727-902-3313 · service@kompletelykustom.com · Kompletely Kustom Marine Inc.
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Spring Specials

Get your vessel ready for the spring season - don't wait!

Break-In Procedures

For Remanufactured Engines

This engine has been rebuilt to give long, satisfactory service. Protect your investment by following these instructions before installing or starting the engine.

Suggested PRECAUTIONS for Remanufactured Engines

These engines have been carefully remanufactured to precision standards, and will perform properly if certain steps are taken by the mechanic when doing the installation. Following is a list of causes for a remanufactured engine to fail early in service, and suggested procedures to prevent failure. When a properly remanufactured engine fails to give satisfactory service, it is usually due to: burning piston heads caused by detonation, pre-ignition or "lugging"; piston scuffing or seizing usually caused by overheating or excess fuel; bearing and crankshaft wear caused by under-lubrication, dirt or coolant seepage; excessive piston and cylinder wear caused by dirt, ineffective air filtering, coolant seepage or excessively rich, air-fuel ratio.

The customer and the remanufacturer have a mutual interest in this engine. We both want it to perform and give long and satisfactory life.

We recommend these precautions:

  1. Be sure to prime the oil pump, oil lines and fill the oil filters with oil using an auxiliary pump, operating the internal oil pump with a hand drill, or an external pressure tank connected to the oil pressure gauge or sending unit fitting before starting the engine. It is desirable to fill the crankcase in this manner. If using an air pressure tank be sure it does not run out of oil and blow air through the lines.
  2. Proper air-fuel ratio is vital in today's engines. Be sure the carburetor or fuel injection system has been remanufactured to manufacturer's specifications. Manifold and cylinder head surfaces should be checked and in good condition (resurface if necessary). Be sure the cylinder heads and manifolds are torqued and retorqued in proper sequence if required. Air seepage can cause lean air-fuel ratio, which causes detonation.
  3. Check fuel pump for proper pressure.
  4. Ignition or diesel fuel injection system should be properly serviced or calibrated, and engine timing corrected. Proper valve lash or clearance is very important.
  5. Be sure to use spark plugs of the correct heat range and gap as specified by the engine manufacturer. Check electronic sensors and sending units for proper operation. Vacuum lines must be properly routed and connected to the appropriate fittings to ensure operation of emission control devices and related engine controls.
  6. Clean the intake manifold to remove deposits from the various passages.
  7. Rebuild or replace the radiator/heat exchanger and hose lines to ensure they are free from deposits so that the cooling system can function properly. Restrictions can cause overheating. Thermostats should be checked or replaced with one of the correct temperature. Use the proper pressure cap as specified by the engine manufacturer, and make sure it is properly seated.
  8. Important - replace filter elements. Thoroughly check engine accessories, which are to be reused. Clean them internally and externally before installing.
  9. The coolant used should be compatible with aluminum engine components, if applicable, and blended to a mixture of no more than 60% antifreeze and 40% water. We recommend that a good sealer with rust inhibitors be added to the cooling system. This will tend to prevent rust and scale deposits and guard against coolant seepage.
  10. Before releasing the engine for regular service, check the air-fuel ratio or carburetor adjustment. Caution the driver against "lugging."

RECOMMENDED "BREAK-IN" PROCEDURES FOR REMANUFACTURED ENGINES

Protect the investment you have in your engine. Take the time to read and follow these recommendations.

CAUTION

Before starting the engine for the first time, be sure it has been properly pre-lubricated.

  1. Never add cold water to the cooling system while the engine is running. The engine should be allowed to run at normal operating temperature.
  2. Start engine and run at fast idle, approximately 1500 RPM, and check the oil pressure. Run the engine for 30 minutes even though coolant may rise to operating temperature in a few minutes. Adjust tappets, if required, carburetor and ignition timing. If the coolant should "boil over," stop engine and allow to cool. Then start again and proceed as above.
  3. When required retorque cylinder heads and manifolds to engine manufacturer's specifications in proper sequence. Readjust tappets if necessary.
  4. Start engine again and make a test run, on the water at 1500 to 2000 RPM, and rapidly accelerate to 3500 and decelerate to 1500 RPM 10 times.

NOTE: Applying loads to the engine for short periods of time causes increased ring pressure against the cylinder walls and helps to seat the rings. This is especially important because you are "breaking-in" the engine with heavy-duty oils. The rapid deceleration increases vacuum and gives extra lubrication to the piston and ring assemblies.

When you have accumulated 25 to 50 hours of operation, change the engine oil and filter according to manufacturer's recommendations for oil type and filter number