The Engine

This is the completely stock 1987 Suzuki Samurai Engine

The engine was in perfect running order before making the Bugzuki, but after all the work it ran horribly.  I thought that I had gotten dust and welding debris in the carb when I did the work.  Part way through the job I realized that I had forgotten to cover the top of the carb.  So I rebuilt the carb.  Inside I accidentally broke the mixture sensor wires.  Needless to say it ran horribly after that.  Later I found that I had not plugged some of the wires into the alternator.  All in all I did not have to rebuild the carb, but I did and I wasted it. I tried 2 more Suzuki carbs and have been equally dissatisfied with all of them.  Time to try something different.

Things done or to be done to the engine.

Replaced all of the seals in the engine and checked the rings -- looks really good. Oops forgot to change the valve stem seals - I found them in the tool box.  I was wondering why it smokes a little.

It is nice having an engine that does not leak oil or water.  All it does now is get very dirty.

When I put the engine together I did not put locktite on the crankshaft bolt. Oooooops.

The bolt came loose and shattered the shaft key.  Luckily the pistons do not hit the valves so my valves are still OK.  I had a Sprint Metro with almost the same engine so I stole the needed parts off it to fix the timing system.

 Trying a Weber Carb - A lot more power.

 

When it is cold it is pretty bad though - the electric choke and accelerator pump don't work.  Well worth the time and money though.  I still need an adapter to get a nice intake line.

I made my own adapter plates for the Weber.

The verdict is in.  The Weber, I got is old and broken.  The accelerator pump and choke do not work.  Overall the low end torque is almost non existent.  But at about 3000 RPM and above there is a vast improvement.  If the choke and accelerator worked it would probably be great all around.

A new addition to the problems just came up.  The carburetor no longer functions.  I got about 1 year out of it so that is pretty good for 60 bucks.

Now it is time to start the fuel injection system.

 
Build an EFI unit - This next quarter I will be starting my microprocessor classes. Designing a Multiport Injection system. I already have the system mostly laid out.  There are some minor changes that I have to do to make it look nicer, but I am getting close.

 

         Here is a link to my intake manifold design project

Intake Manifold Design and Construction