[Trust_In_Thrust]

I had the red light coming and going in the speedometer panel while driving today(the light which is indicator for hand brake , oil level , brake oil).Went to my trusted mechanic and we decided to fist check disc pads.(the brake oil level was near low level).The pads were finished so got Bosch pads (KBX taken over by Bosch now) for 220INR. Labour was 200INR .Total cost pads plus labour 400INR. No blinking light now in speedometer console.

[Trust_In_Thrust]

The Zen odo stands at 89000Kms. Due to heavy rains in Delhi over last couple of weeks there were numerous floating sessions ( car waded through water which entered clutch housing ). Due to this the idle tensioner bearing got bad . So this loud whooo sound accompanied by metal grinding noise was coming .I replaced that today at MASS .Mine is Delphi Ac for that it is 590Inr and 1900Inr labour was what i was charged plus taxes. Now there is no irritating noise .I still do not understand why labour is so high as all they had to do was raise car on lift and open two bolts to replace this part .I also got the car washed .

[saket77]

Originally Posted by Trust_In_Thrust

I had the red light coming and going in the speedometer panel while driving today(the light which is indicator for hand brake , oil level , brake oil).Went to my trusted mechanic and we decided to fist check disc pads.(the brake oil level was near low level).The pads were finished so got Bosch pads (KBX taken over by Bosch now) for 220INR. Labour was 200INR .Total cost pads plus labour 400INR. No blinking light now in speedometer console.

I think the light must be due to low brake oil. I don' think that the Zen has a feature which will warn for worn out pads. Am I right?

[Trust_In_Thrust]

Originally Posted by saket77

I think the light must be due to low brake oil. I don' think that the Zen has a feature which will warn for worn out pads. Am I right?

Hi, You see if you fill the brake fluid properly when you install brake pads then the brake fluid will go down low only when the brake pads near there lower limit .So the red light will still glow . Often people fill up the brake fluid even when brake pads are not changed or higher than maximum level .This is a mistake .

Getting the car washed earlier in the day.

[Jetta_Volkmann]

Hi Trust in Thrust, Wow that is some serious care and maintenance. Congrats. Spotless. Zen is a complete reliable car.

My Brother in law owns a 2001 Zen Lxi. Completed 160K Kms till date and in immaculate condition so far. It still runs in petrol. Though some problem will creep up occasionally, he still loves and maintaining well. I have driven it extensively. One sour point is if we switch on the air conditioner there is some loss of power.

Drive Safe.

[ByDesign]

Nice piece of work! I love old 800's and zen's. Easily one of the most charismatic hatches still on the road. It's on my to-do list to buy an old suzuki 800 and a zen like you have purchased.

The manner in which you stumbled upon this car is very similar to my Palio as well. Always went to see something newer, stumbled upon the car, and fell in love. We're a rare breed where we buy a car based on that kind of love. Safe driving!

[Trust_In_Thrust]

I faced a issue . The wire which comes from alternator to battery via a fuse link got burned at connector point. MASS said it is because over time connector got loose . Now issue is connector is i think 12 pin and lot of signal wires also use the same common shared connector. MASS says new connector is not there and you will have to buy complete wiring . For now i have used a 4 gauge wire to connect (burned down section) instead of connector and taped it all up and covered with a sleeve. However local electrican was saying over time this joint will become loose and it will heat due to which insulation will break down and you best bet is to open all wiring and replace the alternator wire in the OEM loom. Any suggestion on a solution to connect power wires using some tools , material .

[sushrutha]

Excellent review and very nicely maintained Zen.

Originally Posted by Trust_In_Thrust

6.) Font Left Headlight Changed at 50000kms for Inr 15000/- from MASS. .

I'm sure this should be read of 1500 INR

[Trust_In_Thrust]

I did google and found out that soldering a joint entirely will avoid heating of wire at point of joints . So got it done and hoping the solution is permanent.The yellow wire is the additional section i had to put in after the joint at coupler got burned . The hole in coupler is where the earlier wire used to rest .My electrician had to use a large soldering iron and we finished nearly a roll of solder wire trying to make sure we completely cover the joints . The joints i made was of handshake type and used three thin copper wires to tighten the joint before soldering .

[Trust_In_Thrust]

1.) I had got the timing belt , timing bearing changed at 80000kms as preventive maintenance. However after every few weeks the belt either became too loose or too tight thus giving me weird noises at idling , very low rpms. MASS had adjusted it twice in last 10K kms . It started again and this time they took a whole day ( and yes they opened the timing cover , refitted it again ,checked i think 5 times ) . I believe i will not face the issue any more .

2.) The gearbox mounting which sits under front co passenger floor was also readjusted as it was making some weird noise when car the clutch/gear used to engage at low rpms.

Total Charges at MASS Inr 393/-.

And getting the monthly car wash .

Also i asked MASS about the burned Alternator wire at coupler point as in previous post and they said it is known issue in Zens and 800MPFI . They all get the coupler at same spot burned up as i got mine.

[saket77]

Hello Zen Fans!

