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Old 6th November 2008, 23:53   #1
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Default 2lac+ kilometers m800 engine rebuild project.

This Diwali the good ol Green baby crossed 10 years of use and abuse and clocked 2lac+ on the oddo. Initial plan, was to install an alto motor, but couldnt find a suitable doner in time. Many crashed alto that came through had people killed in it. Am not paranoid but frens and family and especially wife insisted not to go for them types otherwise.
Hence thought of selling it but was not fetching more than 50k. Goosh! that alloy and tubless alone had set me back by 21k. Add another 4.5k for those big spot light. 25 k for the body and engine.LOLZ!
I thought, what the hell, why not a rebiuld project, luckily I had a spare four days after diwali.
Also Ahm Kabadi friends found two doner, a battered '04 Zen and '02 esteem heart. but lot of work on frame for four days, Had to scrap the idea. Maybe later sometime next year.

As time had come and magic two rotation of oddo took place, had to open her up. Still amazed with what Papa Suzuki's boys had done back in Japan. It easily reached three figure speeds without a hitch in such conditions of head.

enjoy the images.
Thanks

Resting for three more Days
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Battered Head
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Gasket
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Block
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Head Disassembling
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Removing mounting bolts
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Block Disassembling
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Removing Crank, Pistons and Connecting rods
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Hardest part for me is to secure the bolts that comes off.
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Intake Manifold and Carb
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Old 7th November 2008, 00:02   #2
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Wow.. Very well detailed post.

Polish and port the heads, it'll run like a dream.
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Old 7th November 2008, 00:05   #3
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phew!! At first sight of the title, i thought it was a 2lac+ rupees engine re-build process( which gave me the thoughts of turbo et all)...hehehe
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Old 7th November 2008, 00:10   #4
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Default Part Ii

Getting Hands in this state is a great joy.
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Flywheel, always change the small bearing along with the flywheel.
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Redone Block
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Pistons ready to be installed with connecting rod and pins already installed.
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Pistons Installed
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Redone Crank
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Redone Head, same 6 valver. Sigh!!
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New Oil and Coolant pump, check the loctite 596 used neatly along with new Oil seal. Always change all the Oil seals and O rings (Oil strainer etc).
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Timming Belt install, Well setting this need lot of practice, i mean the tensioner.
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Old 7th November 2008, 00:25   #5
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Default Part Iii

Timming Cover Pad kit
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Flywheel base and oil seal installed. You can never go wrong while installing flywheel. Check the small guide between two upper sockets.
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This what a oil seal looks like, As i said before never use any old ones even if it looks good to naked eye.
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Gasket, Again, it cannot go other way round, check the small copper washer thingy.
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Unlike much of member here I am swear by Valeo. I hate Ceekay.
Valeo has lesser springs, but the springs are much thicker and sturdier. If ever there is an insanely tuned 800 which goes past 160 mark, I bet it will never fail.
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Yeah! the plane jane Micos. MGA supplies champion, avoid those at any cost.
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Cleaned Gearbox, not purely clean, but what could you expect in 4 days project.
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Clutch bearings, Change these also while changing Clutch+Pressure plate.
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The Comparo between the old and new
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Assembled carb intake manifold and Head
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Old 7th November 2008, 00:37   #6
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Default Part Iv

This is the mod that I had done long ago, added that extra piece and removed the thermostat valve completely.
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That heater assembly is donated from an old zen. Look! though I have new pipes now. Lolz!
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Battered steering Rake
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New Sona rake
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Tools of the trade, very handy eastman small and mid.
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Loctite 596, gasket maker
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Mr. Mannaram, a great helper
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Very old, but very useful for a DIY guy like me.
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The Kharcha List, add to that head & block job and labour, thats me and mannaram.
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Old 7th November 2008, 01:24   #7
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Wow!! Thanks for sharing SirAlec. Am sure the entire project was a success and hope you enjoyed it thoroughly. Let us into the drive experience post facto!!
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Old 7th November 2008, 03:57   #8
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thanks for the info.
and Siralex ,I have my M800 engine at 90000 kms done.during 85K ,the thermostat failed and hence radiator fan hadnt worked for a long time.when I took a hill route during that time ,engine seized as in pakka knocking sound etc.still after cooling ,car went on.later ,changed the gasket and currently going on.but lacks power.I am in for repairs in a selling point of view
I have few questions :
1) Is it enough to change piston rings ?
2) Is it possible to rebore the cylinders in this car?

