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TEKA GX-200 Honda Rules and Specifications
Engine Scrutineering
Engine Scrutineers will be approved and appointed from time to time. Only approved Engine Scrutineers may inspect
and seal engines. Engine Scrutineers may charge a fee for this service. A list of approved Engine Scrutineers is
available on request.
The Engine Scrutineer will pay particular attention to the finish of all components to ensure that they match the
standard unit. The Engine Scrutineer may check and compare any suspect component with a standard part as supplied
by Honda MPE Australia. Checks and measurements may be carried out to ensure that tolerances are within those
specified by Honda. Engines will be sealed by the Engine Sealer using lock wire and lead or plastic seals.
The Engine Sealer shall keep a record of the engine numbers of engines sealed for endurance karting events.
Engine seals will be inspected by the Scrutineer(s) prior to each event. It is the teams responsibility to ensure that
engine seals are intact and in place. If a seal is broken the engine must be represented to the Engine Scrutineer for
inspection and sealing. No engine inspections or sealing will be available at events unless specifically requested or
approved by the organiser or the Engine Sealer.
At the conclusion of an event, the organiser reserves the right to take away any engine or engines for inspection and/or
dynamometer testing if they wish. If any infringement is found to exist the team will be liable for any inspection fee.
Engine Specifications and Regulations
Engines
The only permitted power plants are standard 6.5hp Honda GX200 series QXU engines in as
supplied condition from Honda MPE Australia or it’s appointed agents. Note: Honda MPE
Australia will admit no warranty claims on engines used in practice or racing.
Modifications
Modifications to engines are strictly limited to the following:
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Removal of the governor mechanism and oil switch. If the whole mechanism is removed, the holes in the
crankcase must be sealed to prevent oil leakage.
Fitting of alternative exhaust valves (Honda Part No. 14721-ZH8-810)
Fitting of alternative valve springs (Honda Part No. 14751-ZH8-940 or 14751-ZE1-000)
Fitting of alternative carburettor jets
Size 68 (Honda Part No. 99101-ZF5–0680)
Size 70 (Honda Part No. 99101-ZF5–0700)
Size 72 (Honda Part No. 99101-ZF5–0720)
Size 75 (Honda Part No. 99101-ZF5–0750)
Substitution or complete removal of the air filter is permitted, however the outer air filter casing must remain
as standard and in place. No modification to the outer or internal of air filter housing is permitted.
The linkage connecting the throttle cables to the standard carburettor throttle arm is free and it is permitted to
fit throttle return springs to each carburettor.
Apart from the modifications above, no engine parts other than genuine Honda parts, as specified for this engine type,
may be (a) The use of thermal barrier coatings / ceramic coatings on or in the engine / engine components and on or in
exhaust components is prohibited.
(b) The use of anti friction coatings on or in the engine/engine components is prohibitedused. Furthermore, it should be
noted that the terms “standard” and “genuine” refer not only to the components used but also to the number used and
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the manner in which engines are assembled. Apart from the modifications specifically mentioned in these regulations,
the engines should be completely standard and all components should remain in place unless it specifically states that
you are allowed to remove them.
Reboring
Reboring of the engine or regrinding of the crankshaft is not permitted. No sleeving or surface material change to the
bore is permitted. No other metal removal from any component is permitted. No polishing of the cylinder head,
combustion area, inlet tract or exhaust port tract is permitted. Chemical agents must achieve carbon removal only. It
would not be expected to see casting marks or imperfections removed.
Internal Additions:
No additional material may be added except in the case of engine repairs and shall only restore engine or components
to original specifications.
a) The use of thermal barrier coatings / ceramic coatings on or in the engine / engine components and on or in
exhaust components is prohibited.
b) The use of anti friction coatings on or in the engine/engine components is prohibited
Gaskets
a) Side cover gaskets, as well as carburetor bowl gaskets and o-rings must be of stock appearing shape.
b) Maximum thickness of the exhaust gasket is 0.125” as raced, with only minimal leakage permitted.
c) Two induction gaskets are required, one on each side of the phenolic spacer. These induction gaskets shall be
of stock appearing shape and each shall have a maximum thickness of 0.030”(0.1mm) compressed.
