Help! New Honda pull start wont pull.

[jimraysr]

Thanks for the input. Just hate reinventing the wheel. )

Jim

 

[Irish John]

Honda engine stick now solved!

Well guys and gals, your input has been tremendous and according to the Honda mechanic I talked to today all very sound logical advice. I tried everything mentioned and my last try was to look inside the motor at the governor spindle to see if it was blocking the crank or something. I gave up and took the motor back to the Honda dealer who gave it to a mechanic. The mechainic split the motor down the diagonal middle and there he found a piece of black plastic that shouldn't have been there.
he couldn't see how it could have locked the motor dead but when he took it out and put the motor back together it turned over with the rope pull.
I think we expected something small to be stuck inside causing a blocakge but neither of us could see how a small piece of black plastic could do this.
The problem apears to be solved but neither of us know quite why. How the black plastic got there is anyone's guess but it must have happened in the assembly line.
Anyway thankyou kind members for your help and I'm off to start a thread on my new bike build using the Honda. This thread can now be closed.

 

[jimraysr]

Un stickie Honda

John, really happy that there wan't any damage to the motor.

I am guessing the piece of plastic was in the gears of the camshaft or the cam itself?

Wouldn't take much there to jam up the works. As I recall the gear ratio is normally a 4:1 advantage to the cam. (Cam turns at 1/4th the speed of the crank.)

Jim

 

[Irish John]

Irish-

As you know, I have never run with a governor and I have never had this problem. One question- is the governor shaft sticking out of the engine still where it was before?

Jim- that should work- as long as the governor lever is not working the throttle plate, the governor is disconnected. You can leave the hardware on or off. I took it all off just because I was not using it and never will.

Also if you leave the govenor spindle on the Honda a Hoot GB can't be fitted cos the spindle sticks out where the drive sprocket goes. It probably interferes with the Grubee GB too but I haven't fitted the gearbox on yet. Better take a closer look. Problems all the way it seems.

 

[jimraysr]

Honda Governot and a GruBee gear.

No problem with the Honda linkage and mounting the GruBee gear. The drive sprocket clears the governor shaft by maybe a 1/4" (6 cm)

I had to remove the BruBee in order to remove the governor lever from the shaft coming out of the engine. Now that I know that the flat is just a reference and not keyed to the lever, I could adjust the governor idle speed with the transmission in place. So far very happy using the governor and the throttle cable operating the manual speed lever.

No knowledge of the Hoot, so no comment there. Guess John has both.

Jim

 

[Irish John]

No problem with the Honda linkage and mounting the GruBee gear. The drive sprocket clears the governor shaft by maybe a 1/4" (6 cm)

I had to remove the BruBee in order to remove the governor lever from the shaft coming out of the engine. Now that I know that the flat is just a reference and not keyed to the lever, I could adjust the governor idle speed with the transmission in place. So far very happy using the governor and the throttle cable operating the manual speed lever.

No knowledge of the Hoot, so no comment there. Guess John has both.

Jim

What do you mean by the FLAT? I see the big governor arm attached to your bike so what is holding it on? Easier to tell us how the governor isn't attached than how it is? Can't really make out what you mean exactly.
What disconnections, if any, have you made to it?

 

[jimraysr]

Using Honda governor wt. throttle cable.

No change to the factory linkage at all.

The governor shaft comes out of the crankcase and has a flatted end.

They put the governor lever on the shaft at the factory so the flat of the shaft is at 90 degrees to the lever length.

I only loosened the pinch bolt of the governor lever and turned the shaft so the linkage to the carburetor is held near minimum when the engine is running and no tension on the spring from the manual speed lever.

In turn I have the throttle cable connected to the manual lever.

Jim

 

[Irish John]

Problem Solved

If anyone is reading this thread the problem wasn't any of the above. After many weeks and a few more Honda motors locking up I've discovered the answer and it's caused by a simple bolt. Read about it on this thread:
http://www.motoredbikes.com/showthread.php?p=164040#post164040