Go Back   Team-BHP > Under the Hood > Modifications & Accessories


Reply
 
Thread Tools Search this Thread
Old 6th November 2008, 23:53   #1
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
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
Name:  1 resting for 3days.jpg
Views: 14715
Size:  102.0 KB

Battered Head
Name:  2a old head.jpg
Views: 14727
Size:  123.0 KB

Name:  2b old head.jpg
Views: 15057
Size:  121.5 KB

Name:  2c old head.jpg
Views: 13988
Size:  92.2 KB

Gasket
Name:  3 old gasket.jpg
Views: 14359
Size:  135.4 KB

Block
Name:  4 old block.jpg
Views: 15085
Size:  84.9 KB

Head Disassembling
Name:  5 head on vice.jpg
Views: 13870
Size:  78.5 KB

Name:  8 head disassembly.jpg
Views: 13679
Size:  78.2 KB

Name:  9 head disassembly1.jpg
Views: 13478
Size:  84.0 KB

Removing mounting bolts
Name:  6 removing rear mounting bolt.jpg
Views: 13500
Size:  90.4 KB

Name:  7 removing front  mounting bolt.jpg
Views: 13344
Size:  95.3 KB

Block Disassembling
Name:  10 block dissassembly.jpg
Views: 13324
Size:  81.9 KB

Name:  11 block dissassembly.jpg
Views: 13368
Size:  83.1 KB

Name:  12 block dissassembly.jpg
Views: 13063
Size:  80.3 KB

Removing Crank, Pistons and Connecting rods
Name:  13 crank remove.jpg
Views: 13225
Size:  71.1 KB

Name:  14 crank remove.jpg
Views: 12948
Size:  85.0 KB

Name:  15 crank removed.jpg
Views: 12874
Size:  81.5 KB

Hardest part for me is to secure the bolts that comes off.
Name:  16 bolts.jpg
Views: 12837
Size:  76.7 KB

Name:  17 bolts.jpg
Views: 12774
Size:  97.9 KB

Intake Manifold and Carb
Name:  18 intake and carb.jpg
Views: 12470
Size:  93.2 KB
SirAlec is offline   (1) Thanks Reply With Quote
Old 7th November 2008, 00:02   #2
BANNED
 
Join Date: Jan 2007
Location: NAMMA BENGALURU
Posts: 5,613
Thanked: 2,459 Times
Default

Wow.. Very well detailed post.

Polish and port the heads, it'll run like a dream.
PAVAN KADAM is offline   (1) Thanks Reply With Quote
Old 7th November 2008, 00:05   #3
Senior - BHPian
 
badboyscad's Avatar
 
Join Date: Feb 2007
Location: TN
Posts: 1,443
Thanked: 153 Times
Default

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
badboyscad is online now   Reply With Quote
Old 7th November 2008, 00:10   #4
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default Part Ii

Getting Hands in this state is a great joy.
Name:  19 Dirty hands.jpg
Views: 12677
Size:  95.7 KB

Flywheel, always change the small bearing along with the flywheel.
Name:  20 flywheel.jpg
Views: 13025
Size:  97.5 KB

Name:  20a flywheel.jpg
Views: 12584
Size:  91.7 KB

Redone Block
Name:  21 redone block.jpg
Views: 14249
Size:  82.2 KB

Pistons ready to be installed with connecting rod and pins already installed.
Name:  22 pistons.jpg
Views: 13269
Size:  94.9 KB

Pistons Installed
Name:  23 pston installed.jpg
Views: 12626
Size:  82.9 KB

Redone Crank
Name:  23 redone crank.jpg
Views: 12461
Size:  81.6 KB

Redone Head, same 6 valver. Sigh!!
Name:  24 redone head.jpg
Views: 12422
Size:  97.9 KB

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).
Name:  25 oil pump and coolant pump installed.jpg
Views: 13009
Size:  91.9 KB

Timming Belt install, Well setting this need lot of practice, i mean the tensioner.
Name:  25a timming belt installed.jpg
Views: 12328
Size:  61.3 KB
SirAlec is offline   (1) Thanks Reply With Quote
Old 7th November 2008, 00:25   #5
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default Part Iii

Timming Cover Pad kit
Name:  25c timming pad kit.jpg
Views: 12288
Size:  66.6 KB

Flywheel base and oil seal installed. You can never go wrong while installing flywheel. Check the small guide between two upper sockets.
Name:  26 Flywheel base and oil seal installed.jpg
Views: 12814
Size:  83.2 KB

This what a oil seal looks like, As i said before never use any old ones even if it looks good to naked eye.
Name:  26a oil seal.jpg
Views: 12322
Size:  82.5 KB

Gasket, Again, it cannot go other way round, check the small copper washer thingy.
Name:  27 gasket.jpg
Views: 11759
Size:  76.5 KB

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.
Name:  28 Valeo clutch.jpg
Views: 12781
Size:  103.9 KB

Yeah! the plane jane Micos. MGA supplies champion, avoid those at any cost.
Name:  29 mico plugs.jpg
Views: 11759
Size:  65.4 KB

Cleaned Gearbox, not purely clean, but what could you expect in 4 days project.
Name:  30 Gb clean.jpg
Views: 12053
Size:  86.2 KB

