Swissauto 250 - Break-In Procedure

1
ENGINE BREAK-IN
IN PROCEDURE
BEFORE STARTING !
1. Charge battery:
• The battery must be full charged before the first start using a desulphating charger with a low output current
(±0,5A)
2. Oil level:
• Fill oil (around

around 0.4 liter) until the level is just above the middle of the inspection glass. It is absolutely imperative
that you use the recommended oil of 0W-30.
0W Do not use other oils! The oil membrane system won’t work.
• Remove spark-plug and push start button during 10 seconds. Check oil level again and fill up if necessary.
3. Radiator:
• Fill cooling system with approximately 0,7 liter water. (a 10% mix with anti-freeze
anti freeze is recommended) The cooling
system purges automatically.
4. Fuel:
• Be sure that the carburetor is filled with fuel before starting. You can do this by blowing on the breather pipe of the
fuel tank with compressed air. (Do this smoothly to avoid fuel tank explosion!)
5. Clutch housing needle bearing:

bearing
• Lubricate clutch housing needle bearing with copper grease.

grease
6. Temperature:
• In the summer (outside temperature 25°C à 30°C)

30°C the operating temperature of the water shall fluctuate between
55°c and 65°c.
• During winter, when the outside temperature is around ±5°C,
±5°C the operating temperature must be much higher to
avoid condensation. An operation temperature between 75°c and 85°c is required.
1
2
THE FIRST START
• Start the engine and let it run on a preferable 2.500rpm. Allow engine to run until cylinder head is warm to the
touch, then switch off and drain the warm oil. Do not allow to idle.
• To drain the oil, remove plug below, then remove spark plug and push start button during 10 seconds. (remove all
metal parts from magnetic drain plug)
• Clean oil filter. (We recommend you to clean it every time you change the oil)
• Now refill oil (repeat n°2 -oil
oil level).
• Once this is done, your engine is ready to break-in.
break
RUNNING IN THE ENGINE
First of all it is important to know that the performance and the lifetime of an engine are highly
dependable on the way that engine is ran in. With other words: Up to 10% of the engine performance can go lost if it isn’t
run in on the correct way. And this loss is permanent!
So if you want to have a reliable engine that has ±35hp and more, we suggest you to follow strictly our recommendations
recommendatio
concerning the break-in procedure!
In general:
Important for a good break-in
in of the engine is driving it FULL throttle to the predetermined rpm.
(See graph.) Do not drive flat lines with half throttle! This will overheat the piston and can cause serious engine
damage!
Swissauto 250 break-in

break cycle
14000
12000
10000
8000 First 30 minutes break-in
break
RPM
6000 Second 30 minutes break-in

break
4000
2000 Third 30 minutes break-in
break
0
1 2 3 4 5 6 7
In this particular case this means:

• Don’t rev up higher than 8.000 rpm during the 30 minutes.
• Replace oil after 30 minutes.
• Continue procedure, but don’t rev up higher than 10.000 rpm during another 30 minu
utes.
• Replace oil and clean oil filter again.
• Continue procedure, but increase load slowly until you have reached 12.000 rpm on the end of the last 30
minutes.
• Replace oil and clean oil filter again.
• Now the break-inin is complete and your engine is ready to race.
2
3
CHECK DURING BREAK-IN
Temperature
• In case there should be quick temperature changes, stop immediately and control water level.
Oil level:
• In case you don’t run stints of a complete hour, it is absolutely necessary you control the oil level every time you
stop. It is recommended to do this just after you have switched off the engine. The oil level should be:
Minimum just above the middle of the inspection glass.
Maximum just below the top of the inspection glass.
MORE SWISSAUTO 250 TIPS
Cold start:
• Not the water temperature, but the oil temperature is the most important! Dyno simulation showed that it takes up
to 4 laps until the oil has reached its operating temperature.. Therefore we suggest you to warm up the engine on
the stand before you go on the track.
• The first lap you go out on the track you will find a drop back in water temperature because the engine isn’t
completely
pletely warmed up. Once you see the water temperature rising to a constant level, the oil is on temperature.
The minimum temperature we advice to have before going full throttle is 65°c.
Gearing:
• Depending on the track and the weather circumstances we suggest you to gear the engine in such a way that it
revs up to 11.800rpm
800rpm on the quickest part of the track. Various testing taught us that this set-up
set mostly results in
the best lap times.
• Always lubricate chain and sprockets when drive train is still hot.
hot (Directly
Directly after coming in). By doing this, the
lifetime of the gearing and chain will be extended.
Torque absorber:
• The Swissauto 250 torque absorbing sprocket carrier is a part that helps to prevent chassis fatigue caused by a kart
engine. The new generation of kart engines does generate much more stress on the tubes where the engine is
attached. This innovative sprocket carrier absorbs much of the power peaks so the bending of the chassis is a lot
less. A must for each Swissauto 250 driver, but also
als very popular in other categories.

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1

• Fill oil (around

5. Clutch housing needle bearing:

• Lubricate clutch housing needle bearing with copper grease.

• In the summer (outside temperature 25°C à 30°C)

THE FIRST START

RUNNING IN THE ENGINE

Swissauto 250 break-in

6000 Second 30 minutes break-in

In this particular case this means:

CHECK DURING BREAK-IN

Minimum just above the middle of the inspection glass.

Maximum just below the top of the inspection glass.

MORE SWISSAUTO 250 TIPS

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