2lac+ kilometers m800 engine rebuild project.

SirAlec · 16th October 2009, 20:56

There is no size difference in fenders. its the mounting points. even the light mount can be fitted on old one but it needs little cutting and adding extra bits of metal sheet.

left side has the old mount points and right side has new mount points. as it was completely destroyed beyond repair.

IndrojitSircar · 16th October 2009, 22:58

Quote:

Originally Posted by SirAlec

There is no size difference in fenders. its the mounting points. even the light mount can be fitted on old one but it needs little cutting and adding extra bits of metal sheet.
left side has the old mount points and right side has new mount points. as it was completely destroyed beyond repair.

I ment the difference in mounting point.It's my fault i was not clear.I'm sorry.
Tell me something do you have any pictures of the modification done on the fenders?

SirAlec · 17th October 2009, 01:07

Sorry! i don't! As i was very busy with work. even the car was towed by my driver and one of my friends mechanic at M.A.S.S. I couldn't even take pictures of the damages.

As far as i know base (apron) needs to be drilled at places for screw to fit.

anujmishra · 17th October 2009, 09:12

Hi SirAlec, Excelling looking 800. Need one suggestions. I have 2003 800 AC with mint condition.

I want to change headlights and tail lights to new design. Would you suggest to buy from MASS or outside I can get cheaper? MASS was quoting something 1400 Rs. per pair of rear light set. Is the original company product available outside?

SirAlec · 17th October 2009, 14:44

headlights from maruti are very expensive. It comes along with motors etc. And is about Rs.2700 a piece. I bought DKMAX, a lumax brand lights at 2200 a pair. It maybe cheaper in delhi and other bigger cities.. This was ordered unofficially by my M.A.S.S. friend as he cannot buy products from outside. As i don't take bill from him so its no complications. I don't like the new rear lights. Hope this answers your queries.

PatienceWins · 18th October 2009, 08:12

Excellent thread. Rated 5 star!!

Very informative. Thanks for the pictures.

anujmishra · 18th October 2009, 08:35

Quote:

Originally Posted by SirAlec

headlights from maruti are very expensive. It comes along with motors etc. And is about Rs.2700 a piece. I bought DKMAX, a lumax brand lights at 2200 a pair. It maybe cheaper in delhi and other bigger cities.. This was ordered unofficially by my M.A.S.S. friend as he cannot buy products from outside. As i don't take bill from him so its no complications. I don't like the new rear lights. Hope this answers your queries.

So much of price difference of Headlights

. 2700 a piece to 2200 a pair. I have also one query. New headlights comes with levelling motor. Do this will work in older cars which does not have headlights levelling.

SirAlec · 18th October 2009, 15:08

I didn't find any use of the motor, i use the old style patch on it. The price difference is due to the motor i guess.

mycarhasablower · 24th January 2010, 18:37

Quote:

Originally Posted by SirAlec

already done that Covered 280kms. will change oil and coolant at 1000.
thanks for the tip.

1. I guess so. following is the original suzuki data for F8B. I guess it matches that of zen. But i would rather not change the stroke ratio. That will lead to more extra work on tuning. I am very bad with numbers.

2. Yep it was reworked. But if the condition of block is too bad to be rebored, get a half assemlly. its just 9.5k. with crank, connecting rod, pistons, pins. Only head job is left then. Block will last way beyond 2.4lac kms if treated well.

Data Sheet
Attachment 67754

you mentioned that a half assembly includes crank as well, but here in delhi i just inquired , its for 11.5k and doesnt include crank....can you reconfirm plz?? or is it that the spare parts guy is trying to rip me off??

SirAlec · 29th January 2010, 15:23

it includes everything (lowerpart) except head. I am dead sure about this.

S.I.N.G.H · 29th January 2010, 20:19

congrats sir, the ride looks great. i must say- old is gold. very well elaborated and explained thread i must say.

SirAlec · 29th January 2010, 23:29

thank you very much!

Its a very capable car and chasis. There so much potential in this package, but very few are interested in this car or tunning it.

SirAlec · 14th November 2010, 21:24

After about 8 months Mallu painter friend from Allepy, Raju returned after his exams.

He wished to polish the old car which is very dear to him as much as it is to me. So he summoned it to his garage. We did lot of work on steering as after this year's rain, the roads is full of pot holes. Wife's driving added to its toll.

Since he had lot of time which is rare. We decided to cut the hood. He asked me for a designed that i wanted. Was not interested at first but anyway decided to go for it anyway. Goggled it and found couple of them, made a printout and gave him.

Here are the results. Guys what do you think.

This is what i liked.

2lac+ kilometers m800 engine rebuild project.-test-large.png

This is what he made.

2lac+ kilometers m800 engine rebuild project.-result-kenden.jpg

The steering, balance rod, suspension etc. overhaul.