In the quest of preparing my Zen (MPFI-Jelly Bean) for about a 1600 Km long run expected next month, I am getting the following job done tomorrow:

1. Timing belt change: Car has not run much, but the age is about 11 Years now, hence it was due.

2. Spark Plug Change: Done about 11K kms on the current 'Champion' set. Contemplating which brand to replace with.

3. Coolant Change: 3 Years since coolant was flushed.

4. Brake Overhaul: Though they appear fine, just want to make sure that the brake pads have good life left on it, else change them. Brake fluid replacement will also be done.

5. Air filter change: Nothing flashy; just with the OEM brand & design.

6. Steering rack & tie rod greasing: Zens have a tendency to have a hard steering when parked in the sun for long, hence the SA advised for it.

7. Transmission oil check/ replace: will be decided as per its condition.

I have planned for these jobs but please advice if I have missed something important.

Regards,
Saket

[Trust_In_Thrust]

Originally Posted by saket77

Hello Zen Fans!

In the quest of preparing my Zen (MPFI-Jelly Bean) for about a 1600 Km long run expected next month, I am getting the following job done tomorrow:

1. Timing belt change: Car has not run much, but the age is about 11 Years now, hence it was due.As per MASS upto 1lacs timing belt does not need change.Our Zen is 2003 and i got it changed at 80K kms in 2013.

2. Spark Plug Change: Done about 11K kms on the current 'Champion' set. Contemplating which brand to replace with.I only check the plugs and if too much wear only then change it.I found NGK better.

3. Coolant Change: 3 Years since coolant was flushed.

4. Brake Overhaul: Though they appear fine, just want to make sure that the brake pads have good life left on it, else change them. Brake fluid replacement will also be done.If you top up brake oil to level when putting in new pads then you can look at the oil level to know life of pads left . You really dont need to open the calliper to know the life in pads.

5. Air filter change: Nothing flashy; just with the OEM brand & design.

6. Steering rack & tie rod greasing: Zens have a tendency to have a hard steering when parked in the sun for long, hence the SA advised for it. If non Power Steering the steering only tightens if the alignment is wrong ( it will begin to tighten towards the left or right extreme) .I have never faced tight steering issue .

7. Transmission oil check/ replace: will be decided as per its condition.

I have planned for these jobs but please advice if I have missed something important.

Regards,
Saket

All the best for your trip.

[saket77]

Got the job done. Details as following:

1. First, the timing belt: The cost of the timing belt is Rs. 775/- & the tensioner pulley assembly which is replaced along with it costs Rs. 616/- for the Zen. The timing chain cover & water pump pulleys were opened to expose the timing chain. When we saw the belt, it was in pristine condition! There was literally no difference between the new chain & the one on my car and I am not exaggerating even a bit. I think that probably Dad might have got it changed when I was away. So, after all this, the chain was not replaced and left as it was. But labour charges were incurred obviously - Rs. 650/-

2. Spark Plugs: I was looking for NGK plugs but for the thread size & rating, only Champion plugs were available. Changed with those only. Rs. 60/- per piece.

3. Coolant Change: The coolant was changed completely. IIRC, the cost of coolant was about Rs. 250/- with two bottles of De-mineral water used.

4. Complete Brake Overhaul: A complete overhaul was done. The brake pads have good life left, hence, the callipers were greased. The real shock came with the rear wheels. The RR wheel drum brake was not engaging at all!
The brake cylinder had seized. The LR brake was engaging but later the cylinder was found to have a leak. Both cylinders were replaced. Old brake fluid was flushed away & new fluid filled in the system. Cost of cylinders - Rs. 289/- per piece. Labour- Rs. 400/-

5. Air filter element replaced. Cost Rs. 265/-

6. Steering was checked thoroughly, and was found to be quite okay. Hence, no steering job.

7. Transmission oil was good hence, nothing done here too.

8. The Water pump belt & Alternator & AC drive belts were completely worn. Both were replaced. Cost Rs. 160/- & Rs. 140/-. Labour charges - Rs. 150/-

9. Paid Service: Rs. 960/-

Total expenses Rs. 4500/-. The car is now fit. Just noticed a slight humm while travelling over 50 KMPH on a silent road with windows up. Have a feeling that its a wheel bearing. Will get it checked before the journey. Rest the car is driving great.

Regards,
Saket

[saket77]

A problem had cropped up. There was a sound whenever the car crossed speeds of 40-50 KMPH, which was more prominent with windows rolled up, good road & the car in 5th gear. I had my doubt on the rear wheel bearings which was proved to be correct when the bearings were removed from the drum. One bearing's inner ring had developed a crack. However, replaced all the 4 bearings of the rear wheels.

Now the car is vibration & noise free. Total cost involved: Rs. 1200/-
(About Rs. 600/- for bearings, Rs. 450/- labour and balance paid to the Govt.)

[saket77]

The car is finally back from a 1000 Km marathon run over 3 days with zero issues. Returned about 20-21 KMPL as it consumed about 50 litres of fuel in the process. The ride behaved fantastic throughout.

The car will be up again for a 700 Kms drive very soon.