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Glow Plug Recommendation:
The glow plug can make a big difference in how your engine performs. We recommend using a "hot" heat-range glow plug intended
specifically for performance engines like the Thunderbolt # 3 (P/N 115559) or the McCoy MC-59 (P/N 690215) during the break-in
process. After the break-in period you may want to use a medium heat-range glow plug like the McCoy MC-8 (P/N 690205). Do not
use glow plugs intended for four stroke airplane engines. Using the wrong type of glow plug will cause the engine to run erratically
and make it difficult to tune properly.
Air Filter:
The air filter is a very important part of your engine. Failure to use the air filter will damage the engine in a very short period of time. If
you are driving your vehicle in very dusty conditions. Also make sure that you "wet" the air filter as described on page # 10.
If, during the break-in process, the pull-starter assembly slips when you
try to start the engine, the one-way bearing and pull-starter shaft may
be coated with excess fuel oil. This can occur because the excess oil in
the engine during the break-in process gets into the one-way bearing.
To fix this, carefully remove the one-way bearing and the pull-starter
shaft, clean them with rubbing alcohol and reassemble the parts. Use
the engine exploded parts view to see how the parts are assembled.
Also, be careful when removing the pull-starter assembly to ensure that
the recoil spring does not uncoil and fly out.
ENGINE BREAK-IN TIP "WHY IS MY PULL-STARTER SLIPPING?"
Step 1: Breaking In the Engine
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WARNING
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Do not adjust the low speed needle valve until after the engine has been broken-in. You can begin to adjust the low
speed needle valve after you have broken in the engine and after you have read and understood Step 2: Fine Tuning the Engine on the
next page. The high speed needle valve is preset from the factory for easy starting in most conditions for the break-in period. The high
speed needle valve setting will differ on your engine because of different fuels used, glow plugs, temperature and outside air pressure.
The needle valve settings given in Section # 4 are all-around good settings to start with should you get your settings too far out
of adjustment.
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Follow the previous procedures in Section # 5 to fill the fuel tank and start the engine.
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Once the engine starts, keep the glow starter attached to the glow plug and let the engine run for about 10 seconds without giving it
throttle. This will allow the engine to warm up. At this point the engine should be running very "rich" and the engine will also sound like
it's running rough.
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After the engine has been running for about 10 seconds, remove the glow starter from the glow plug. Advance the throttle in
short, quick bursts and drive the truck around for about 2-3 minutes. If the engine is running rich enough, you should notice white
smoke coming from the exhaust pipe and the engine should sound like it’s running very rough. Also, the truck will barely be moving
because the engine is running so rich that it won't produce much power. This is what you want for now. If there is not white smoke
coming from the exhaust pipe, richen the high speed needle valve. After 2-3 minutes stop the engine by pinching the fuel line to
the carburetor.
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Let the engine cool for approximately 10 minutes, then restart it. Set the high speed needle valve mixture to a slightly leaner setting,
about 1/8 turn more in. Repeat the procedure above then stop the engine and let it cool for approximately 10 minutes.
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Repeat the procedure above, while leaning the high speed needle valve slightly more each time. In all, you should run the engine a
total of about 45 minutes. After 45 minutes of run-time the engine will be broken in. Run the engine with the high speed needle valve
set slightly rich, but lean enough to power the truck adequately. At this point the engine should hold a good setting on the high speed
needle valve and you can begin to fine tune the needle valve settings to increase performance.
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IMPORTANT
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It is of the utmost importance that the engine never be leaned out too much. When running the engine, you should
always be able to see a trail of white smoke coming from the exhaust pipe. If you can’t, stop the engine immediately and richen the high
speed needle valve. You should also make sure there is plenty of air flowing over the cylinder head to keep the engine from
overheating.
Continued On Next Page
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