2lac+ kilometers m800 engine rebuild project.-steering-overhaul.jpg

2lac+ kilometers m800 engine rebuild project.-steering-overhaul1.jpg

SirAlec · 14th November 2010, 21:41

Some closeup images. Its a phone cam. It looks much better than in images.

2lac+ kilometers m800 engine rebuild project.-maruti-800-hood-scoop-closeup-1-.jpg

2lac+ kilometers m800 engine rebuild project.-maruti-800-hood-scoop-closeup-2-.jpg

2lac+ kilometers m800 engine rebuild project.-maruti-800-hood-scoop-closeup-3-.jpg

techkarl · 21st May 2012, 11:47

Quote:

Originally Posted by SirAlec

This is the mod that I had done long ago, added that extra piece and removed the thermostat valve completely.
Attachment 67500

Attachment 67501

That heater assembly is donated from an old zen. Look! though I have new pipes now. Lolz!
Attachment 67502

Battered steering Rake
Attachment 67503

Attachment 67504

New Sona rake
Attachment 67505

Tools of the trade, very handy eastman small and mid.
Attachment 67506

Loctite 596, gasket maker
Attachment 67507

Mr. Mannaram, a great helper
Attachment 67508

Very old, but very useful for a DIY guy like me.
Attachment 67509

The Kharcha List, add to that head & block job and labour, thats me and mannaram.

Attachment 67510

Attachment 67511

Can you send me a copy of the service manual ?

16th October 2009, 20:56	#61
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	There is no size difference in fenders. its the mounting points. even the light mount can be fitted on old one but it needs little cutting and adding extra bits of metal sheet. left side has the old mount points and right side has new mount points. as it was completely destroyed beyond repair.
	() Thanks

17th October 2009, 01:07	#63
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	Sorry! i don't! As i was very busy with work. even the car was towed by my driver and one of my friends mechanic at M.A.S.S. I couldn't even take pictures of the damages. As far as i know base (apron) needs to be drilled at places for screw to fit. Last edited by SirAlec : 17th October 2009 at 01:09.
	() Thanks

17th October 2009, 09:12	#64
anujmishra Senior - BHPian Join Date: Jun 2008 Location: Bangalore Posts: 1,290 Thanked: 492 Times View My Garage	Hi SirAlec, Excelling looking 800. Need one suggestions. I have 2003 800 AC with mint condition. I want to change headlights and tail lights to new design. Would you suggest to buy from MASS or outside I can get cheaper? MASS was quoting something 1400 Rs. per pair of rear light set. Is the original company product available outside? Last edited by anujmishra : 17th October 2009 at 09:17.
	() Thanks

17th October 2009, 14:44	#65
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	headlights from maruti are very expensive. It comes along with motors etc. And is about Rs.2700 a piece. I bought DKMAX, a lumax brand lights at 2200 a pair. It maybe cheaper in delhi and other bigger cities.. This was ordered unofficially by my M.A.S.S. friend as he cannot buy products from outside. As i don't take bill from him so its no complications. I don't like the new rear lights. Hope this answers your queries.
	() Thanks

18th October 2009, 08:12	#66
PatienceWins Senior - BHPian Join Date: May 2007 Location: Bangalore Posts: 2,416 Thanked: 807 Times View My Garage	Excellent thread. Rated 5 star!! Very informative. Thanks for the pictures.
	() Thanks

18th October 2009, 15:08	#68
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	I didn't find any use of the motor, i use the old style patch on it. The price difference is due to the motor i guess.
	() Thanks

29th January 2010, 15:23	#70
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	it includes everything (lowerpart) except head. I am dead sure about this.
	() Thanks

29th January 2010, 20:19	#71
S.I.N.G.H BHPian Join Date: Sep 2009 Location: Delhi Posts: 387 Thanked: 134 Times View My Garage	congrats sir, the ride looks great. i must say- old is gold. very well elaborated and explained thread i must say.
	() Thanks

29th January 2010, 23:29	#72
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	thank you very much! Its a very capable car and chasis. There so much potential in this package, but very few are interested in this car or tunning it.
	() Thanks

14th November 2010, 21:24	#73
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	Update! After about 8 months Mallu painter friend from Allepy, Raju returned after his exams. He wished to polish the old car which is very dear to him as much as it is to me. So he summoned it to his garage. We did lot of work on steering as after this year's rain, the roads is full of pot holes. Wife's driving added to its toll. Since he had lot of time which is rare. We decided to cut the hood. He asked me for a designed that i wanted. Was not interested at first but anyway decided to go for it anyway. Goggled it and found couple of them, made a printout and gave him. Here are the results. Guys what do you think. This is what i liked. This is what he made. The steering, balance rod, suspension etc. overhaul. Last edited by SirAlec : 14th November 2010 at 21:25.
	() Thanks

14th November 2010, 21:41	#74
SirAlec Senior - BHPian Join Date: Sep 2006 Location: zxc Posts: 3,393 Thanked: 726 Times	Some closeup images. Its a phone cam. It looks much better than in images.
	() Thanks