Fasteners (Non-Tech. Items)
Unless otherwise specified, non-tech. items include :
a) Any bolt hole except the rocker stud bolt holes may be re-threaded, and or fitted with a helicoil or thread
insert.
b) Any bolt may be replaced with a stud or socket head cap screw. The throttle butterfly screw must remain
STOCK
Governor
a) The governor and decompression apparatus may be removed from the engine, including the portions attached
to the camshaft. Any EXTERNAL holes caused by this removal MUST be plugged.
Coatings
a) The cylinder block side cover and head finish and texture must be AS CAST from Honda.
Recoil
a) The standard utility recoil starter assembly must be entirely in place and must be the only method of starting
the engine.
Shrouds
a) A shroud to replace the stock fuel tank will be permitted. Part Number BD-185 will be the OEM part.
b) Flywheel shrouds must not be altered in any way to alter the airflow or change appearance, except for chrome
plating or painting.
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Switch
a) The ignition switch may NOT be removed and must function. Remote engine kill switches are permitted
however the standard start/stop switch must be retained and must function independently of any remote engine
kill switch
Cooling Fan
a) The only fan that is allowed is a stock unaltered Honda part # 19511-ZE-000.
Valve Springs
a) Valve springs may not be heated and or stretched. Shimming is not permitted.
b) The springs must be a Honda OEM part. Part number 14751-ZXE1-000 or 1451-ZH8-940. Valve spring color
is a non tech item.
Bearings
a) Main bearings must remain as a press fit in the block after the engine has attained ambient atmospheric
temperature .
b) Loctite type compounds, pocket dimpling/knurling or any other form of retaining devices are NOT permitted.
c) Main bearings must be standard, unaltered, genuine Honda parts manufactured and listed for the Honda GX200 engine.
Block
a) Block must be an original OEM Honda GX-200 part.
b) Block must be in original cast condition. .
c) Welding to repair cracks or breakage is allowed only in areas where the affected portion does not require remachining and not in an area where the welding may be construed as a performance gain.
Cylinder Head
No alteration, modification is permitted to the head or head gasket surface. Valve seats may not be re-seated shallower
in the head. Head interchange between GX-160, GX-160/K-1 and GX-200 is not permitted.
The entire inlet and exhaust tract surfaces must remain STOCK as compared to one of the three configurations possible
in other known stock heads.
Thread saving devices in the spark plug hole must be installed so that a combustion chamber volume test will be the
same as with the original thread.
Head Gasket
GX-200 head gasket may not be altered in any way.
Valve Cover Gasket
Stock Honda valve cover gasket may be replaced with any gasket of the same basic shape as the stock Honda gasket.
The thickness of the gasket must be within specifications listed for the engine. The gasket may be affixed to the valve
cover.
Valves
Valves must not be altered, polished, lightened, welded, grazed, or machined in any way. The original 45 degree set
angle must be maintained.
The valve guides in the GX-200 may, as a means of repair be able to be replace to standard dimensions of worn out or
damaged valve guides.
Fitting of alternative exhaust valves (Honda Part No. 14721-ZH8-810) is permitted
Piston and Rings
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a)
b)
c)
d)
Re-sizing, knurling, or lightening of pistons is not permitted.
The use of piston button or buttons is not permitted.
Coating of pistons is not permitted. Anodizing of a piston is not permitted.
All three piston rings must be used, installed correctly, with the identification marks toward the head. Ring
tension may not be changed by heating or other means.
e) Ring gaps are not subject to technical inspection. The ends of each piston ring may only be altered in a way
that appears to be the same as a known, stock, unaltered, Honda ring for the engine.
f) The piston oil control ring (third ring) may be either single or 3 piece design, provided that it or they are stock
OEM rings, appropriate for the engine.
g) Piston rings and pistons (dished or flat top) are interchangeable between the GX-160/K-1, GX-160/T-1 and
GX-200.
Camshaft
a) No alteration, additions, removal of material, modifications or machining of any kind is permitted, with the
exception of removal or partial removal of the decompression apparatus.
Crankshaft Gear
a) The crankshaft gear can not be rotated to change the camshaft timing on this engine.
Flywheel
a) Must be stock and unaltered as used on the QXU model.
Shrouds
a) The cooling shrouds must be present and unmodified.
Ignition
a) Only OEM parts are permitted, except for the flywheel key. No CDI.
b) Ignition timing can not be altered from stock.
c) Coil mounts are not to modified in any way so as to change ignition timing.
