Maruti 800: Technical Issues & Solutions

[mandar7477]

friends and experts,
recently my maruti 800 has started to act wierdly on petrol, (being convetred to lpg), the carb has been overhauled by ASS and then by myself. Now the problem is that it idles and runs nicely when stationary. But after a run nearby it starts flooding with lots of petrol smell and rough idling. i tried to find the problem but in vain. the hoses are in good condition, gaskets and everything is in good condition.

advices and suggestion are welcome.

regards

mandar

 

[VR Shenoy]

friends and experts,
recently my maruti 800 has started to act wierdly on petrol, (being convetred to lpg), the carb has been overhauled by ASS and then by myself. Now the problem is that it idles and runs nicely when stationary. But after a run nearby it starts flooding with lots of petrol smell and rough idling. i tried to find the problem but in vain. the hoses are in good condition, gaskets and everything is in good condition.

advices and suggestion are welcome.

regards

mandar

Im not an expert but these are my suggestions:

Better check the cap of the fuel tank, sometimes petrol may evaporate from there if there is a gap and causes petrol smell.

Also check the return line because you did o/h of your carburetor,may be some point is lose.

Also check the petrol vapor filter, whether any pipe is lose.

pls do give your update to help others too.

Good luck to you.

 

[Aditya_Rnc]

friends and experts,
recently my maruti 800 has started to act wierdly on petrol, (being convetred to lpg), the carb has been overhauled by ASS and then by myself. Now the problem is that it idles and runs nicely when stationary. But after a run nearby it starts flooding with lots of petrol smell and rough idling. i tried to find the problem but in vain. the hoses are in good condition, gaskets and everything is in good condition.

advices and suggestion are welcome.

regards

mandar

Try replacing the venturies,float,and the jets. Also check the pumping jet if it is broken or ok. This can cause rough idling

anyways, sumit sinha can give you better advice.

Keep us posted.

 

[swiftshashi]

Try replacing the venturies,float,and the jets. Also check the pumping jet if it is broken or ok. This can cause rough idling

anyways, sumit sinha can give you better advice.

Keep us posted.

Dear Aditya sir,

Since you are so experienced with carbs, can you kindly explain what purpose the venturies, float and the jets serve in the carburettor?? You do know I am a complete noob when it comes to carburettors, hence looking forward to an enlightening session on these things.

Regards,
Shashi

 

[mandar7477]

@vr shenay,
sir thanks for your suggestions.
the tank cap is ok . i have also checked the petrol return line. it is flowing like it should . now i dont think my car has got a Petrol Vapor Filter . Where is it fitted in the car?


@aditya_rnc.
I wanted to change the venturies. I think that the problem, the primary venturi moves a little bit when moved by hand. AS i had said earlier on this forum the guys at the Maruti ASS had damaged the carburetor. AS it si the secondary is not working and i am not wnating to make it work again as most of the running is in city limits only. I hardly go on the highways.

I wanted to ask some questions:

1. how to fit the venturies in their places tightly.

2. what about the emulsion tube inside the venturi.

3. Pls tell me the part number for the venturi, primary as well as the secondary.


Also can some one shed some light about the address of the Maruti authorised spares sales shop in Pune. I know one near satara road, i.e. Sai service. any other will be appreciated.

thank you all for the replies

regards

 

[VR Shenoy]

@vr shenay,
sir thanks for your suggestions.
the tank cap is ok . i have also checked the petrol return line. it is flowing like it should . now i dont think my car has got a Petrol Vapor Filter . Where is it fitted in the car?


@aditya_rnc.
I wanted to change the venturies. I think that the problem, the primary venturi moves a little bit when moved by hand. AS i had said earlier on this forum the guys at the Maruti ASS had damaged the carburetor. AS it si the secondary is not working and i am not wnating to make it work again as most of the running is in city limits only. I hardly go on the highways.

I wanted to ask some questions:

1. how to fit the venturies in their places tightly.

2. what about the emulsion tube inside the venturi.

3. Pls tell me the part number for the venturi, primary as well as the secondary.


Also can some one shed some light about the address of the Maruti authorised spares sales shop in Pune. I know one near satara road, i.e. Sai service. any other will be appreciated.

thank you all for the replies

regards

Dear Mandar, Just attaching a photo of Gasolin vapor filer. you can find it next to the wiper water bottle or near the intake of air hood. Which model M- 800 is is yours? mine is 1998 model.

