Thanks AVB.
Ah well, such is internal combustion engines. It's such a pity when something seemingly minor sends an engine to the recycling area at the tip.
So as a summary for anyone in the future experiencing governance (is this the correct use of the term) problems, here's my take on it (although I could be wrong and would be happy for anyone to correct me). Similarly, I don't know the right names for each of the parts we are talking about here. For instance, now I see the set up, using the term governor shaft is ambiguous at best. I have made up my own terms in an attempt to clearly distinguish between parts, but if there are correct terms or better terms, please correct the record.
SUMMARY:
1) excessive range of rotation of the governor shaft probably is a diagnostic tool
I really think that, despite what I said earlier, that the 90 degree rotation of the shaft initially was real and symptomatic of the type of failure I experienced- UNLESS my understanding of how the unit is set up is wrong. The governor gear shaft somehow came free from its pressed connection into the upper case, fell to the bottom of motor, allowing the governor arm shaft a wider range of rotation. The reduced motion I experienced later was because the displaced pieces got in the way of the lever on the end of the governor arm shaft.
2) no evidence other than the racing motor was apparent- no metal in oil, no obvious performance problem upon start up.
3) the fact that this problem arose immediately after carburetor repair was pure coincidence, as was the starter motor problem
4) 630 hrs of operation before failure
630 on the clock- no guarantee this is the original motor). I can't speak for the maintenance schedule of the previous owner, but in the short time I have owned it (probably on 50 hrs of operation), I have routinely changed oil and filter, with little else done to motor. I hadn't adjusted valve clearances or anything similar. I have been too busy fixing the drive, perhaps unnecessarily.
QUESTIONS (AVB?)
1) so if it were possible to somehow attach the governor gear shaft in the upper case it may fix the problem (if only temporarily)?
2) does knurling the shaft actually raise metal on the high spots? This would effectively increase the shaft diameter, and thus potentially allowing a refit?
3) what about having a new shaft made up, slightly oversized where fits into case? Would need to drill out the hole to accommodate.....
4) is there any other way of permanently joining the shaft to the case, even if it only brings limited extension to the life of motor?
5) what actually happened here?
The shaft somehow became loose by the hole in case becoming elongated or something similar? The shaft itself shouldn't wear because it's just a press fit?
Next, the arm on the end of the governor shaft that can push up on the governor gear shaft when fully rotated counter clockwise doesn't hold the gear assembly in place and there was room for it to fall into the bottom case?
6) Is this a common internal failure?
We have spoken of the decompression valve failure that can lead to governor failure, but mine has no such set up. Is this an Intek specific problem? Twin cylinder v single?
7) Is there anything that would hold off a failure like this?
8) If I install a single cylinder Chonda, I imagine there will need to be significant throttle and choke cable re-engineering, fuel line modification and electrical work done. Anyone got any experience with this? Easy? Difficult?
Thank you
