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Good work being persistent everyone! As soon as I first read this post I thought CR-1 but OP said it was good, so I immediately checked that off the list. Just goes to show you that nothing can be taken for granted. Test...Test...Test...Test....replace....confirm

Don't worry about the head gasket thickness, my experience has been that using the "standard" thickness gasket that comes in the gasket kits works just fine. I'm not even sure if you can still buy the other thicknesses or not. You should just remove the radiator and shroud assembly. Its easy and...

Perhaps, but it's rubber touching steel and the part that touches is where the steel nipple of the metering pump is inside the hose, so there is very little chance for any vibration or movement between them, but setting them all with a slight gap would work just fine.

Something you could try is to 1 by 1 remove the line and injector, reorient it so it's off to the side of the motor and crank it over and observe the fuel spray from each metering pump / injector combo. If you find 1 that doesn't spray when it should or continues to spray after the fuel...

They are fine left out in the weather but keeping the rain and snow off it will make it last even longer!

One other thing to keep in mind is that the metering pump levers will move easier once the pump in installed and slightly compressed. When out of the unit the spring on the bottom is being held on by pulling against the plunger, once installed that spring force on the plunger goes away. Used...

Battery covers should be arriving ~Tuesday

How can we get a bulk shipment sent to the states? (y)

Well, for starters you have to bolt the pumps down otherwise the pins will hit on the underside of the block and bind up. Look at the sticky at the top of the generator forum for tips on installing the metering pumps. Also, the linkage is not connected to the lever arm with a solid connection...

24v Carter fuel pump. I know it requires some 5/16 JIC fittings to work like original. Getting close to the finish line. Be careful on the fuel pump fittings. If memory serves me right the 803 uses 1/4" JIC fittings on the fuel pump lines. The 003 is 5/16 on most of the fittings, but 802 and...

I know the vast majority of generator ( and other items ) owners with dual batteries usually go with the built in Noco Genius 2X series chargers. Hardwired, permanent install, wired direct to the battery terminals, just plug it in and walk away.

A couple suggestions for everyone: When an injector totally refuses to budge, the thread on top for the hard line is the same as some automotive metric lug nuts, 12mm 1.5 or 1.25 pitch ( dont recall which off hand ) you can thread the appropriate lug onto it and use adapt a dent puller ( slide...

Wow, I just looked and Amazon has this little thing for $55 Prime Deal. Granted for that money you need to buy the tig torch and gas regulator separately, but at 8lbs. and $55! I might buy one just so I don't need to lug by big welders around for little things!

Well, it may not be that its the wrong camshaft, it just doesn't allow us to easily determine if your camshaft has spun within the gear without removing it. I say continue with your investigation. If you find that Both #1 valves are not closed at TDC ( and for approximately 90* crank rotation...

One of my go-to cheap load banks has always been a used electric oven. Often found on the side of the road and/or cheap on Facebook. I use if for load testing, powder coating and lots of other "shop" activities. Probably could load test and bake a pizza at the same time, but powder coat and...

You can also connect an ohm meter to the fuel sender. move the float slowly up and down and look for dead spots where your meter shows an open circuit. Sometimes you can clean the coil with acetone or brake cleaner, if the dead spot is caused by a thin bit of varnish.

Well Houston, we have a problem! I have cam/ gear assemblies for both an 802A and an 803A but neither have that slot in the cam face. They are both solid on the end. I assume this must be something related to LPW4 Vs DN4M ?? I don't recall which this cam was from, but assume both are...

Humm, I just thought of something. The slot for the governor is cut into the camshaft, the gear appears pressed on and the alignment dot is stamped into the gear. If I take a picture of my camshaft from the end, you should be able to judge the location of the timing dot relative to the slot...

Jack, you can also look for continuity between all 4 positions on S1. 2,4,6 and 8 should all have continuity to each other. if they don't then your missing some of the jumpers. If that's the case you can just make up some short wires to connect the disconnected terminals together.

Mark, FYI your rational isn't going to tell you what you want to know. The pistons will always be at TDC based on the timing marks because it isn't the crank or the gears that may have slipped. The only thing that would be off would be the position of the valves when the piston is at TDC if the...