It’s been a while since I’ve updated this thread and since today is a rare sunny day here in Patnitop, I don’t have much of an excuse. 4865 hasn’t got much TLC for most of 2020 and no long trips because of the corona lockdowns and restrictions. Yet, with the snowfall predicted on the 12th of December it seemed only practical to visit Lalaji (our Gypsy mechanic/overlord) & Sambi (our electrician) and give it a once over. Thankfully G decided to join me on his motorcycle because a visit to Lalaji needs 2 people. One to learn from him another to fetch the spares that he needs to his exacting specifications. No non-genuine parts allowed and even genuine are inspected and often rejected for another piece.
Conversation at shop
Dealer - “Sir, you’re buying a lot. Who is the mechanic”
Me - “Lalaji”
Dealer - “taking back non genuine parts, yeh to nahi lagayenge…plus the ones you’re taking will need a month to install”
What followed was a
3 day (and nights) learning workshop in the workshop.
The front ball and rocket joints were pronounced ok which was a relief because that is a 2 day job. “But there’s something wrong with the rear brakes” - Lalaji remarks. One whole day to service the rear brakes and bearings. The driver rear brake pistons is shot, it is rebuilt with original TVS-Girling parts. The passenger rear bearings need preventive replacing and original SGP can not be found. Takes a few hours to get the MGP parts and to convince Lalaji to put them on. Back home at 2100 hours. My friend’s G’s parents worried and intrigued.
Day 2 is a full carb rebuild. One of the few jobs that no mechanic will do…willingly. Even Lalaji ha stopped doing it owning to petrol and throttle body cleaner inhalation. Don’t take my word for it - check its your mechanic. But G insisted and they go a long long way back. Lalaji’s father was his father’s Indian Chief motorcycle mechanic. I am on managing Lalaji’s phone as a personal Do Not Disturb assistant.
So the carb was taken apart, cleaned multiple times. The last of the SGP repair kits that we have been hoarding for over 10 years now is put in. The slow jet is not exact so its filed with the thinnest diamond file and replaced. To cut a long story short we came back home from the workshop at 0100 hours. Much to the chagrin of the family!
Day 3 is a general checkup, distributer timing, tappets and all fluids change & engine tuneup. G’s family decide to visit, they were probably thinking we had the gypsy as an excuse while off gallivanting to the nearest bar or something. So a nice picnic lunch on one of the shells of old M800. Back home at 12 PM - dead tired but the gypsy purrs like a fluffy kitten. I reckon a couple of horses have been re-put back in the engine. The current state of tune is power over economy owning to the fact that winters mean pushing through fresh snow in 4L.
Finally here's a list of what we achieved in 3 full days -
1. fresh oil
2. fresh coolant
3. fresh transmission fluid
4. all 4 brakes inspected & bled. Rear brake piston replaced, new pads in the rear
5. Full carb service and rebuild using SGP spares
6. Gear lever bushes replaced
7. General tuneup, tappet adjustment, new distributer point & timing adjustment
8. New spark plugs and HT leads
9. New coil lead
10. Windshield wipers replaced
11. Wiper water throw motor rebuilt
13. Starter "ghuggi" replaced with original TVS LUCAS part and all non functioning bulbs, lights etc replaced.
The drive back to Patnitop is sublime, the engine purrs along and I sit back and let G enjoy the drive back. He’s earned as much for running around sourcing the parts. Back home, I decide to take off the aftermarket LPG and Air Conditioner setup off because a) I never intend to run it on LPG b) AC is no use in the hills and c) the amount of piping confuses me when I’m working on the engine. So I dig out my spanners and get to work. Thankfully I’d applied WD40 to all bolts the previous day and they came off without much chagrin. Once all the extra piping and wiring are off, I take a roll of electric tape and seal off the loose wires.
Finally follow with a Diesel cleanup and a car wash the next day. This diesel drenching has given me a good idea about the rust spots. There are a few on the body but for a 25 year old girl its fairly spiffy thanks to regular washing. I reckon this bosyshell will outlast the engine. Finally the 4865 is in a state of mechanical tune that is in harmony with my state of mind.
And while we were working on this we get this bit of good news. SO that means I can run the 4865 for another 10 years!
This calls for a long trip planning so crank up favourite driving song playlist and chalk out a Google Maps line through Nepal and on to Darjeeling and Arunachal and Meghalaya. That’s where the old girl is headed in 2021.
“East bound and down, loaded up and truckin'
A-we gonna do what they say can't be done
We've got a long way to go, and a short time to get there
I'm east bound, just watch ol' "Bandit" run
Keep your foot hard on the pedal
Son, never mind them brakes
Let it all hang out 'cause we got a run to make
The boys are thirsty in Atlanta
And there's beer in Texarkana
And we'll bring it back no matter what it takes”
I had put off the interiors and the paintwork because this news was a rumour till last year. It is now official. So now I’m going to start with the interiors and the paintwork for the 4865. I was contemplating powder blue (my favourite shade on the old Japanese M800) but that is shot down by my girlfriend who has no sense of nostalgia
) so Olive Green or Pure White it is. The idea is not to bling up the old girl but to source whatever OEM is available and keep it completely and immaculately stock (and hence reliable).
Plan to start with securing a pair of used rear jump seats and replacing the door trim (which has seen better days) then off to other bits and bobs like the rear door lock cover and more… But most of that will be achieved after the winter snow melts. For now I plan to live and love the mechanical purity of the 4865 over the next 3 months.