Please advice me
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Old 7th November 2008, 13:03   #9
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hey good "Infomages" you have here.BTW why you say champion spark plugs are to be avioded are they no good.
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Old 7th November 2008, 13:12   #10
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Looks like it is now ready for another 2L+ kms. Good job.
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Old 7th November 2008, 13:19   #11
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Quote:
Originally Posted by deepclutch View Post
thanks for the info.
and Siralex ,I have my M800 engine at 90000 kms done.during 85K ,the thermostat failed and hence radiator fan hadnt worked for a long time.when I took a hill route during that time ,engine seized as in pakka knocking sound etc.still after cooling ,car went on.later ,changed the gasket and currently going on.but lacks power.I am in for repairs in a selling point of view
I have few questions :
1) Is it enough to change piston rings ?
2) Is it possible to rebore the cylinders in this car?

Please advice me
Changing piston rings will be a good option as it will be an engine overhaul,
rebore of the cylinders are also possible which will be grime free for the pistons to move make sure you use the exact piston rings as if the work is not carried out well oil will be burned out having a white smoke
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Old 7th November 2008, 13:28   #12
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DIY ??

WOW !!

Amazing job! What kind of preparation did you have to do - as in did you know what and how to do this beforehand?
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Old 7th November 2008, 15:31   #13
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SirAlec,

What a way to get one's hand dirty! Great job!

This needs to get into the 'What can one do over a extended weekend' list.

And thanks and ton for the snap filled narration.

So, how do you find the ride now?
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Old 7th November 2008, 15:47   #14
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Quote:
Originally Posted by jayraj View Post
Changing piston rings will be a good option as it will be an engine overhaul,
rebore of the cylinders are also possible which will be grime free for the pistons to move make sure you use the exact piston rings as if the work is not carried out well oil will be burned out having a white smoke
I am thinking of the same.also ,some suspension works in pending.
I hope total bill will come under 5K.
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Old 7th November 2008, 15:48   #15
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Guys! thanks for showing so much interests. First I was shy on posting, I thought nobody will be interested in plain jane overhaul.

Quote:
Originally Posted by nishant_kingpin View Post
Let us into the drive experience post facto!!
As i said before, its a plain jane overhaul. The performance is as usual, 800ish, I get better mileage now though. This partcular example is bit better than usual 99' 800, i had a great ol' man in ahm who reworked the venturi etc on this mikuni.

Quote:
Originally Posted by deepclutch View Post
thanks for the info.
1) Is it enough to change piston rings ?
2) Is it possible to rebore the cylinders in this car?

Please advice me
When you open up the engine. Its always a good idea to check all the things. I have all the data of this particular engine. And 2 lac kms is lot of kms. So I did the block too. Its better to do at once than to open it again. Hence I change almost all the parts, even oil and coolant pump, which were still in good shape.


Quote:
Originally Posted by sumeethaldankar View Post
hey good "Infomages" you have here.BTW why you say champion spark plugs are to be avioded are they no good.
I had bad experience before. I found many short ones in new package. As i have a friend who owns the M.A.S.S. i fiddle quite with his inventory.

Quote:
Originally Posted by vikram_d View Post
Looks like it is now ready for another 2L+ kms. Good job.
Sure it is

Quote:
Originally Posted by kb100 View Post
DIY ??

WOW !!

Amazing job! What kind of preparation did you have to do - as in did you know what and how to do this beforehand?
Preparation is that you have to have lot of time atleast three days. I created the list and ordered the parts long before opening it up. Get different card board boxes for bolts, parts etc, I used the computer parts boxes, one which were lying a plenty in office.
I borrowed special tools and a helper from a M.A.S.S. owner friend, Unique Motors, Abu.
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