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Discussion Starter · #1 ·
just looking for a heads up on my dixie chopper generac mower, i blew a rod yesterday and took it to the shop and they saying 6 hour labor at the least, at 65 per. the mower has 79.4 hours on it, but is 4 years old,(out of warranty) i have searched forums and see very few rods broken, did i just get a lemon? also would it be worth putting a 27 horse kohler on it if parts and labor run close to a new motors cost? or kawasaki 27 horse motor? i'm definately not a mechanic so i need advice. thanx ......... this is in relation to a 2005 dixie chopper with 60" 27 hp generac. its the residential unit not commercial, and oil was just changed, changed 3 times since new,
 

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just looking for a heads up on my dixie chopper generac mower, i blew a rod yesterday and took it to the shop and they saying 6 hour labor at the least, at 65 per. the mower has 79.4 hours on it, but is 4 years old,(out of warranty) i have searched forums and see very few rods broken, did i just get a lemon? also would it be worth putting a 27 horse kohler on it if parts and labor run close to a new motors cost? or kawasaki 27 horse motor? i'm definately not a mechanic so i need advice. thanx ......... this is in relation to a 2005 dixie chopper with 60" 27 hp generac. its the residential unit not commercial, and oil was just changed, changed 3 times since new,
I'd check out the price of a complete new engine. Try the pricing, but if the rebuild comes to more then 60% of a new engine then I think you should definatley go for a replacement. Once you do a rebuild you then commit to possibly continued expense. The new power unit should have a full warranty with it.
Good luck Phil :)
 

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I agree with the above post, do NOT let them touch your engine! I learned that the hard way after having one rebuilt (23 kaw). When they finished I had as much in it as a new engine would have been and it only had a 60 day warranty on it. The bad thing about it the power did not seem like it was anywhere near what it was before and they had to go back into it again two days later for a bad oil leak. I will never again have an engine rebuilt, will get a brand new one. There are several sites I remember seeing on here but can't remember them all that sell engines. I think one was mowparts.com and the other was smallenginewarehouse.com. There were more but can't remember them all.
 

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Discussion Starter · #4 ·
thanx guys for the info, anymore will be helpfull also, if i buy a new motor, what should i go with, kohler, kawasaki, ect.? i am wanting 27 horses, not sure why but thats what the generac was that blew, so i definately don't want to downsize, i keep up about 5 acres with it,
 

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I know it's out of warranty, but have your dealer call Chopper. Generac had a problem with rods. It's Usually the #2 cylinder. The rod will be broken at the top towards the piston, about 3/4 of the way up. There were porous rods in their engines. We had at least 10 of these, all on choppers that were built in 04/05. They may be able to do a courtesy adjustment. Call chopper direct if you have to. If the rod is broken like I describe, I would bet the farm on it being a bad rod from the factory. All the engines I found broken rods in had a few more hours than yours. Was it full of oil when it happened?? Good luck, JOHN
 

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Discussion Starter · #6 ·
I know it's out of warranty, but have your dealer call Chopper. Generac had a problem with rods. It's Usually the #2 cylinder. The rod will be broken at the top towards the piston, about 3/4 of the way up. There were porous rods in their engines. We had at least 10 of these, all on choppers that were built in 04/05. They may be able to do a courtesy adjustment. Call chopper direct if you have to. If the rod is broken like I describe, I would bet the farm on it being a bad rod from the factory. All the engines I found broken rods in had a few more hours than yours. Was it full of oil when it happened?? Good luck, JOHN
thanx john i appreciate that, i will definately check that out, however i have also gotten a few prices on new moters, i have gotten a price of 2,000 for a 30 hp kohler shipped to my house with exaust and new wiring harness. basically everything i would need to be back in business. plus another 200 labor to install, about 2200 total, for everything, is this reasonable? or can this price be beat? thanx
 

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I don't mean to throw cold water on the idea of a new engine, but I think something like a 27HP Kawasaki would cost somewhere in the 1800-to-2000 dollar range plus the cost to have the old engine removed and the new one delivered and installed. If the rebuild is going to really cost only about $400, I'd be thinking seriously of that if I could get the mechanic to firm up his estimated price. I never liked a "well........it'll be somewhere around...." quotation. I'd rather get an "at most" quotation than an "at least" one, and I'd want a written guarantee before starting the rebuild. By the way, $65 an hour for labor seems low. Where I live, it's more like a hundred.
 

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Discussion Starter · #8 ·
yeah i am keeping in mind the rebuild cost, but i need to have my ducks in a row if the rebuild goes to high, the service manager says it is 65 per hour+ parts, but the mower has not been torn down yet so the damage has not yet been revealed. we have this hurricane coming here to baton rouge so our state is in shutdown mode, everything is closed except grocery stores and gas stations, i won't know anything till late next week, and grass needs to be cut, i hate the fact i can't mow. want to puke!!!
 

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Yeah, that is the same crap they told me also. It will be around 600 bucks and went twice that. They claimed they found more wrong when they got into it. But the deere dealer here has a bad reputation for that. I better have an exact price and not a penny over or no deal on any repairs!
 

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Don't assume that the mechanic rebuilding your engine is 1) fully competent and, 2) highly experienced at rebuilding engines. Finding top quality rebuild mechanics is iffy, at best. Ask questions before releasing your engine to the mercies of the shop.
 

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Discussion Starter · #13 ·
Ok, I Got The Mower Back And They Say That The Bolts Had Backed Off In The Motor, No Broken Rods And No Damage Was Done, Charge Was 200 To Tear Down Motor And Put It Back Together, However It Doesn't Seem To Have Top End Power Like Before, Like It Is Not Reving As High. Doesn't Take Much Grass To Bog Down The Motor, How Can I Give It More Throttle?
 

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The Bolts Had Backed Off In The Motor"
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HUH..where would these magical bolts be located?I would think they would be on the outside/top of the motor,no tear down required,just a simple turning of some wrenches/sockets.
 

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Discussion Starter · #15 ·
Well It Was In The Motor, It Was Making Awful Noise Down In The Housing. The Crankshaft Bolts I Think Is What They Told Me,or Somewhere Around The Crankshaft, Man I Got So Much Goin On, Gustav Just Hit Us Now Ike Is On Top Of Us, I'm Running Like A Chickin. I Can't Even Remember Exactly, But It Still Beat 3,000 For New Motor. Lol
 

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If you ever decide to replace the motor, make sure it is the same as the original. Belts, pulleys, wiring harness, etc. need to line up precisely and it's a much smoother job with the oem. (IMO, and I've done it both ways.)
 
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