Forum:
hello again, still havent sorted out the cutting out prob i have with my 92 hijet, so bought another for spares, when i got it it was knocking like mad (like a machine gun) thought it was a stuck or bent vave, but they all seem to work fine, (after takin head off,) looks like somebody has had a go at fitting a new piston (home diy job barrel just sandpapered) when the piston is at top u can move it and get a slappin sound, the other 2 are fine no movement or slap from them ok lads here,s the question any ideas as to how to fix it???? and stop it slappin on its travels,any ideas welcomed, but DONT want to put it in shop and get it rebored gonna cost to much and dont want to take the eng out ,tough one 
ideas please
thanks
steven
ps did anyone see the diahatsu workshop manual on ebay , 54 + 2 postage nearly fell off my chair!
PISTON SLAP
Not too sure you have many options if you want to repair the problems caused by a dodgy rebuild. Either replace the unit with a secondhand unit which could have more problems or bite the bullet and get the engine rebuilt. I thinks you would be lookin at a rebore and o/s pistons at the very least. Unfortunately if one bore and piston is worn you can't just drop an oversize in one and let it hone itself in, it will cause all kinds of problems even if you could get an oversize to fit which I doubt 100%. When you hear a tale like that you wonder what type of brain does that type of thing.
As for the Manual I paid back in 1994 £80+ P&P from a firm in the UK for a full Sportrak Manual, PAPER that is, now I have it on CD from ebay £2.99, progress. Of course the CD version is a copy complete of the paper version but the original is more usefull being to hand in the garage. It has earnt it's money over the interim years but was a bit pricey when at that time a Haynes for other cars was 10.99
OLDMINIMAN
M J Young
Manuals, paper x CD
I have an old Computer, a 500,whatever AMD unit( very old,in computer time) in the garage,with a 15" screen , running Windows 98, given to me to take away,this allows me to read my Fourtrak manual/CD,bought from this site,( get ONE !!!!!,you never know how useful it maybe, and it helps keep this site alive). This saves me coming into the house with mucky overalls and greasy hands.
I have added a WiFi card to allow Internet access via my wireless router so I can access the Internet if I wish, my only expense.
It's a pity Haynes decided that not enough Fourtraks were imported to the UK to make it worth while producing a manual.
Edward (ews) '92 Fourtrak 2.8 TDX
in reply
would do if i could get the cb41 eng on cd, in the meantime have stripped the head and block down, head cam etc seem ok, as does the crank etc its had new bearings fitted, and new rings, however when i took the pistons out noticed that 1 off them has been rubbin on 3 sides(cotterpin sides) from just below the oil scraper ring to just below the cotter pin, same on the bore,not deep marks just rubbed,so took block to be de glazed (profesionaly) and he recons the marks will go with this, he is also going to polish the rub marks out on the piston for me and recons it should be ok?, I,ve got my doubts about the piston and thionk maybe a replacement would be better, however its the cost NOTHING diahatsu do is average price its always sky high and considering these vans are third world runabouts one wonders how they ever afford to repair them???????? still at a loss as to how the piston can rub on 3 sides, unless its slightly oval,will ge the engerneer to check that tomorow, still waitin for the torque settings for the head,main berrings and con rod berrings lads, nobodys posted them for me as yet!
thanks again
steven