Quote:
Originally Posted by Matt G.
You can't cut that off...that's a bolt hole for the starter/generator bracket. You basically have two options:
1. Use a sharp cold chisel and hammer to break that gear on the thin side between the webs, clean out all the shards, add a magnetic drain plug, and hope no shrapnel got where it shouldn't have.
2. Take out the crank and do it the right way.
I have done #1 but would recommend #2 since you need to replace the rod anyway; you'll be halfway there. That way you can measure the crankpin and bore and piston and determine if you can get by with a set of rings or if you need an overbore and oversize piston. I would also replace the governor gear and cross shaft and brass nut if you take it apart that far.
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I was being facetious about cutting off the nipple...but i am certainly going with option #2, i don't have time to redo things these days so it needs to be done right the first time. I'll start going through the Kohler manual and tear it down in the next couple days whenever i can find a couple of hours to burn. If i can stay out of a machine shop i wwill be happy, that is my new goal.