Honda Gx160 200 Clone Gokarts Usa-PDF Free Download

Honda GX160 200 clone GoKarts USA

2020 | 13 views | 7 Pages | 1.28 MB

GokartsUSA.com HPO High Performance Option Installation Honda GX, Titan TX200S ... Honda GX160/200/clone ... Clamp down on the bolt with vice grip,



Engine Speciations Deconstruction Instructions
Model TX200S
Engine type 4 stroke 25 inclined single
Bore Stroke 68mm 45mm
Displacement 196cc
Compression 8 5 1
Horsepower 6 5HP 3600rpm
Max Torque 13Nm 2500rpm
Ignition Non contact transistorized
ignition TCI
Starter Recoil hand operated Step 1
Unboxing the engine
Air cleaner Semi dry oil bath dual double
silent cyclone 1 Carefully open the box to take out the engine
Fuel tank 3 6 L 2 Take the engine out of the box and take off the
capacity cover
Fuel 290g HP hour
Consumption 3 Set your engine down on your work table
Engine oil 0 6 L
Deconstruction of the air filter and carburetor
Dimensions L 12 3 4 W 11 0 H 14 3 4
Crankshaft 3 4 x 2 7 16 Step one carefully take off the gas tank with a SAE
Dry weight 35 lbs 5 16 or 8MM and SAE 3 8 or 10MM socket and a
3 8 ratchet Standard American Edition The gas
tank is attached to engine with 3 bolts The front 2
bolts require you to use the 3 8 socket and the rear
bolt requires you to use the 5 16 socket Lift up the
gas tank and set it aside for now
Step two take off the wing nut on top of the air filter
Next lift up the air cleaner cover then loosen the
second wing nut and remove the foam filter The last
step is to remove the gasket and the grid cover
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 2
Step 1 Diagram
3 8 Socket Lift up the gas tank and set
it aside for now
Step 2 Diagram
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 3
Step 3 Step 4
Choke cover removal Throttle lever removal
Step three using the 3 8 socket and ratchet Step four now it s time to take off the throttle
remove the fuel lever and choke lever cover lever arm The lever is attached to the engine
After the bolts have been loosened move the fuel with 2 5 16 bolts Remove the spring and lift up
lever and choke lever all the left so that both of the lever make sure that you do not remove the
them are in the off position governor or it will drop down into your engine
socket with a
3 8 ratchet
Throttle lever arm
Carburetor removal
Step five after the throttle lever has been
removed you can now remove the carburetor
and set it aside for now Now you see that there
You will need
are two 4 5 bolts To remove them use a pair of
to remove this
bolt in order to vice grips Clamp down on the bolt with vice grip
take the cover make sure that the vice grip is clamped on the
off bolt at 1 5 in Start applying pressure to remove
the bolt Repeat the same process on the other
Fuel lever
Pull forward upon the Twist to the left
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 4
Installing the Mikuni Carburetor and Step 2 Diagram
Exhaust Pipe
Now that you have removed the exhaust and the carburetor
it is time to install the HPO kit on your engine
Installing the exhaust pipe
Step one attach your Stinger or Fatty exhaust to
the engine block and start to tighten the 1 5 nut
on to the exhaust Stop tightening it when you Installing the exhaust pipe
feel the nut is snug on the bolt Step three now it s time to install the throttle
cable to your carburetor To attach the throttle
cable make sure that the cable is already set
place on your bike Now unscrew the cap on the
carb and take out the spring Now that you have
removed the cap and the spring you will be able
to see the slide inside the carburetor Reach in
with your index finger and pull out the slide
Carburetor Cap
Installing the exhaust pipe
Now push the needle jet out threw the slide
Step two now it is time install your new Mikuni Notice that there are five notches at the top of
carburetor First install the exhaust manifold to the needle where the clip can be adjusted You
the intake Use two 3 8 bolts to attach the can adjust the clip by putting it on the desired
manifold to the intake tighten until you feel it is setting The bottom notch would be the richest
snug air to fuel ratio and the top notch would be the
leanest setting But for the base line test adjust
the clip to its center notch
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 5
Needle Jet
Finish building the carburetor
Step four now thread the throttle cable through
the top of your cap and out through the slide The
slide will have an opening at the bottom Once
the cable is through the slide grab your wire stop
and thread the cable through the wire stop and
then adjust the tightness of the cable with the
screw on top of the wire stop Now it s time to
thread the spring in threw your wire cable To do
this take the end piece of the spring and open it
slightly so that you can twist on the spring on to
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 6
Step 5 Step 6
Installing the carburetor Installing the gas tank
Step five screw the cab back on to the Step 6 now that you have attached the
carburetor Now you can attach the carb to the carburetor and the exhaust pipe it s time to install
the gas tank again Cut the piece of fuel line to
manifold You will need two 3 8 bolts and two
the correct length and attach it to the fuel tank
3 8 nuts Now attach the air filter to carb with the with two hose clamps Now you can finally install
hose clamp Stop once you feel the hose clamp is the fuel tank on to the engine Bolt back the nuts
to the engine
snug on the carb
Congratulation you have successfully
installed your HPO kit on to your
TitanTX200S
GokartsUSA com HPO High Performance Option Installation Honda GX Titan TX200S 7


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