Magnum 20 Rebuild

This is where we can discuss all the stuff made after IH's sale to MTD.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Even though my drill just skimmed the threads....it screwed right in and got tight just right.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Doing the boring stuff this weekend.....cleaning bolts and a few more small parts. I had all the hardware bagged and labeled. I did not feel like resorting so I had three different jars set up w mineral spirits and cleaned small batches. You see here the intake....after a bath in thinner....the air compressor took off all the paint. I'm debating when to repaint some of this stuff. It sure would b nice to hit it now as it's perfectly clean.....but don't feel like masking stuff off. I may just try some and see how it goes.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Mike.....why u so nosey?
Oh man....where do I start. Let's see..in Jan when this sounded like a good idea I did not have.....three kids doing sports..... busy work.....lawn to mow....stuff like that.
I have it all bagged an tagged ready to go. I'm kinda stalled w the measurements on the crank. I have not done any work to it yet and I'm hopping not to. I need to secure a mic or have my nephew come down and check it all out. The back of the bearings have a 10 indentation on them? Is this a fluke or is this an oversized?
I have a wing of the basement off limits for the boys.....but still get nervous when they r down there w friends.
I installed an 18 in the mower for the summer mowing......cause swapping engines was easier than the 60" deck..... :lol:
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

Just trying to keep you on your toes......obviously I am not doing my job :lol:

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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Let me start by saying....i don't have a micrometer. I ended up buying a dial caliper. I took some heat from Tom for not buying the right tool for the job. After he settled down and stopped whining...he was a big help with my rustyness in reading the dial.Thanks T.S. So...It seems nice to me and I feel good about its accuracy. The crank main bearing surfaces feel great and measure almost perfect. Bearings show a little wear..they r at about the max spec so new std. ones r one there way. The rods I used the plastic gauge and are also well within specs.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

The new old stock crankshaft bearings came yesterday. I worked with a guy on eBay....to my door...$90 for both. Not bad!
But.... for me spending $90 bucks......i was hopping for more "wow". The new bearings are almost the same as my old. The difference is about half the thickness of a piece of copy paper. This is almost unmeasurable with my limited equipment. With all parts dry..(no oil) I can get a very slight movement up and down w the bearings on the crank. Once oil is introduced.....it does not move and feels real nice. This is for both new and old.
So I kinda feel like money was wasted but I had no idea until I had a new one to compare. I guess if for nothing else.....i can now say "NEW CRANK BEARINGS" :(
I guess the only thing left is to start puttin er together :)
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Oh....i don't know if u guys remember....i said the old bearings had a 10 stamped on the back. The new ones do also. So this has nothing to do w the size. Kinda dumb if u ask me....not to put the size on it.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

So...it was raining on Sunday night.....i was bored so I went down to look over my engine. I started assembly....very slow mind u! I'm walking through the manual step by step. It's going good.
Oil pick up
Oil pick up
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Oil pump
Oil pump
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Governor install
Governor install
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Last edited by dag1450 on Mon Jun 06, 2016 8:03 pm, edited 1 time in total.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

I got the new bearings on.... crank in... cam in .....all clearances r perfect. Next step is to seal the surfaces and bolt the block together.
Crank bearings
Crank bearings
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Tappets
Tappets
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Timing marks
Timing marks
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Cam end play
Cam end play
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

Ole nosey checkin in....looking good :beer:

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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Mike....i hope your having fun.. watching me do all the work :x
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

You bet your bippy I like watching you work :lol:

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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

I'm waiting to hear that dude roar!

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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

U and me both Mike! Got some things done today. Block halves bolted together. Closer end plate on and oil line adapter thingie. As I as torquing the bolts I was very careful to get the reading ......on the old school inch pound wrench. Ultra black seemed to meet all the criteria for this job. The manual asked for oil on the cam plug seal....i used black there as well.
Sorry no sealent shots
Sorry no sealent shots
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Not reading newtons
Not reading newtons
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

As I was preping for the next step I came across a bugaboo. On the middle ring....the manual shows one thing and I have another. It revolves around the pip mark that should face up....and the inner side has a 45° chamfer. If I put the dot or pip mark up.....the chamfer will b down? The old rings match the manual. :(
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This is highly technical information we r dealing with here.....
This is highly technical information we r dealing with here.....
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:roll:
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Got these things still to install.....not fun!
Crank seals. My kit gave me three of each end. I may need them all.
Crank seals. My kit gave me three of each end. I may need them all.
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

