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T0M-C

Engine Rebuild - can a rookie tackle it?

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T0M-C

I've got a D200 with a Kohler engine, model # K532S.  It's listed for sale with all of my attachments currently, but if I can't get it sold I'm wondering if I could tackle the Engine rebuild myself.

 

My experience - in middle school I dissassembled and reassembled a 5hp brigs.  It had undergone this process many times (all by 7th grade kids) and didn't run before or after.  I grew up on a large farm, so I have "fixed" alot.  Most engine related stuff was either under waranty or too techincal or too time consuming to do on farm, so it almost alwasys resulted in a service call.  At age 32 I undertook my first and only major project - replacing the engine in a geo metro.  I took my time and learned a fair ammount as I went.  And it ran when I was done!  I have alot of tools that would not be found in a typical suburban home garage, but not alot of the specialty tools found in a mechanic shop.  (welder, pullers, press, torque wrenches - yes... hones, Plasma cutter - no)

 

The Machine - engine rebuild is the scarry part for me, but if I tackle this it would be a frame up resto.  It runs and everything works to some some degree.  the engine in particilar starts good.  sometimes when it is warm and running at full throttle, usually under load, it will bog down and start spewing white to blueish smoke.  This lasts for about 5-15 seconds and feels like its rinning on 1 cylinder.  This weekend, in preparation of concreating my shop, I decided to move it "out back".  the blower was on front so I threw a battery in and started it, drove it to the middle of the shed and put the Brinly disc on back.  after parking it out back I walked in the shed and Noticed that there was quite a bit of blue haze in the air, so it is burning some oil all of the time.

 

The question - Is this something I could tackle on my own?  It would be a Snails pace project - lots of other hobbies, not to mention the family.

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MalMac

Well it seems like you have some mechanical ability and with the knowledge on this site, you should be able to do it. There are a lot of people on here that are darn good and can lead you through it and show you how it's done. With the help you can get on here I would not be scared to tackle it.

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Racinbob

:WRS:  I would agree that you have the mechanical aptitude to do a complete rebuild. Get a copy of the service manual and take it one step at a time. By the time you're done you'll wonder why you were apprehensive in the beginning. There's lots of tolerances, etc. that you have to keep in mind but it will be in the service manual. If you get hung up on something you definitely found the right forum to come to for friendly help.  :) 

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pfrederi

If the cylinders are badly scored or worn you will probably want to take that part to a machine shop.  Same if the crankshaft needs to be gound undersized. The other consideration is tools.  Unless you plan on doing other motors by the time you by the various tools you will need it may be cheaper to have the job done.

 

By all means read the manuals look at the tools you need to have. pull the heads and look at the cylinder bore then decide if you want o send it out or do it yourself...

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SousaKerry

Yeah like said above get the manual and dive in.  Lots of help here on this site and probably someone close to you would would be willing to give you a hand if you get too stuck.

 

The first step would be to remove the heads hand have a good look at the bores post some pictures and we can tell you pretty quick if it is worth rebuilding.  But if she runs decent and no strange noises then most likely all it will need are new rings and a honing.

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Shynon

Sounds like you have the skills to do it, cleanliness will make for a great engine.

 

           Tom

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oldredrider

Anyone who ever built or rebuilt an engine was a rookie at first. Common sense, the proper tools and a service manual along with some basic mechanical skills will be all you need.

If you think you can do it...you can do it.

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Terry M

I don't know much about The D200 tractor or the engine. But you may want to research what parts are available and the cost of them before you decide. :)   With that said(just my 2 cents)   I Look forward to seeing your rebuild.    I think those "D" series tractors are really Cool looking...and  If I had the room or the time, I'd think about buying it!!   You have a really nice work horse there with some really nice attachments :handgestures-thumbupright:  Hopefully, we can look forward to seeing it action someday :)  :)

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520HC

Not to scare you off Tom, but a Kohler 532 is a complicated engine to rebuild. Also parts are hard to get for these engines. They are a beast, but look through the manual before you start and you will see what I mean.

