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It won't be a failure... EVERYTHING can be repaired, it's just a matter of working your way through the gremlins. If you got the set cheap, being a non-runner, you can dump a ton of parts and money into it and still be ahead of the game based on what 803's sell for these days!

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...

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...

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...

I'm not quite sure what you mean by the Aux pump has good pressure? The aux pump ( mounted under the rear cover just above the tank ) only sends from from an external tank ( wen hooked up ) to the generator's tank. Only the pump next to the radiator sends fuel to the metering pumps.

FYI, definitely make sure the throttle cable is not all the way in. You probably want it pulling the throttle lever on the side of the engine so there is about 1/4" - 3/8" space between the tip of the curved lever and the high limit screw. Definitely do as LITD mentioned to confirm fuel flow and...

Do you have all the injectors bolted down tight or are they just sitting in the holes?? IF they are not bolted down fully, the arm will hit the underside of the block surface and bind the rack, you must have them almost fully down against the block for the arm to clear the underside of the...

It doesn't really matter, there's no area on the block to seal against the additional material that defines the 4 squares anyway. Go with the 4 square one, but save the open one for a rainy day incase you need another.

Humm... that doesn't really seem right to me. I've used those gaskets on both the LPW4 and LPW2 and never stacked up both gaskets. I don't think there's any openings in the block or cover that prevent either gasket from being used by itself. IIRC I used 1 gasket on one machine and the other...