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I would start with the Radio Shack clearance section that appears to be your operator cube where the missing relays are! :ROFLMAO: A lot of extra wires in there that appear to be taken from elsewhere and put there.
The relays and switches are readily sourceable through places like Mouser and...
Yeah those photos don't look bad at all... All the leads you see are disconnected from a single TB (genhead output) just behind the firewall near the air filter.
Look forward to more photos.
I just use a flat cut piece of 1/4" rodent mesh and ( 8 ) self tapping sheet metal screws and just go over the entire cutout with the machine lofted for easy bottom access.
I've recently begun using aluminized tape on the round battery holes under the trays, when machines sit without batteries...
Definitely make sure there isnt a second washer in there, and as Ray said... you may just need to anneal them. Only so many things could be causing this. You did confirm there are no hairline cracks in the injectors anywhere?
The primary mission of that cutout is to quickly evacuate water from the engine bay, under fording conditions. It will also allow for fresh air during use to pass through the system... but I believe there is sufficient cubic footage available solely through the side vents to keep everything...
As DieselAddict said, just try holding the start switch much longer. There is a disconnect in the circuit... You cannot hurt the starter (you actually need to hold it a few seconds so the set will begin to produce power after it hits operating rpm). If it then doesn't work, then the...
Start out at 61.5, and load it up. If you end up back around 60 under full load, you are doing OK (provided its running steady with no real variation).
Don't expect for an 802 to hold 60hz at no load, and full load without having to adjust the frequency cable to compensate for the load. Try...