295cc Rebuild Question

[sluggo99]

Hi Everyone - I'm new here and need some advice/feedback on my first rebuild. I have a '96 TXT 295 that began running very poorly then got to the point where it wouldn't start. So (primarily just for the experience of rebuilding an engine) I pulled it out, bought a manual and a rebuild kit, and rebuilt it. I pretty much followed the steps in the manual “to a T”, and it all went back together without a problem. I’m now ready to drop it back in the cart, but I’m a little nervous about one thing -the engine is very tight, to the point where you can’t manually move the drive clutch (at all, not one iota!). Before the rebuild, it was difficult to carry the thing if you grabbed it by the drive clutch because it rotated so freely. I’m concerned now that the alternator won’t be able to crank it over. Does it sound like something’s wrong or is this normal? Any advice would be appreciated.

[raydhd]

I can see being tight on cpmpression but not moving iota sounds like a rod bearing binding or some other mechanical malfuntion.

[Diceman1530]

Can you turn it over with the spark plugs out

[sluggo99]

No, still won't budge with plugs out. One thing that hit me earlier tho was that I haven't put any oil in it yet -could that be the problem? Also, I had to use quite a bit of force on a break over bar when I timed it and for valve adjustment -is that normal or an indication something's not right? Thanks for your responses!

[raydhd]

Did you prelube all the moving parts during assembly?

[sccowboy]

I would not force it at all. You should feel some resistance but not "binding". If it is binding like that then you may consider taking back down and double checking that you have it reassembled to spec. Did you measure the cylinders and make sure that you have not only the correct pistons but the correct rings on them?

[sluggo99]

Yes, everything was prelubed, but I didn't measure the cylinders. I figured since the rings and pistons came together in the kit they should be compatible, and that I wasn't changing the size of the bore so the pistons should be same as old ones. They did seem pretty tight going in, but having never done this I figured that wasn't a problem. As I mentioned, it took some force to turn it when I adjusted the valves, but it didn't feel like it was binding, it just seemed tight. If I decide to take it apart, are there any gaskets that aren't reusable?

[raydhd]

If they were that tight going in it is hard to imagine not cracking a ring during installation. That could explain your engine lock up.

[sluggo99]

One of 'em took a couple good wacks with a rubber mallet to get it started then went in ok. The second one was not as bad. Sounds like I probably need to disassemble and take a look. Thanks to all for the help.

[sccowboy]

Locate your old pistons. They will have on the top either 25, 50, or nothing if stock. As soon as you pull the head you will see what I mean on the new ones. Also some suppliers have been known to mix up the ring packs. I probably would not reuse the head gasket.