Honda 160 cc engine surges

[Nakwasina17]

I have a one year old Troy Bilt lawnmower with a 160cc Honda engine. It ran fine last summer, but this summer it surges. I have removed the carb and sprayed every orifice with carb cleaner. I unscrewed the main jet but couldn't get it out of the center housing. When I removed the fuel line after the shut off valve, there was very little flow, so I cleaned the fuel filter and that improved things a lot. But, the engine still surges and just doesn't run with full power. Really baffling. I would appreciate any suggestions..... When I reinstalled the carb after cleaning, might I have gotten a gasket in the wrong way and so the fuel:air mixture is off?

 

[robert@honda]

Sure sounds like there is a fuel-delivery issue. Pretty good chance there is some tiny debris or gunk in the carburetor. While you can clean one, it can be a challenge to do the job 100%, and it is much more effective to simply replace the entire carburetor and gaskets. A carb for this engine usually retails for <$20 at most Honda dealers. New gaskets will help prevent air (vacuum leaks) which can also cause rough running and hard starting.

When you do it get it running smoothly again, be sure to drain all the fuel from the tank and carburetor before you put it away for the season. Modern gasoline (with Ethanol) won't store for very long without attracting water and forming slime/gunk on small carburetor parts.

On the side of the engine block is the Honda Engine Serial Number, usually in the form of "GXXXX-1234567" Write down this number and contact you local Honda dealer to get the new parts; most keep them in-stock and can help with install/remove tips or do the work for you if you wish. Here's a link to find a dealer in your area:

Find A Honda Dealer