Clutch bearings, Change these also while changing Clutch+Pressure plate.
Name:  31 clutch bearing.jpg
Views: 12957
Size:  70.1 KB

The Comparo between the old and new
Name:  32 clutch bearing new and old.jpg
Views: 12011
Size:  60.3 KB

Assembled carb intake manifold and Head
Name:  33 head plus intake plus carb.jpg
Views: 12234
Size:  88.3 KB
SirAlec is offline   (2) Thanks Reply With Quote
Old 7th November 2008, 00:37   #6
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default Part Iv

This is the mod that I had done long ago, added that extra piece and removed the thermostat valve completely.
Name:  34a mod for heater.jpg
Views: 13573
Size:  75.2 KB

Name:  34b mod for heater.jpg
Views: 12478
Size:  83.0 KB

That heater assembly is donated from an old zen. Look! though I have new pipes now. Lolz!
Name:  34c mod for heater.jpg
Views: 12923
Size:  79.2 KB

Battered steering Rake
Name:  35 ol steering.jpg
Views: 12055
Size:  87.8 KB

Name:  35a ol steering.jpg
Views: 11635
Size:  107.4 KB

New Sona rake
Name:  36 new steering.jpg
Views: 12027
Size:  90.0 KB

Tools of the trade, very handy eastman small and mid.
Name:  37 tool of the trade.jpg
Views: 11764
Size:  86.2 KB

Loctite 596, gasket maker
Name:  37a loctite gasket maker.jpg
Views: 11925
Size:  68.5 KB

Mr. Mannaram, a great helper
Name:  38 Mannaram the helper.jpg
Views: 11585
Size:  48.5 KB

Very old, but very useful for a DIY guy like me.
Name:  39 serv man.jpg
Views: 11645
Size:  101.6 KB

The Kharcha List, add to that head & block job and labour, thats me and mannaram.
Name:  40 bill.jpg
Views: 12357
Size:  120.0 KB

Name:  40a bill.jpg
Views: 11929
Size:  98.7 KB
SirAlec is offline   (2) Thanks Reply With Quote
Old 7th November 2008, 01:24   #7
BHPian
 
nishant_kingpin's Avatar
 
Join Date: Apr 2005
Location: New Delhi
Posts: 334
Thanked: 2 Times
Default

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!!
nishant_kingpin is offline   Reply With Quote
Old 7th November 2008, 03:57   #8
Senior - BHPian
 
deepclutch's Avatar
 
Join Date: Oct 2008
Location: Muvattupuzha
Posts: 1,120
Thanked: 109 Times
Default

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
deepclutch is offline   Reply With Quote
Old 7th November 2008, 13:03   #9
Senior - BHPian
 
sumeethaldankar's Avatar
 
Join Date: May 2007
Location: Mumbai
Posts: 2,671
Thanked: 1,019 Times
Default

hey good "Infomages" you have here.BTW why you say champion spark plugs are to be avioded are they no good.
sumeethaldankar is offline   Reply With Quote
Old 7th November 2008, 13:12   #10
Senior - BHPian
 
vikram_d's Avatar
 
Join Date: Jul 2006
Location: Bangalore
Posts: 2,380
Thanked: 936 Times
Default

Looks like it is now ready for another 2L+ kms. Good job.
vikram_d is offline   Reply With Quote
Old 7th November 2008, 13:19   #11
Newbie
 
Join Date: Oct 2008
Location: Mumbai
Posts: 13
Thanked: 0 Times
Default

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
jayraj is offline   Reply With Quote
Old 7th November 2008, 13:28   #12
Senior - BHPian
 
kb100's Avatar
 
Join Date: Feb 2006
Location: Bangy Boy!
Posts: 1,554
Thanked: 14 Times
Default

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?
kb100 is offline   Reply With Quote
Old 7th November 2008, 15:31   #13
Senior - BHPian
 
Join Date: Dec 2007
Location: Dubai
Posts: 3,860
Thanked: 128 Times
Default

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?
HappyWheels is offline   Reply With Quote
Old 7th November 2008, 15:47   #14
Senior - BHPian
 
deepclutch's Avatar
 
Join Date: Oct 2008
Location: Muvattupuzha
Posts: 1,120
Thanked: 109 Times
Smile

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.
deepclutch is offline   Reply With Quote
Old 7th November 2008, 15:48   #15
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

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.
SirAlec is offline   Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search


Similar Threads
Thread Thread Starter Forum Replies Last Post
My Gypsy Rebuild Project krishnathanthri 4x4 Vehicles 326 26th June 2014 23:59
Project M800 with F10A swap noidaboy Modifications & Accessories 115 11th March 2013 12:25
Creaking noise in Cedia : 15K kilometers on the odo ranjithc Long-Term Ownership Reviews 1 25th November 2008 10:21
1000 kilometers, 781cc, 12 hours, 1 rider. The beginning of something special. Rtech Travelogues 124 30th October 2008 18:42
m800 vs ikon (what comp can a M800 be?) manaa45 Street Experiences 13 31st March 2005 12:06


All times are GMT +5.5. The time now is 11:37.

Copyright ©2000 - 2017, Team-BHP.com
Proudly powered by E2E Networks