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Yes, left hand thread, fine thread as well, but I don't recall what size off hand.

Yup, the good old Suzuki Samauri overflow bottle! AND, if any of you 802/803 guys out there need a cap for an OEM overflow bottle , head to Walmart, buy a 5Qt bottle of Super Tech Oil ( any viscosity will work ) this is the blue bottle / house brand Walmart oil. Use the oil for whatever you...

If I recall correctly there were 2 duplicate threads running ( which gets confusing ) the purpose of deleting one is to keep all the data contained within a single thread and not have different people posting info in 2 different places. I think the problem here is that the primary thread got...

Correct, they absolutely do need to be indexed correctly otherwise you will have all sorts of issues. FYI, you have to call them metering pumps. "Injector" as related to the 802 and 803 will mess up your search results and you may not find what you're looking for. Can you post a link to that...

I know several folks here have disassembled and rebuilt their metering pumps and documented their work. The issue will be finding those threads because the search function will only get you so deep into the details. If non of them happen to read this, you may need to hunt around here on the...

Yup, another member just did the same conversion on an 002. https://www.steelsoldiers.com/threads/mep-002a-only-outputting-125v.218341/page-6#post-2558386 Start by reading this thread as well as the one from Craig Tull that is linked to it. That should get you on track.

Injector sprays look good to me. You may be on to something with the governor. The way the rack works is when not running and the fuel solenoid retracted, the spring on the rack moves it fully rearward. This rotates the pins on the metering pumps to the full fuel flow position ( wide open ) As...

Did you test them by attaching the fuel lines with them positioned off to the side? I doubt the soot is the root cause, but rather the effect of the real problem. I'd check to see if you have a deeper mechanical problem with the injectors before cleaning off the soot and reinstall. Or better...

Jeeze... prices have gotten even more out of hand since the last one I bought! If you rebuild, please post up who you end up going with and cost. I have an untested "core" that I should test and/or rebuild.

I assume you did these tests with the machine running... in which case, yes your alternator ( or voltage regulator ) is bad. Unfortunately you will not find it at your local parts store. They do come up on ebay and other places from time to time, just make sure you are searching for the right...

Do you know anything about the engine or gen head's condition? If not, the first thing I would do is get it running ( using a temporary fuel source etc. ) to be sure the engine is worthy of building a gen around. all a diesel needs to run is fuel, air and power to the starter.

Looks like a perfect candidate for another SX-460 AVR conversion.

Looks to me like the last time the switch was on with batteries in it the set was running and had oil pressure. As soon as you turn the switch again oil pressure will read zero, so with it still reading 30 psi that means no one has touched it since the last time it was running.... ( unless the...

Can't wait to see what you find with injectors out. I wonder if the flaming cylinders have injectors stuck open and just dumping fuel into the cylinders.

As Guy and LITD have mentioned, there is something wrong with the start-up. It seems to crank a little to quickly and take too long to light off. It sounds like there may be a compression issue on 1 or more cylinders, but first you need to get it to run within the operating RPM so you can do...

It was most likely neither of those 2 issues. The 802 doesn't have a DC voltage regulator, it has an automotive style alternator and they aren't being removed from service specifically due to age, condition or cosmetic damage. They are all being removed from service because they are being...

That's odd! Usually a rib tearing off a belt is due to misalignment or even the incorrect width belt, but it would be pretty obvious if you had a belt that was too wide! After the rib tore off was the rest of the belt in the correct position with 1 empty rib on the damaged side, or by chance did...

You should be able to use 2 wrenches, hold the lower fitting and loosen the upper nut for the line. Then tighten the lower fitting, then tighten the line nut. Hopefully that will be all you need.

Yes, it is very easy. A little time consuming, but easy. I've always just used the "flowing the pump" method, check it once, calculate how far away from PC you are, check the chart to see what button you need.... then try to find one at a reasonable price! ( this can be the hardest part ) Then...

The part in question is the metering pump, not the injector, the other thing is that the gasket for the pump has nothing to do with fuel, it's for oil. If you are leaking fuel at the metering pump it has to be coming from the pump itself or the line. It can not be leaking fuel from under the...