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Not to split hairs, but I would not go with 1/2" bolts. You are better off with 5/8" or 3/4" Mainly because these machines use a couple different length screws and 1/2" won't work in all positions, so why not get 1 size that fits all? For instance, on the rear panel around the fuel tank, several...

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!

I usually just go on the internet and find 10-32 ( 5/8" or 3/4" long ) flange bolts and serrated flange nuts ( for places where you don't have the captive nut ) Either stainless or galvanized. They usually come in bags of 50 or 100 Think I've used ebay before and possibly Amazon. Pretty much...

Either one is better than pump diesel! Essentially the same product but without the added road taxes. Not sure on the price, but many carriers will also bring you off road diesel in a 55gl drum if you don't have a storage tank, but I can only assume it is substantially more expensive that way.

Home heating oil goes in everything diesel that I own. ( none of which are for road use ) Treated with Opti Lube XPD.

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...