Spark Plugs
a) Spark plugs are free, however the plug reach is to be 19mm with 19.2mm being a maximum, measured
from the upper gasket surface of the spark plug to the parallel lower squared edge of the threaded portion
of the plug.
b) Any spark plug cap may be used.
c) No spark enhancers or boosters are permit.
Carburetor
a) No alteration, modification, or machining of ANY kind is permitted of ANY part of the carburetor, unless
specifically stated in this document.
b) The choke assembly must remain completely intact and stock.
c) The throttle plate and plate fastening apparatus must remain STOCK for this engine.
d) The portion of the throttle shaft within any part of the body of the carburetor must conform to the
measurements of the stock, unaltered shaft for this engine.
e) The exterior control linkage apparatus may be modified or replaced in a manner approved by the technical
inspector.
Fuel Systems.
Pulse Pumps can be fitted using either the original hole used by the governors once they have been removed or by
utilising the inlet manifold. If via the inlet manifold, the fitting used must be a commercial off-the shelf product with
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no modifications and must protrude into the inlet port no less than 0.5mm, thus making de-burring unnecessary. If the
port is modified in any other way the engine will not pass scrutineering. No electric fuel pumps are permitted.
Spark Plug Gasket
a) A gasket and or a temperature gauge sensor must be installed under the upper surface of the plug.
b) The height or thickness of the gasket or sensor must be greater than 0.1mm”
Clutches.
All karts must be fitted with dry air cooled Noram GE20-219 centrifugal clutches. Clutches will be used to transmit the
drive with a maximum engagement speed of not more than 2,500 rpm engines speed. The Noram GE20-219 clutch
sprocket has 20 teeth.
HONDA GX-200 SPECIFICATIONS
BLOCK
a. The engine block must be in an “as cast” except where allowed by the regulations.
b. The only block that can be used is the GX-200.
BORE
a. 2.677” (68 mm) minimum – 2.720” (69 mm) maximum.
STROKE
a. 2.118”(53.8mm) minimum – 2.136”(54.25mm) maximum.
PISTON
a. Length 1.920”(48.75mm) minimum. Dished pistons must remain as cast.
CYLINDER DECK HEIGHT
a. Piston must remain 0.020”(0.5mm) minimum below deck throughout the full rotation of the
crankshaft.
b. The finish of the deck is not subject to technical inspection.
COMBUSTION CHAMBER VOLUME
a. 28.0 cc minimum.Measured with the cylinder head in place as raced
HEAD HEIGHT
a. Measured from the head gasket surface to the unaltered valve cover surface
2.885”(73.3mm) minimum.
b. The finish of the head gasket surface is not subject to technical inspection.
PORT DIAMETERS
a. Must be as cast.
b. Entire tracts must be STOCK when compared to a known shock head.
VALVE SEAT DIAMETER
a. Exhaust: 0.872”(22.15mm) Max
b. Inlet: 0.910”(23.10mm) Max
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VALVE SPRINGS
a. Honda OEM part number 14751-ZXE1-000 or 1451-ZH8-940 only.
VALVES
a. Must be GX-200 valves only, or fitting of alternative exhaust valves (Honda Part No. 14721ZH8-810) is permitted.
VALVE LIFTERS
a. Base width: 0.935”(23.75mm) minimum, 0.945”(24.0mm) maximum.
b. Height: 1.355”(34.4mm) minimum, 1.370”(34.8mm) maximum.
c. Base thickness: 0.073”(1.85mm) minimum, 0.083”(2.1mm) maximum.
IGNITION
a. Ignition timing can not be changed from stock.20 deg btdc
b. The flywheel must be a stock OEM flywheel for the QXU model.
CRANKSHAFT ROD JOURNAL
a. 1.175”(29.8mm) minimum.
CONNECTING ROD LENGTH
a. 2.350”(59.7mm) min -2.370(60.1mm) max inside, unaltered.
CONNECTION ROD BIG END BORE
a. 1.177”(29.9mm)min – 1.184”(30.0mm) max.
PISTON PIN
a. Outside diameter 0.705”(17.9) minimum, 0.710”(18.0mm) maximum.
b. Inside diameter 0.557”(14.6mm) maximum.
c. Length 2.120”(53.8mm)
CARBURETOR
a. Venture 0.575”(14.6mm) NOGO
b. Emulsion tube height 0.438”(11.1mm) GO and 0.460”(11.7) NOGO
c. The air bleed screw tab can be trimmed so the screw can be adjusted.
