I fixed my 1982 G1 carb - Throttle Shaft Hole

[sontag1]

I was having to run my cart with the choke pulled out. That is how I got it last week. Well after a lot of reading, some good advice, and some digging in my carb, I found that the Throttle Shaft had a lot of wiggle room in the Throttle Shaft Hole. It was making my cart run lean, and that is why I was having to run with the choke pulled out. It looked like I was about to start shopping for a new carb. After I thought about it for a while, I decided that I had nothing to lose by trying to fix it. At first I thought I would JB weld that hole closed and re drill the opening. I did NOT end up doing that. So after I got the carb off this morning I could see that the body of the carb was not damaged. There was some sort of brass bushing around the shaft that had worn out. That is where all the wobble was coming from. (picture 1) This is how I fixed it. I am going to try and give step by step with pictures:

I removed the carb and then removed the bowl, float, and needle (picture 2). While you have the carb off you might as well clean it.

As you can see in (picture 3) the screws holding the plate on the shaft are pretty stripped out. They actually came out fairly easy. I was worried for nothing.

Picture 4 shows the shaft out and the worn bushing laying beside it. Picture 5 shows the shaft with the replacement bushing. Even a blind hog finds an acorn every once in a while. I do not know what it is called, but it is used to crimp ground wires together. I had a container with several, but the card that id's what is in the container is gone (of course).

I will continue in a reply so I can upload more photos.

[sontag1]

In Picture 6 you can see that the body of the carb is not damaged.

In Picture 7 I put the shaft in the hole so you could see how much play there was.

In Picture 8 I am getting ready to slot the bushing so I will slide over the shaft.

In Picture 9 I have cut the slot, and I got it on the first try.

In Picture 10 you can see the old bushing and the new bushing with slot.

[sontag1]

In Picture 11 (my worst picture), the new bushing is on the shaft and shaft is in the hole.

In Picture 12 the bushing and shaft are seated. This took a little force, but it worked great!

In Picture 13 the carb is put back together and the old bushing is laying beside it.

There is no play in the shaft now. I installed the carb and went for a ride.

It ran without the choke. Carb fixed. Now we have to wait and see if it stands the test of time. I hope this will be able to help some of you gear heads out there! Not too bad for a scientist I must say.

Kevin

[GMB74]

Excellent job! Now, can you give us some clues on where to find that brass fitting so we can duplicate your repair? It is pretty common to have that bushing wear out, and it is not available separate from the carb.

[Mike Mac]

Nice fix and good documention! Did it work?

[sontag1]

Yes it worked. I am able to run the cart with no choke at all.

The thing I used as the 'new bushing' is a very common wire connector in residential or commercial construction, and any electrician would know what it is called. You can find it on the shelf at Home Depot or Lowes by the wire nuts. Just take a good look at the picture 10, and you would be able to spot it on the shelf. I do not know what it is called though. As soon as I had the shaft out of the carb body and I saw the old bushing, I knew what I needed. I just happened to have a couple laying around the garage. Of course, they were in one of those clear packages and I had thrown away the label.

I have turned wrenches most of my life (out or necessity), but I am a complete noob at this small engine stuff. I know that my cart still needs some serious tweaking to get it where I want it, but it is running about twice a fast as it did before the repair (i drilled the arm on the gov after I fixed the carb) and no choke at all. I was having to run full choke to get it to do anything yesterday. I wired the butterfly in the exhaust open and did a muffler BBQ too.

[Mike Mac]

Good deal Son, glad your making progress! Just wonderin if you needed to put one in the bottom as well? Fun having a good running car!!

[sontag1]

The bottom of the Throttle Shaft had some sort of rubber like bushing on it, and it was still in great shape. It seated tight in the "well" at the bottom of the carb body. There is very little (if any) wobble in the shaft now. I was really pleased at how it all went back together.

[Mike Mac]

[sontag1]

The "new bushing" is a:

Gardner Bender Steel Crimp Connector, 18-10AWG
(you can also get them in Copper)

I am not sure of the size I used. It would probably be for 12-14 guage romex. They are cheap, so you could buy a couple of sizes to have on hand when you have the Throttle Shaft out of the carb body.

Here is a link to Home Depot where I bought it:

http://www.homedepot.com/Electrical-...atalogId=10053

Now you are equipped to fix your carb if the Throttle Shaft Bushing (upper) is worn out.