Honda GX160/GX200 Carburetor | Complete Repair Guide
The Honda GX160 and GX200 engines are legendary for reliability. They power generators, pressure washers, water pumps, go-karts and countless industrial applications. But even Honda carburetors fail eventually, usually from ethanol-contaminated fuel sitting too long. This guide covers diagnosis, cleaning and replacement.
Table of Contents
- GX160 vs GX200 Differences
- Equipment Applications
- Carburetor Design Overview
- Failure Symptoms
- Cleaning and Rebuild
- Replacement Guide
- Governor and Adjustment
GX160 vs GX200 Differences
Both engines share the same basic carburetor design with minor jetting differences.
| Specification | GX160 | GX200 |
|---|---|---|
| Displacement | 163cc | 196cc |
| Horsepower | 5.5 HP | 6.5 HP |
| Main Jet | #75 typical | #80 typical |
| Carburetor | Keihin design | Keihin design |
The carburetors look identical and often interchange. The difference is in the main jet size. Using a GX160 carb on a GX200 may cause lean running; using a GX200 carb on GX160 may run slightly rich.
Equipment Applications
These engines appear everywhere:
Generators:
- Honda EU2000i, EU3000i
- Champion, Generac and others using Honda engines
- Rental equipment generators
Pressure Washers:
- Honda GCV series
- Simpson branded units
- Industrial washers
Water Pumps:
- Honda WB and WT series
- Trash pumps
- Dewatering pumps
Construction Equipment:
- Plate compactors
- Power trowels
- Concrete vibrators
Recreational:
- Go-karts
- Mini bikes
- Racing applications
Agricultural:
- Tillers
- Log splitters
- Chippers
[NEED REAL IMAGE: Honda GX200 engine on generator showing carburetor location]
Carburetor Design Overview
Honda uses a Keihin-style carburetor known for quality construction.
Key Components:
- Aluminum die-cast body
- Float bowl with drain
- Removable main jet
- Pilot (idle) jet
- Choke butterfly
- Throttle butterfly
- Optional fuel shutoff solenoid (some models)
Part Number Examples:
| Description | Part Number |
|---|---|
| GX160 Carb (standard) | 16100-ZH8-W51 |
| GX200 Carb (standard) | 16100-ZL0-W51 |
| Rebuild Kit | 16010-ZE1-812 |
Genuine Honda carburetors run $60-100. Quality aftermarket units are $15-35.
Failure Symptoms
Hard Starting - Multiple Pulls Required
Engine eventually starts but requires 10+ pulls even with proper priming.
Causes:
- Pilot jet clogged (affects starting fuel)
- Choke not closing fully
- Low compression (not carb related)
Won’t Start at All
Cranks but never fires. Spark present at plug.
Causes:
- Both jets clogged
- Float needle stuck closed
- Fuel not reaching bowl
Runs But Surges
Engine hunts at all speeds. RPM rises and falls cyclically.
Causes:
- Restricted main jet
- Air leak at carburetor gasket
- Governor issue
Runs Rich - Black Exhaust
Excessive fuel consumption, black smoke, sooty plug.
Causes:
- Choke stuck partially closed
- Float needle leaking
- Main jet too large (wrong carb)
Dies Under Load
Starts and idles fine but stalls when you apply load.
Causes:
- Main jet partially clogged
- Fuel delivery restriction
- Vapor lock (hot weather)
Fuel Leaking
Gas drips from carburetor.
Causes:
- Float needle not seating
- Bowl gasket failure
- Cracked fuel inlet
Cleaning and Rebuild
Honda carburetors respond well to cleaning. The quality construction means they often rebuild successfully.
Tools Needed
- Screwdriver set
- 10mm wrench
- Carburetor cleaner spray
- Compressed air
- Small wire or welding tip cleaner
- New gasket set
Disassembly
1. Remove carburetor from engine
Drain fuel first. Disconnect throttle linkage and fuel line. Two bolts hold carb to intake.
[NEED REAL IMAGE: Honda GX carburetor removed showing jets]
2. Remove float bowl
Single bolt with attached gasket. Drain remaining fuel.
3. Remove main jet
Located in the emulsion tube tower. Flathead screwdriver. Note: main jet size is stamped on jet (#75, #78, #80, etc.)
4. Remove pilot jet
Small jet near the main jet passage. Very easy to damage - use proper sized screwdriver.
5. Remove float and needle
Push hinge pin out. Lift float and needle together.