Sai service has service station at Decaan Gymkghna and one more at Khadki.

Just see the page no 87 , where you can find the parts nos of ventures etc with MGP prices given by me while I got the parts for my catb when the o/h was done.

In case you are doing DIY of your carb and if you don't get the venturies at Sai, let me know, I have kept mine by cleaning them and can send it to you so that you can try to fix at your end and if it works it is fine, otherwise you can change it later once you get the fresh delivery. There is no supply of new cab now a days and only some parts of carb are available at some MGP only.

 

[mandar7477]

thanks shenoy sir for the photo, fortunately my car is a 1993 model and does not have the vapour canister.

I know that Sai service has a service station at deccan gymkhana and khadki but now a days they dont sell spares at ASS. they have a shop at satara road.

i read page 87 and got the part numbers. very thankful on behalf of all 'tai'gers for posting the part numbers. Now i have not got time to go to maruti authorised spares shop for the ventury due to some busy schedule, but will try to be there some time.

About the venturies. Day before yesterday i looked down the carb throat and fortunately found that the primary venturi had come loose in its socket. So took a wooden rod and hammered the venturi lightly in its socket. I did not understand how it came loose on its own. as of now the car is running pretty fine.

Regards

mandar

 

[VR Shenoy]

thanks shenoy sir for the photo, fortunately my car is a 1993 model and does not have the vapour canister.

I know that Sai service has a service station at deccan gymkhana and khadki but now a days they dont sell spares at ASS. they have a shop at satara road.

i read page 87 and got the part numbers. very thankful on behalf of all 'tai'gers for posting the part numbers. Now i have not got time to go to maruti authorised spares shop for the ventury due to some busy schedule, but will try to be there some time.

About the venturies. Day before yesterday i looked down the carb throat and fortunately found that the primary venturi had come loose in its socket. So took a wooden rod and hammered the venturi lightly in its socket. I did not understand how it came loose on its own. as of now the car is running pretty fine.


Regards

mandar

Surprise !!!! you are a car doctor, good. petrol smell gone ?

 

[harish_gkumar]

Hi Friends
Can you recommend me the correct shifting speed for each gear in maruti 800 5 speed? for my 800 4 speed need to accelerate a bit more than 5 speed why So?

 

[VR Shenoy]

Hi Friends
Can u recommend me the correct shifting speed for each gear in maruthi 800 5 speed?..for my 800 4 speed need to accelerate a bit more than 5 speed ..y So?

At 10 km, go to 2nd gear and speed could be 25 km, at 3rd gear - 30 to 35 km, at 4th gear - 50/55 km and at 5th gear - 65/70 km and can accelerate once the road is clear and broad on highways.

As regards your problem of 4th gear , when did you change the gear oil? just check by using your dipstick and top up. If it doesn't solve the problem, may be you have to check your clutch for wear n tear because depending upon the style of driving and the road condition, the life of the clutch could be anything from 40000 to 50000 kms. This could be bit expensive affair as change of clutch cover assembly, bearing with shaft and also the Flywheel could cost you not less than Rs 3500.

Give your update for others to solve similar problems.

Good luck to you.

 

[harish_gkumar]

At 10 km, go to 2nd gear and speed could be 25 km, at 3rd gear - 30 to 35 km, at 4th gear - 50/55 km and at 5th gear - 65/70 km and can accelerate once the road is clear and broad on highways.

As regards your problem of 4th gear , when did you change the gear oil? just check by using your dipstick and top up. If it doesn't solve the problem, may be you have to check your clutch for wear n tear because depending upon the style of driving and the road condition, the life of the clutch could be anything from 40000 to 50000 kms. This could be bit expensive affair as change of clutch cover assembly, bearing with shaft and also the Flywheel could cost you not less than Rs 3500.

Give your update for others to solve similar problems.

Good luck to you.