I did some internet digging......and found that ring technology is ever changing. I am only discussing the second ring or middle one....and take what I say with a grain of salt. :lol:
The old Kohler was called a "torsional compression ring". The new is "reverse torsional compression" where that 45° chamfer will now b facing down.
This info was not from any Kohler website.....just from various sources. There seems to b several different names for these as some also use the word twist. It don't matter to me .....all I need to know is that I don't have a mistake and that the pip or dot goes up. Now I just need to make sense of the ring direction sheet.....that is mostly in foreign language.
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Tom Scott
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Re: Magnum 20 Rebuild

Post by Tom Scott »

Dave, you are moving along well on the build now! Unless Kohler made some horrific mistake, the pip should face up. Check the paper work that came with the rings, there might be a brief mention of the pip and chamfer you missed. You do have a history of sometimes "speed reading"! :lol:

Also, Kohler's website should have a contact email as well.

Also, also,... I would get the installation tube for the oil seal. I'm definitely looking into that for my next seal install.
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Re: Magnum 20 Rebuild

Post by SWilliams »

I use a piece of 1.25" Sch 40 PVC pipe to install the seals. Added a collar made from a reducer that stops it when the seal is 1/16 inside the bore. I give them a coat of Yamabond-4 that will "glue" them in, then I stake the case in 6 places as well. I HATE having them come out.
Owner of an 1863, 2263 (1863 W 22hp engine!) 2084 and a 2 - 2284s.


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dag1450
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Re: Magnum 20 Rebuild

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Thanks guys. Yea Steve I have my PVC pieces in my tool box. One thing I was thinking about was trying to bush it down to the size of the crank.....so even if I hit it kinda off center it will stay centered. I will look at the depot to see if this is possible. I know I used a piece of pipe for one end.....and I used a coupling for the other size. I will post pics of what I use and find.
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dag1450
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Re: Magnum 20 Rebuild

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Got my $.50 cent seal driver all figured out.....i have precision bushings inside the inch and a half pipe. I quick ran in the old seal......perfecto!
No more hammer for me
No more hammer for me
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Got both crank seals in. The new seals came w a grease on the wear surface.....i put oil on the crank and a little on the inside edge. I then used a tooth pick and smeared a touch of permatex #3 on the block surface. Like Steve said....1.25" PVC pipe for the flywheel end....and my special driver on the PTO end.
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dag1450
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Re: Magnum 20 Rebuild

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Rings on....i just need to find my compressor.
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Top ring must have a special wear surface..... maybe chrome?
Top ring must have a special wear surface..... maybe chrome?
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dag1450
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Re: Magnum 20 Rebuild

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Last weekend I was all set to get the cylinders on. I get my ring compressor on and start to snug it down when I hear "snap"! I had no idea what it was...but thought I should check out. Pull it off and there the top ring is in half. So later that day my nephew stops by and notices a spec of something in the broken end grain of the cast iron ring. That is just what I needed to see to let me know it was not any of my doing. I'm in talks right now for a return.... we will see what happens. In the last pic.. if u open it up and zoom in u can see the inclusion UNBELIEVABLE
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

Well that just sucks!
I wondered how you were doing on this but didn't want to be nosey :lol:

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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

Mike, Yea u got that right.. this does SUCK! BUT...being a husband, father of teenagers, homeowner and contractor.....ive gotten used to :( SUCKS! and like professor Tom S. and others have pointed out....better to happen now than after running for a few months. I bought my "master" rebuild kit at Pats Small Engine. At first i was like...well i bought this six months ago....its on me...but im the type that says "it never hurts to ask". So i called Pats and they said send me a pic of the crack and we will go from there. After they saw it they said send it back and we will see what kohler says. I would hope he has a good feeling about a replacement before he would have me ship it back. So im shipping just the one ring kit back tomorrow and going from there. If it doesnt go well it will set me back about $75 bucks. STD rings r about $30. .10 over are crazy money :shock:
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

If you have to buy rings call TotalSeal and get gapless.

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Tom Scott
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Re: Magnum 20 Rebuild

Post by Tom Scott »

dag - Ring update? This is like watching a TV show with too many commercial breaks... Let's gitt'r done!
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2182-1, Kwik-Way Loader, 3-pt & rear pto, 442 tiller
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dag1450
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Re: Magnum 20 Rebuild

Post by dag1450 »

I have nothin! I guess I will call Pats next week.
Looking ahead....does anybody have tips for adjusting the valve clearance. Im thinking I have to take it to the machine shop for this step. Idk. Any ideas?
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BigMike
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Re: Magnum 20 Rebuild

Post by BigMike »

Bench mounted sander with a table,a block of wood and slowly sand the end of the stems until its right.
Wait a minute......i'm not allowed in this sand box for my oil comment :D

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