order to maintain the maximum capacity In this instance the kart may be fitted with a pulsed fuel pump s which will take a vacuum feed from either the governor rod hole or one drilled in the inlet manifold tapped to accept a vacuum fitting Fuel pipes must take a direct route to the carburettor and be safely secured An extra loop of fuel pipe may be used as a return feed to the tank One in line fuel filter of nominal capacity per engine may be fitted whose dimensions do not exceed circumference of 10cms and length excluding stubs of 5cms 4 Exhaust The standard exhaust must be used but a unit modified and sealed by an Agent may also be used In this case the unit will bear a seal applied by an Agent and it is the competitor s responsibility to ensure this seal is in place at all times At any time the modified unit on the engine can be exchanged with one held by the scrutineer who will then send the competito
9. e drilled in the tag on the restrictor for the purpose of affixing an official seal This restrictor is not permitted in Senior engines Honda GxX160 technical regulations Version 9 Jan 2014 Page 2 of 9 6 Permitted main jets size 68 PN 99101 ZF5 0680 size 70 PN 99101 ZF5 0700 size 72 PN 99101 ZF5 0720 size 75 PN 99101 ZF5 0750 Emulsion tube must be either part number 16166 ZH8 W50 16166 ZH 810 or 16166 Z4M 921 see drawing 1 in Appendix 1 The throttle actuating arm can be modified to accept an actuating rod onto the throttle butterfly a method of mounting a throttle actuating cable and a method of mounting a throttle return spring only 7 Carburettor air box Must be standard unmodified The additional silencer part number 17235 ZE1 831 may be used 8 Air filter The original air filter if used must have the base washer in place it can have it s paper or foam or both removed Alternatively it can be omitted completely or be substituted for another filter In any case the plastic outer cover must remain as standard unmodified and fixed securely in its Original position 9 Spark plugs Must be standard unmodified from the following list only no other can be used The standard Honda resistor spark plug cap as supplied with the engine must be used where a non resistor spark plug is used otherwise plug cap is free Permitted spark plugs NGK BPR6ES BP6ES BP5ES BPRSES Nippondenso W20EP U W20EPR U W16EP U W16EPR
10. ffers no mechanical advantage over a standard QHG4 spring PN 14751 ZH8 9400 i e a force of 8 kg will compress the spring to less than 18 5mm overall length Valve rockers cam followers and pushrods must be standard unmodified 13 Valves Valves will be standard unmodified Valve seat grinding and cutting is allowed to the single standard profile only 45 and 30 cut to restore seat width as specified in the latest Honda manual for the engine type Valves of T1 and T2 engine are not interchangeable 25mm Inlet valve 26mm 24mm exhaust valve 23mm 62 2mm exhaust valve length 63 mm 14 Cylinder head Will be standard unmodified and measure a minimum of 73 98mm from the rocker cover gasket face to the cylinder head gasket face Ports must be standard unmodified The standard de burring marks and sharp edges should AA always be present A maximum measurement of 29 25mm mn inlet and 28 25mm exhaust must be present between VE the cylinder head gasket face and the land surrounding the valve guide see drawing 4 in appendix 1 Cylinder head of T1 and T2 are not interchangeable 15 Head gasket Must be standard unmodified and will at all times have a minimum thickness at all points of 0 95mm when used on K E and T1 engines l Alternatively these engines can use 4 off gasket part number 12251 ZLO 003 which when measured together at the sealing ring must have a minimum thickness of 0 9
11. gr 7mm con rod bolt 6mm 18 Crankshaft The governor gear can be removed The position of the cam gear wheel is free The standard key must be used on all engine types The crankshafts are interchangeable between K E and T1 engines only You cannot transpose complete crank rod and piston assemblies between T1 and T2 engines In all instances the final stroke must be 45mm 0 15mm The T2 crank may be used as a replacement in the f T1 engine but it is not 4 permitted to use the T1 crank in the T2 engine Honda GxX160 technical regulations Version 9 Jan 2014 Page 5 of 9 19 Flywheel The flywheel must be standard unmodified and have a minimum weight of 2 2kgs The T1 and T2 VESS are not interchangeable The key may be reduced in wia or otherwise modified but we SNS aps not omitted The ignition timing must W d SW be set checked with the engine at p 7 TDC and the ABkC marked template tool in place The edge of the magnet must not intrude into the split marking _ the go V and no go X area of the is template for the particular engine a A type SAD If the output shaft keyway and throw of the crankshaft are aligned then the ABkC nye location tool can be used to assist with the setting For accuracy the crankshaft must be rotated against the location tool in a clockwise direction flywheel side before the reading is observed on the template tool The standard unmodified fan must be used with all fins in place
12. iding that the system and replacement fixing used are of no different size or pitch to the original and therefore offer no mechanical advantage over the original fixing or alter the position of the original fixing 2 DEFINITIONS 2a The standard unmodified component This means that the component has not had its substance altered in any way It has had no material removed from it or added to it It will be of the same original material Where appropriate it should have the manufacturer s original manufacturing process or machining marks on it It is the component defined as being applicable to the particular engine type 2b Engine types The original QHQ4 engine to engine number 7664037 shall in this document be called the K engine The QHQ4 engine from engine number 7664037 onwards shall in this document be called the E engine The QHQ4 engine with suffix T from engine number 1000000 onwards shall in this document be called the T engine This will also include all unified specification engines GX160UT1 QHQ4 and QHG4 GX160UT2 QHQ4 and GX160RT2 QHG4 engines T2 will be eligible with exceptions as notified in the following document 2c Legality limit In general terms and where not clarified or qualified elsewhere in this document the legal limit for eligibility purposes shall be deemed to be the service limit as specified by Honda in the most up to date Honda Service manual for the particular engine http www honda engines eu
13. r s exhaust back to an Agent for inspection If this unit is found to have been tampered with in any way then the competitor will be penalised retrospectively No other repair or modification is allowed Exhaust Part No 18310 ZH V90 or 18310 Z4M O000 can also be used and modified as above The Agents currently are Focus Racing 0178 737 6655 and Kart 0192 083 1000 The heat shield should be in place at all times Where the original fixings have failed they can be replaced with a rivet type thread repair which can alternatively be welded in original position 5 Carburettor The T1 carburettor must only be used on the T1 engine type and the T2 carburettor on the T2 engine type both standard and unmodified However all carburettors are subject to normal dimensional criteria Overall length manifold face to airbox face is 53 9mm min and oor go ir no i go gauge is 13 2mm 13 3mm Pilot jet size 35 y TA only the mixture screw tang can be removed The T1 has 140 stamped on the throttle valve lt and four small holes just below the mixture screw point The T2 has 150 stamped on it with only three holes at the same point see Appendix note 1 When used as a Cadet or Junior engine only the official ABkC restrictor plate which may be deburred must be fitted between the carburettor and insulator and have an opening of no more than 16mm diameter see p 8 This size may be altered during the year see p 7 A2mm hole may b
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