Excell 2500 powerwasher

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  #1  
Old 07-29-15, 12:10 PM
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Excell 2500 powerwasher

I had to replace the cam pulley on my Excell XR2500 Honda GC160 engine, I also had to split the block as the exhaust valve came loose and logged itself in cylinder, to do that I needed to remove the water pump. The engine runs great without the pump installed but when I reinstall the pump I cannot pull the starter rope at all. The engine seems to be seized so I took the pump off and started the engine with no problem, any ideas would be appreciated.
Thanks larenzo
 
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Old 07-29-15, 12:16 PM
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I must hold the wand trigger open so the water can flow while starting my washer maybe your is the same. Have a good one. Geo
 
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Old 07-29-15, 12:19 PM
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Is the pump seized? Is it aligned properly to the engine?
 
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Old 07-29-15, 05:35 PM
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That's the vertical shaft model with the pump underneath the engine. Like Dane mentioned..... it sounds like the pump isn't lined up right.

To further comment on Geo's suggestion..... I have a water shutoff valve between the water supply and the pressure washer. I leave it off and turn it on as soon as the engine starts.
 
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Old 07-30-15, 05:28 PM
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Sorry for getting back so late, but no the pump is not seized it moves freely.
 
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Old 07-30-15, 05:37 PM
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The pump sits on the engine shaft and has a set screw in contact with slotted area of the shaft. It also has four bolts that screw into the engine block, so that it is aligned properly.
 
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Old 07-30-15, 05:54 PM
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Remove the spark plug and slowly pull the engine's start cord and feel what's going on. You'll be able to feel and hear if there is anything binding or hitting. You know the engine runs so it has to be something related to the pump or how it's attached to the engine.
 
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Old 07-30-15, 06:09 PM
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Not sure what you mean when you say the pump is underneath the engine, it actually mounts on the shaft behind the engine. The pump is horizontal to shaft although the engine is vertical with the shaft below the engine running front to back.
 
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Old 07-30-15, 06:15 PM
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With the pump attached I cannot pull the starter cord, the cord pulls freely and the engine starts easily when the pump is not attached
 
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Old 07-30-15, 07:08 PM
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Not sure what you mean when you say the pump is underneath the engine, it actually mounts on the shaft behind the engine. The pump is horizontal to shaft although the engine is vertical with the shaft below the engine running front to back
I have read this several times and can't figure out what you are saying. Check down in the hole where the crankshaft goes for a foreign object. It sounds like it's pushing so hard on the crankshaft that it's binding up the engine.
 
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Old 07-31-15, 04:40 AM
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Does the pump turn when it's not on the engine? Have you confirmed that it is not seized?

What was the original cause of trouble for the engine? I'm wondering if the initial problem was not the exhaust valve.
 
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Old 07-31-15, 08:47 AM
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Yes the pump turns when it is not mounted to the engine. The original problem was a broken cam pulley. While replacing the broken cam pulley I some how knocked the exhaust valve off the rocker arm and it fell into the engine cylinder, so I had to split the engine in order to free the stem valve, after cleaning and honing the cylinder, I put it back together and replaced the broken cam pulley, now the engine is running properly, but not with pump installed.
 
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Old 07-31-15, 09:00 AM
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The engine block has two parts the sump and the cylinder head, the head is part of the cast and does not come off. As I said it gets split in two parts, so I took it apart and clean out the broken pieces of the cam pulley and installed a new cam pulley. Now the engine runs fine, but I can't start the engine with pump installed.
 
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Old 07-31-15, 01:47 PM
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The engine runs. The pump turns when not bolted to the engine. Something isn't right with the way they are being put together. Try removing the spark plug from the engine again and start mounting the pump. Just start the bolts and pull the engine starter cord. Keep doing that until you find the point where things bind.
 
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Old 07-31-15, 03:21 PM
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Thanks

Thank you to everyone who replied to this thread. The power washer is running great, still not sure why it was binding but I followed the directions of the last reply by Pilot Dane and hooked up the pump to the engine with the spark plug out pulled the starter cord and got no resistance so I put the spark plug back in pulled the cord twice and it fired right up. Thanks again, off to wash the F-150.
 
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