Thanks Shenoy.
I have to elaborate this part of my question ---> "for my 800 4 speed need to accelerate a bit more than 5 speed ..y So?"
I Have two M800 cars One with 5 speed transmission and other with 4 speed transmission..My doubt is ,in my M800 4 speed i have to accelerate in 3 rd gear a little bit upto 50 kmph to forth gear. is it normal?..in 5 speed 5th gear takes from 45 to 50+kmph easily..and i need to rev 4 speed engine than 5 speed to attain speeds

My shifting pattern for 5 speed
****************
1st to 2nd=20kmph, 2nd to 3rd =30kmph, 3rrd to 4 th =40 , 4th to 5 th=45/50kmph

pattern for 4 speed
*****************
1st to 2nd=20kmph, 2nd to 3rd =30/35kmph, 3rrd to 4 th =45/50

Are these patterns okay? am I unnecessarily revving the engine / damaging the transmission?

 

[mandar7477]

Surprise !!!! you are a car doctor, good. petrol smell gone ?

yes sir all the smell gone and a almost fine running engine overhaul. except for a bit of cold starting hesitation and a bit of flat spot at cold idle, everything is fine. But some time later i will need to overhaul the carb myself.

well one big question to ask you and all other owners and enthusiasts. WHAT IS THE NUMBER OF TURNS "OUT" FOR THE MIXTURE ADJUSTMENT SCREW. Mine one settles at around 2 to 3 turns. 2.5 to be specific.

regards

mandar

 

[Subhash]

Headlight assembly

I have Maruti 800 of 2007 model and I need to replace the parking bulb with LED.I have the LED with me but can able to replace only right side and the left side failed because of battery and radiator .SO please inform how to take the headlight out and change it.Only I found two screws up and down there maybe another how to remove that.

 

[VR Shenoy]

Dear Shashi, Harsh, Aditya, silver_dove, and all the other simple but Proud Maruti 800 car owners ::::::just giving update on Mileage after 4 yrs by o/h of the carburetor in July and running it for about 500 kms in 3 months.

The Mileage has now gone up to only 13.2 km in the city run as I never gone outside Mangalore. I expected at least 15 - 16 km. If 13.2 km in the city means about 15-16 km only on highway run. There is one more issue as the Tyres have become harder and time has come now to replace all the 4 Tyres, so it may add another 2 km per litre of petrol which I hope so.

3-4 months back, some interaction took place with you all as regards the new tyres. I did check up with Tyre dealers today and got the following details.
1) Michelin Tubeless Tyre of 145/R 70 ( 12") suitable for M- 800 is not available in the market for M- 800. I wish to go for only stock size and not more. some one suggested 145 / 80 R ( 13").
2) Bridgestone Tubeless Tyre of this size is also not available in the market for M- 800. However with Tube is available at the cost of Rs 2700 per Tyre.

There are only 2 options now left.
1) Firestone Tube less Tyres of 145/R 70 ( 12") is available at Rs 2400 per Tyre. The same stock steel Rims can be used and there is no need to go for new Alloy Rims. However only after opening the old tyres and checking the status of Rim, they will be able to tell me whether I have to go for new Rims or use the same stock steel Rims. Each new steel Rim costs about Rs 900. I had been to the best place by name " Wheel Care" which is no 1 place for car wheels and have good name in Mangalore as honest people. So far I had been to this place only while buying my earlier Bridgestone - with Tube Tyres and always get the wheel Alignment n Balancing done here.

2) wheel care doesn't deal with Good year. I checked with another Tyre dealer about Goodyear Tyre 145/R 70( 12') , each costs Rs 2700. I don't know about this place but none of the other Tyre dealers have/ keep Good year Tyres.

So need your input again to freshen up my mind to buy new Tyres, preferably next week.

Thanks in Advance.

 

[VR Shenoy]

Re: Maruti 800: Technical Issues and Solutions

I got my 2003 Maruti 800 restored. Car was parked in open since a long time and has accumulated rust. Here are some pics after restoration.
View attachment 221152
View attachment 221153

Hello Udit, I like the new painting of your car. Could you please tell me whether you had the same paint earlier or different one? While doing the painting work, they had to scrap the previous one fully up to base metal before spraying done. How many coats were done. How long it took and they had to remove the complete seats, door lining etc. How much it costed you.
Appreciate your giving me some details, as after replacing my car tyres, I am thinking to get the painting done. My car is white color but thinking to go for different color like grey like yours. By the by, which make is your paint and what is exact name of the color.
Regards and Thanks