KyBlue 655 #1 Posted September 16, 2014 Before I start putting the Kohler back together tomorrow night I thought I'd ask the experts and see if there are any tips, tricks, pointers, or information that I'll need before reassembly? I used my ball hone on the cylinders and made sure all the fins were clean tonight. Hit the Head gasket Mating surfaces with a straight edge and some emery cloth ... 220 grit. I hope to put the case back together tomorrow night, and get the jugs on as well ... Look forward to the input, and of course... I'll get pictures for ya'll ...cause w/o pictures... It didn't happen right? Thanks for the Information, in advance. S. 2 Share this post Link to post Share on other sites
19richie66 17,500 #2 Posted September 17, 2014 Dont have any advice but will be watching as I have two magnum twins. I can always learn something new. Share this post Link to post Share on other sites
Pickle 43 #3 Posted September 18, 2014 (edited) Ball hones are not the best method of cylinder honing as they simply rough the surface and skip over hard spots. You would do much better honing with a three stone hone. Check your oil pump and oil pump gear shear pin, get some real assembly lube for bearings and rods(I use Royal Purple) Check your crankshaft end play and drive the flywheel side seal in after assembling the cases. Take care in the valve stem adjustments before final assembly, use new wrist pin keepers and align your ring sets to the proper gap opening orientation after checking for proper ring end gap dimensions. Some of this may not apply as the last Kohler twin I rebuilt as a KT series. Edited September 18, 2014 by Pickle 1 Share this post Link to post Share on other sites
Geno 1,929 #4 Posted September 18, 2014 I agree with Pickle on the ball hone thing, I only use the 3 stone also. 2 Share this post Link to post Share on other sites
KyBlue 655 #5 Posted September 18, 2014 Cylinders were in too good of a shape ... There were no Rough spots, no gouges, no deep scratches. Ball Hones have their uses... at least in my shop. I've used them on many rebuilt V8's over the years with Zero issues... I've checked the oil pump, oil passages, end play, crank tolerances ... Should be good to go ... Oh and I use Royal Purple Assembly Lube, and it'll get RP oil as soon as the break in is over. Thanks for the tips 1 Share this post Link to post Share on other sites
Molon_Labe 731 #6 Posted September 18, 2014 Before I start putting the Kohler back together tomorrow night I thought I'd ask the experts and see if there are any tips, tricks, pointers, or information that I'll need before reassembly? I used my ball hone on the cylinders and made sure all the fins were clean tonight. Hit the Head gasket Mating surfaces with a straight edge and some emery cloth ... 220 grit. I hope to put the case back together tomorrow night, and get the jugs on as well ... Look forward to the input, and of course... I'll get pictures for ya'll ...cause w/o pictures... It didn't happen right? Thanks for the Information, in advance. S. You sir are a true gentleman and as you say, "without pictures it didn't happen". Good luck with the rebuild and keep us posted. 1 Share this post Link to post Share on other sites
KyBlue 655 #7 Posted September 19, 2014 Well I'll get pictures when I actually get to the shop. The last couple of nights been rest and recover time from very long days dealing with tons of stupid... Tonight or tomorrow at the latest... 1 Share this post Link to post Share on other sites
KyBlue 655 #8 Posted September 20, 2014 Well ... There is progress! After my company left for the night, I headed right for the shop, closed and locked the door and cranked the stereo ... I spent a fair bit of time cleaning everything! Oh my lord The Chunks of aluminum that I got out of that thing!!! Even Found Trash inside the Oil pump Rotor..Took the time to clean it up, No Lasting damage, everything operates smooth like it should now. Starting putting it back together ... I'll get a bit more done today. I did discover that I forgot to order the plugs and what not for the ends of the Cam shaft! Doh! Now before everybody gets on me too much, I know the outside of the block is Nasty. Normally I'll clean it before teardown, however on this one, I didn't know if it was saveable. Actually I was convinced it was junk, I didn't see the point in wasting time and supplies to clean the outside of it when it was just going to the scrap bin. I will be cleaning and painting it once it's buttoned up. I'll just have to be that much more careful and use smaller brushes and take a bit more time to get it clean. I don't mind the extra. 1 Share this post Link to post Share on other sites
Geno 1,929 #9 Posted September 20, 2014 Wow, what a mess. Share this post Link to post Share on other sites
KyBlue 655 #10 Posted September 21, 2014 Another day in the shop, or well a few hours I should say. I didn't get Everything accomplished that I'd hoped but ... Still got a bit more done. For the life of me I cannot find my Kohler M18/M20 Engine Manual. Guess I'll have to order another one. I don't know for sure how the plugs go on the end(s) of the cam shaft and It's been a year since I pulled it apart, so I don't remember. I'm also missing the odd bolt here and there. Need to find out how the Linkage goes, and of course figuring out all the tins ... Set everything in place figuring out what I need, and what goes where ... I knew I should've taken better (more) photo's when I pulled it apart. Thankfully everything is in Ziplock baggies. Mostly. I did get both heads on, and even with the heads only a little more than finger tight it has decent compression. I'm quite happy. It turns over as it should without any odd noises. For a first Small Engine rebuild that has had a very very very rough life .... I think It's come out good! 1 Share this post Link to post Share on other sites
19richie66 17,500 #11 Posted September 21, 2014 http://www.kohlerengines.com/onlinecatalog/pdf/tp_2204_b.pdf 1 Share this post Link to post Share on other sites
KyBlue 655 #12 Posted September 21, 2014 Thanks! I ordered one last night...I can't see the pictures of the scanned copy sadly. It's always nice to see how things go, not just read how. Does give me the torque and sequence for the head gaskets though! Thank you again! Share this post Link to post Share on other sites
Fordiesel69 259 #13 Posted September 30, 2014 What did you do to the crankshaft. I would assume it needed turned down? Share this post Link to post Share on other sites
Geno 1,929 #14 Posted September 30, 2014 (edited) May or may not. Did you have the local machine shop check it for you? Edited September 30, 2014 by Geno Share this post Link to post Share on other sites