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nrowles

I am a rookie.  I don't know much about that engine or the extent of the rebuild.  But What I can tell you is that if you have the appropriate tools (or can borrow them), a service manual (which I found mine online for free), and the help of this forum, you should be able to get it done.  You can always find things cheaper online too.  I think a complete rebuild kit (which I didn't buy or need) for mine including piston and all was only a bit over $100 on ebay.

 

If you read/skim through my thread on the first page of this engine forum you will see what I mean.  I have only ever done very basic tune up stuff in the past.  With the help of this forum and tools that I didn't have that my buddy let me borrow, I took a tractor from not starting to running by replacing/cleaning entire fuel system, rebuilding carb, pulling head and replacing gasket, cleaning/lapping/spec valves, setting points, replacing battery and cleaning all connections, and replacing the starter.  This is a basic job for some but was quite an undertaking for me.  Now that I have done it, second round would take half the time.....taking the valves out and putting back in took me hours, but now that I know the tricks, it would take me 30 minutes.

 

I didn't go into as much as you would have to but I have never dove into engine work that far before myself and I got it done.  If need be, I think I could have gone further with the help of this forum, the service manual and borrowed specialty tools.  

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SousaKerry

Not to brag but the first engine that I tore down myself completely to the bare block and built back up to actually run was a Wisconsin VF4D.  Which for those not in the know translates as an air-cooled V4 monstrosity that only produces 25 HP has a Wico Magneto and crank (arm breaker)start. 

 

And I did not own any engine tools when I started and had no money either.  Wisconsin original parts are as rare as hens teeth and twice as expensive.  Aftermarket is about the only way to go for most parts and seals, several of these sources are guys making parts in their garage.  All told I think I spent less then $300 although I did not have to do any machine work other then decking the jugs which I did myself on the surface grinder at work.

 

Here is one of the first runs and if you notice I did this in a shed in a box.

 

Moral of the story, with patience and a basic understanding of mechanics anyone can rebuild an engine.  It really isn't that bad.  GO FOR IT!!!

 

http://youtu.be/yBP55btYI2I?list=UUoeEnA8HuHyKEOe_FUP8DEg

Edited by SousaKerry

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buckrancher

good luck finding parts

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Molon_Labe

Growing up as a "farm kid" you will be fine with the rebuild. Take your time and it will turn out okay. Any questions, ask, lots of help here!!! :)

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Digger 66

Welcome aboard Tom .

I can't help with your engine , I'm more into Rotax motors & 2-smokers , but the doctors here are the best in their field .

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953 nut

:twocents-twocents:  Check with your local Community College or Vocational School to see if they have a small engine class. If they do you will have access to all of the right tools as well as the guidance you are looking for. Good luck and keep us posted.

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Mr. 856

If you have a reliable machine shop, can read a book, can read a measuring device(or just let the machine shop do it), can turn a wrench and have 3/4's of brain then yes you can do it. My first engine rebuild was my recent K181. 1st step......manual. Read it before you even start. Morning "board meetings" are great for this. Get everything lined up and go one step at a time per the manual. After each step is complete go back over it once if not twice before moving to the next. I have the mentality or personality........to have do it myself to learn. I can watch so and so and so and so can tell me how to do it but if its not in my face and my hands aren't getting dirty then to me its useless. Dive in. I like you questioned myself over and over before I said "screw it" im going to do this. I fix stuff for a living so I had that going for me. Dive in, take your time, and im sure you will be happy with the outcome.

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Firpo701

I agree. Research everything, and be aware of your machine tolerances, and you'll do fine. Like everyone else says, any questions, just ask. :razz::tools-wrench:

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T0M-C

good luck finding parts

Finding a part is never the problem.  Finding the part you need within your budget is the key!  :teasing-poke: I've had a few responses and inqueries on the for sale ad.  But if I've still got it once concrete is done in my shop, I'll probably have to dedicate a corner and begin disassembly.  :thanks: for the confidence boost and stay tuned!

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