Cleaning
Main Jet: Hold up to light - you should see clean through the center and side holes. Use carb cleaner spray and compressed air. For stubborn blockage, a single strand of wire works but be gentle.
Pilot Jet: Extremely small passages. Spray cleaner through, blow with air. These tiny jets cause most starting problems.
Emulsion Tube: The tower the main jet threads into has small holes. Clear all of them.
Float Bowl: Clean sediment from bottom. Check for corrosion.
Throttle and Choke Shafts: Spray cleaner around shafts and work them back and forth. Check for excessive play.
Inspection
Needle and Seat: The needle tip (usually rubber or viton) must be smooth. Replace if grooved.
Float: Shake gently. Fuel inside means it’s punctured - replace.
Gaskets: Replace bowl gasket at minimum. Full gasket kit is cheap insurance.
Reassembly
Torque the main jet snug but don’t overtighten - it’s brass and strips easily. Install pilot jet carefully. Set float height per specs (typically level when inverted).
Replacement Guide
When cleaning doesn’t work or you need quick results.
Genuine vs Aftermarket
Genuine Honda ($60-100):
- Exact fit guaranteed
- Proper jet sizes
- Better materials
- Longer life
Quality Aftermarket ($20-35):
- Usually works fine
- May need jet adjustment
- Check for casting flash
- Inspect before installing
Cheap Aftermarket ($10-15):
- Hit or miss quality
- Gaskets often poor
- May require rework
- Fine for temporary use
Replacement Steps
1. Turn off fuel
Close petcock or clamp line.
2. Remove air filter housing
Usually 2 bolts. Provides access to carburetor.
3. Disconnect throttle linkage
Note positions before removal. Take photos.
4. Disconnect fuel line
Have rag ready for spillage.
5. Remove mounting bolts
Two bolts attach carb to intake. Slide carb off studs.
6. Transfer parts if needed
Some components may need to swap to new carb (certain linkage brackets, etc.)
7. Install new carburetor
New gasket, slide onto studs, hand-start bolts.
8. Reconnect everything
Match your photos for linkage positions.
9. Test and adjust
Start engine, warm up, check idle and full throttle operation.
Governor and Adjustment
After carburetor work, the governor may need adjustment.
Governor Static Adjustment
1. Loosen governor arm clamp bolt
Located where governor shaft exits engine block.
2. Rotate governor shaft
With screwdriver in shaft slot, rotate fully clockwise (viewed from above).
3. Open throttle
Move throttle lever to wide open position while holding governor shaft.
4. Tighten clamp bolt
Maintain positions while tightening.
Speed Adjustment
No-load speed: Typically 3600 RPM (for 60Hz generators) or 3000 RPM (for direct drive equipment).
Adjust using the throttle stop screw and governor spring tension.
Idle Mixture (if adjustable)
Some GX carburetors have a pilot mixture screw. Base setting is typically 1.5 turns out from lightly seated. Fine tune for smoothest idle.
Common Issues After Carb Work
Engine Overspeeds
Governor linkage connected wrong. Recheck positions.
Won’t Idle Down
Governor spring in wrong hole or throttle cable adjusted wrong.
Runs Lean (Pops Through Carb)
Main jet too small, air leak at gasket or intake.
Runs Rich (Black Smoke)
Choke stuck, float level too high or main jet too large.
Preventive Maintenance
Keep your Honda carburetor healthy:
- Use fresh fuel only - No gas older than 30 days without stabilizer
- Use fuel stabilizer - Every tank
- Run dry for storage - Close fuel petcock and run until engine dies
- Annual cleaning - Remove bowl, clean jets even if running fine
- Genuine fuel filter - Replace annually
Frequently Asked Questions
How long does a Honda carburetor last?
With proper fuel care, 15-20+ years. Many original carburetors are still running on 30-year-old engines.
GX160 carb on GX200 - will it work?
It will run but may be slightly lean under load. Re-jetting is recommended if mixing.
Why is my new aftermarket carb running poorly?
Common issues: main jet size wrong, casting flash blocking passages, float level incorrect. Disassemble and inspect.
Carb cleaner in a can vs dip?
Both work. Dip (like Berryman Chem-Dip) is better for heavy varnish. Spray (Gumout or CRC) works for light cleaning.
Honda GX carburetors are well-designed and rebuildable. Don’t throw them away at the first sign of trouble. A proper cleaning often restores them to like-new operation.