I started the motor the other day and the RPM's were reading well over 5000rpms where it should be 3500-3600rpms. My main question is how to adjust the governor to get the proper rpms before my motor blows!!
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Try a static governor adjustment first as it simply be out adjustment.
Static Adjustment Procedure
Make this adjustment whenever governor arm is
loosened or removed from cross shaft. Adjust as follows:
1. Make sure throttle linkage is connected to governor
arm and throttle lever on carburetor.
2. Loosen nut holding governor lever to cross shaft.
3. Move governor lever toward carburetor as far as it
will go (wide open throttle) and hold in this position.
4. Insert a long thin rod or tool into hole on cross shaft
and rotate shaft clockwise (viewed from end) as far
as it will turn, then torque nut to 6.8 N·m (60 in. lb.).
Sounds like the engine governor is out of adjustment or it is sticking. The engine governor job is to regulate the engine RPM and torque that is needed to power a load and return to the manufactures no load engine RPM. Recommended RPM's on pressure washers and generators are usually governed at 3,600 RPM's because that is where the engine is producing most of its torque and HP.
Your throttle plate and or governor arm may be out of whack. Download a technical service manual in a pdf off the internet and follow the instructions on how to set them. Be sure to put a 6mm pin or bolt in the hole while adjusting. You want to set your governor arm prior to setting the throttle plate. I had the exact same issue on mine and that was the resolution. Good luck and be sure to set your rpms correctly for high and low speed idle. Again the technical service manual will provide info on how to do it all. They sell a little hour / rpm gauge on ebay or amazon for like 15 dollars where you just have to wrap the wire around the plug wire 4 to 5 times and it will read your rpms. :)
Most small pressure washers do not have an automatic throttle control to increase engine speed on demand (activated by trigger on wand). You must set the governor/throttle to about max. to get the rated pressure. A honda motor produces 5 hp when it is turning about 3600 rpm. To increase the life of the pump, use about 80 % of capacity of the pump and increase only for stubborn debris.
No need to plug the injector because under pressure (internal force/pressure) keeps valve shut. It only opens when large nozzle (black tip) is used lowering internal pressure causing siphon effect. Some chemical injectors have a thumbwheel to shut off flow completely. Your plug idea will keep the opening clean for later use. You can adjust pressure by ear. Your pump will take a 6.5 hp engine to develop max pressure of 2700 psi, however, to extend the life of the pump and engine, adjust pressure to about 75 % of capacity or about 2000 psi. To develop 6.5 hp your engine must turn at about 3600 rpm which is over the max rpm of the pump 3400rpm. The rpm of the engine is usually set by using the appropriate governor spring. Easy task, by using the model number and type of the engine, you can determine the proper governor spring and placement on the throttle arm, maybe about 3000 rpm would be sufficient. Now with engine rpm set, turn pressure adjustment up until engine sounds to you like at full labor, then adjust down to a workable pressure for majority of work and turn up for stubborn debris. Good luck with your project.
That lever is the governor. It's not necessarily causing the surging, but when your motor starts to die, it moves and allows more fuel into the engine and lets it speed back up. Sounds to me like you need to either clean the carb, or if there is an adjustment screw, back it out just a bit allowing a bit more fuel into the system during operation.
Most generators (except the latest inverter generators) produce power directly dependent on RPM's. The governor adjustment is critical. This usually is in the form of an adjuster that through a spring, applies a preload to the governor arm. The governor arm is attached to a shaft that disappears into the motor. Inside there is usually a set of weights that when spun faster will attempt to slow the motor and when spinning too slowly will attempt to increase revs. The adjustment you need to make is to the preload spring. They are very sensitive to the motor being in good tune so do the air cleaner, spark plug etc before trying to get it right. Under voltage can do more damage than over voltage so take your time and get it to a good steady correct voltage with your usual expected load on it. A safety trip out box gives you a way to test voltage with a load on & some protection. Work safe
Almost certainly, your problem is being caused by the engine governor being set wrong. The governor is responsible for adjusting the engine as it comes under a load. With the breather off the carb, watch for the linkage that moves all by itself when you pull the trigger. It will have a spring as part of it, and an "arm" that is part of the linkage. This arm has 4-7 holes in it. Moving the spring to a different hole may fix the problem. There is also usually an adjustment screw that you can toy with and see if that tweaks it. But I'd definitely try moving the spring -- 1 position at a time -- and see if it a). helps or b). hinders......... Depending on the answer, you get a clue as to which direction to go with your next adjustment attempt. One of two directions will put the correct tension of the spring/arm and cause the governor to govern correctly.