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New Engine Break-in Procedures

September 27, 2010 | Troubleshooting & Repair
By Maurice P. Cruz, the Phillipines

 

Start-up / Break-in Guidelines

1. Spin engine without spark plugs to circulate the oil before start-up.

2. Use Bosch W6BC spark plugs (.46" extended tip electrode) or W5AC

3. Valve clearances :
a. on a new engine, set at 0.008" for all valves for the first 30 - 50 miles
b. then set valves to 0.001" more than standard or;
c. after break in : set intake at 0.005" set exhaust at 0.007" (Ed: note that factory clearances are .004" intake and .006" exhaust and are preferred by many)

4. For break-in, set timing to TDC. After 2000 - 3000 miles, reset dynamic timing to 30 degrees total advance at 3500 RPM.

5. Keep RPM below 4000 - 4500 for first 500 - 1000 miles.

6. Drive at low but variable speed at cool temperatures

7. Oil temp should not exceed 210 degrees

8. Change engine oil and clean screen/magnet at : 50 miles, 300 miles, 1000 miles, 2000 miles, and thereafter at 2000 mile intervals

9. Check/adjust valve clearances during above oil change intervals

10. Add 1/3 quart of 2-stroke motorcycle oil to the first full tank of gas and/or for the first 2000 miles (add oil alternately while adding gas)

11. Stop and go driving is much better than highway driving.

12. Make sure all guages work, avoid overheating.

13. Use unleaded, premium gas

14. Make sure clutch has about 1" of free play before resistance comes in

15. At 2000 - 3000 miles, adjust throttle linkage to get full throttle

 

Check for Oil Leaks

1. Oil filter can top
2. Oil lines at oil filter can
3. Inlet / outlet oil lines not at oil filter can
4. Oil pressure idiot light
5. Pulley seal
6. Flywheel seal
7. Valve covers
8. Pushrod tubes

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