Shadow Build

[John H]

Gordon, your quote 'If it isn't smoking, it's broken' finally caught up with me. I grabbed the wrong gas can for my 2-stroke Lawn Boy. The second I heard it slowing down and a slight screech, I shut it down. Hopefully I can find parts to rebuild it. It's my favorite mower.

[ATinkerer]

The new synthetic oils will let you get by with a lot less oil than the original mix, but not without any at all.
You may have to get inventive to find those parts these days.
Sorry to see that.
How bad is the journal? Small end also? or just a stuck piston?

Gordon

[Lotus54]

I’ll bet somebody still has parts- easier to find ‘hard to find parts’ now than it would have been 30 years ago.

How is the cylinder?

[Lotus54]

Maybe these guys have the parts?

https://www.jackssmallengines.com/Produ ... -And-Rings

Or:

https://www.ereplacementparts.com/lawn- ... 67463.html

I don’t know the model you have. Some seem to only have 4-stroke stuff

[John H]

Bearings are shot but the crank is good. I found a rod kit and main bearings. The bore / block will be ok but haven't found an early Series-F piston yet. Well, I did find one--$95.00! I'll keep looking. Jacks Small Engines has rings but no piston. May have to go that way and be satisfied it will last as long as I do

[John H]

So much for the LB rebuild, back to serious stuff
The crank is on the truing stand and the flywheels are parallel but both ends are out considerably. Very puzzling as the pin was squared with each flywheel before being pressed in. Going back over every move, I think I have found the problem. I used a different end piece on the hydraulic ram that wasn't deep enough to make contact with the shoulder on the ram.
When putting a feeler gauge between the end of the ram and the table I can now see the end of the ram is not true. The end piece was just following the end of the ram. The ram must be removed from the cylinder so the end can be trued in the lathe. I will probably make a new end piece that will be a perfect fit.

IMG_5558.JPG (224.44 KiB) Viewed 24021 times

[Vincent]

John do you have a photo taken during the pressing operation?

[John H]

Yes, here's the assembly. You can now see the end piece doesn't register on the shoulder of the ram and isn't snug so is held on with a set screw. Post 849 is the same photo.

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[John H]

I have disassembled the crank and will start over with different flywheels. This route will allow me to use the crank pin that is already matched to the rod bearing inserts. I have a larger pin set I can use with a different pair of rods later.
On setting up the fixture in the mill again I discovered the head was not perpendicular to the table. It was out close to .001 in the 8" distance I measured. Still puzzled how this happened but it is now true again.

IMG_5563.JPG (191.31 KiB) Viewed 23935 times

While waiting for a new main shaft for the new flywheels I'm back to pre-assembling the girdraulic forks. I counted close to 100 pieces! Still waiting delivery of the tapered steering stem bearings but can finish all the other parts.

[Lotus54]

It is a shame to take it apart and do over- but a LOT better than having engine issues later.
Always good to catch it early.