Hello everyone
I am sorry for the late update but I wanted to post a comprehensive report and thats why it took time.
After the engine overhauling was done, the gypsy was test driven for about 200 kms where the hesitation problem was again found. But the problem was lesser than before and the character was different. Earlier it was the engine sputtering and dying off and restarting after standing for sometime. This time around the character was something like the engine sputtering sporadically like it was not getting fuel supply or electricity supply intermittently and then again picking up when whatever was not reaching reached the engine.
On discussing the above with the mechanic, he initially identified either the distributor (delco in his words)
or the ignition coil assembly
to be the source of the problem and probably the ignition coil getting heated up and not supplying electricity properly. He initially tied a rag around the ignition coil and asked me to wet it with water (aka radiator for the coil) and see what happens when the problem recurred the next time.
I drove another 100kms and had to stop the gypsy a couple of times with the same problem. I did ike i was told... wet the rag over the coil and tried restarting. Sometimes the vehicle restarted with this maneoveur , sometimes it did not ----
conclusion : I was not sure if the problem was with the ignition coil .
My solution : change the ignition coil and repeat the test drive.
i did another 100kms with the new ignition coil in place. THe problem recurred.
Everything was again checked at the workshop and this time the problem identified as
"sticking needle valve" in the carburetor.
An equally ingenious sollution was also demonstrated by the mechanic. The solution was
to slowy tap over the housing which stored the needle valve and manually drop it and get the carburetor back on track.
I was skeptical about this but had to believe his words when on doing the above manoeveur, the vehicle started on one crank.
Before changing anything else I told him that I would like to take a test drive of another 200 kms and then decide.
Over the next 200 kms, the problem recurred and was solved by tapping on the housing of the needle valve. This convinced me to change the needle valve assembly. so it was changed. (I was very lucky to get the SGP part costing 800/- right here in Nagpur) .
The timing of the engine was reset and the mechanic said :
Your problems are over balak !!! Enjoy your ride in peace.
I drove another 100kms - the problem did not resurface. But a friend of mine who regualarly drives my gypsy from day 1 said that the vehicle still didn't feel as smooth as before although the problem of hesitation was definitely gone.
I attributed this non smooth ride thing to the front prop shaft.
In the next 200kms the problem recurred. Since everything else was now rued out, the problem had to be in the fuel lines.
so this time around I tinkered with the fuel lines and removed the fuel filter and directly attached the main fuel tube (red) to the fuel pump inlet. With this the vehicle started and ran flawlessly for another 150 kms.
And then one fine day in the midst of a marriage party, the gypsy failed to start. It was towed back to the garage where the diagnosis was :
the mechanical fuel pump was shot and had to be changed.
A new fuel pump was immediately not available in nagpur and was costing a bomb (Rs 2400 as compared to Rs500 for gypsy 1L) and as the vehicle had to be started and not let standing it was decided that an electronic fuel pump be installed post haste (costing Rs 700).
While fitting the electronic pump my mech told that even this was not a good solution as electronic fuel pumps are known to fail and that we would have to think of something to make the fuel delivery system more reliable and fail safe.
a few things that he suggested were:
[1] having both the mechanical and the electronic pump at the same time and switching on the electronic pump when needed
[2] having 2 electronic fuel pumps with independent switches.
As of now, the electronic pump is placed somewhere near the tank -it is pumping fuel into the main fuel line (the red tube) which is entering the inlet of the now defunct mechanical pump and then the petrol is exiting the mechanical pump and entering the carb.
The vehicle is running like dream now. Whenever I put on the ignition switch, the fuel pump makes a strange noise ike rut-tut-tut-tut --- the vehicle starts in 1 crank. Fuel efficiency has dropped after conversion of mechanical pump to electronic pump. Earlier I used to get an average of 15kmpl while I am getting 9-10kmpl now. There is a rich smell of petrol whenever I switch off the engine
My question to everyone is :
What is your impression after going thorough my experience ?
How can I increase the efficiency of the vehicle more ?
Is the installation of the electronic proper ?
Is it a good idea to have both the mechanical pump and the electronic pump or 2 electronic pumps ?
Why has my fuel efficiency dropped and how can I go back to my previous fuel efficiency levels ?
Why is my pump making the strange sound everytime I switch it on ?
Anything else anyone would like to add from their experience.
regards,
Dr. Abheek Ghosh