PHENOLIC SPACER
a. Must be stock GX-200. The fuel line guide may be trimmed to facilitate inspection.
PISTON RINGS
a. Must be stock Honda rings for the GX-200.
VALVE COVER GASKET
a. 0.120”(3.0mm) maximum
RECOIL
a. any approved GX series utility motor recoil assembly may be utilized. GX-140, 160,
160/K-1, 160/T-1, 200
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SHROUD
a. Only the one approved shroud can be used part number BD-185
b. No addition of material is allowed.
CAMSHAFT SPECIFICATIONS.
a. Lobe heights:
Exhaust: 1.085”(27.5mm) min 1.095”(27.8mm) max
Inlet: 1.085”(27.5mm)min 1.092”(27.7mm) max.
b. Overlap:
25 – 28 degrees
c. Duration:
240 degrees to 245 degrees
LEFT
0.010”
0.020”
0.050”
0.100”
0.200”
Max lift
0.200”
0.100”
0.050”
0.020”
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EXHAUST
105 – 113 DEGREES
135
151 – 157
170 – 174
215 – 223
0.227”(5.75mm)
293 – 297
342 – 352
000 – 004.5
015 – 020
INLET
329 – 340 DEGREES
357
013 – 019
032 – 037
080 – 086
0.225”(5.70mm)
152 – 158
202 – 208
220-0226
238 - 242
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I
1
AKA Homologation No.
ENGINE
Manufacturer
HONDA
Make
I GX200 (6.5hp)
Model, Type
! QXU Series
Category
ENDURANCE
Homologation
Period
I Pages
This homologation sheet reproduces description, illustrations and dimensions o f the engine at the time o f the
AKA Homologation. All motors must be manufactured within these dimensions
ENGINE PHOTO - DRIVE SIDE
SIGNATURE AND STAMP
OF APPLICANT
(Secretary)
The Endurance Karting Association Inc.
Copyright ©TEKA 2008
ENGINE PHOTO - OPPOSITE SIDE
SIGNATURE AND STAMP
OF AKA
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I
2
PHOTO OF
THE ENGINE FROM THE BACK
AKA Homologation No.
PHOTO OF
THE ENGINE FROM THE FRONT
(not available)
PHOTO OF
THE ENGINE FROM ABOVE
PHOTO OF
THE ENGINE FROM BELOW)
(not available)
Copyright ©TEKA 2008
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I AKA Homologation No.
CLUTCH DESCRIPTION AND SKETCH OF PARTS
NORAM GE20-219 CLUTCH
S P R IN G
"
Copyright ©TEKA 2008
SET SCREW
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DRAFT
AKA HOMOLOGATION APPLICATION
COVER SHEET
Contact Name:
The Endurance Karting Association Inc. (TEKA)
(Secretary)
Telephone (Bus.):
Telephone (Home):
Facsimile No.:
.
E-mail:
Manufacturers Name:
Honda
Engine Name:
GX-200
Model No.:
QXU Series
Units Manufactured Worldwide (Approx):
Commercially available worldwide
Units in Australia (Approx):
Commercially available nationally
Power (HP):
Recommended Retail Price:
Recommended Driver Licence Grade:
6.5hp
$800
C Grade
Benefits to Australian Competitors:
A reliable, durable and cost
effective motor readily available through Honda MPE approved dealers
throughout Australia
Recommended Classes:
185kg Seniors
Signature:
Date:
Copyright ©TEKA 2008
DRAFT
AKA HOMOLOGATION APPLICATION
COVER SHEET
Contact Name:
The Endurance Karting Association Inc. (TEKA)
(Secretary)
Telephone (Bus.):
Telephone (Home):
Facsimile No.:
.
E-mail:
Manufacturers Name:
Honda
Engine Name:
GX-200
Model No.:
QXU Series
Units Manufactured Worldwide (Approx):
Commercially available worldwide
Units in Australia (Approx):
Commercially available nationally
Power (HP):
Recommended Retail Price:
Recommended Driver Licence Grade:
6.5hp
$800
C Grade
Benefits to Australian Competitors:
A reliable, durable and cost
effective motor readily available through Honda MPE approved dealers
throughout Australia
Recommended Classes:
185kg Seniors
Signature:
Date:
Copyright ©TEKA 2008