Duratrax TORQ16 User manual

You are the proud owner of a DuraTrax engine – designed to provide
easy starts and all the power you'll need for thrilling R/C action.
The following instructions contain information you'll need to break-in,
operate and maintain your new engine like a pro. Read and follow them
carefully, and your engine will provide a long life of strong, dependable
performance.
• Model engine fuel is poisonous and must be kept in a clearly marked
container, stored away from the reach of children. Avoid getting fuel into
your eyes or mouth.
• Because model engine fuel is highly flammable, it should also be kept
away from anything that might cause it to ignite (including open flames,
excessive heat, or any objects and materials which could produce a
spark). Smoking must not be permitted near the fuel.
• R/C model engine exhaust, like that of automobile engines, contains
deadly carbon monoxide. Do not run the engine in enclosed spaces –
operate it only in open, well-ventilated areas.
• Your engine will become very hot as it runs. Touching any part – particu-
larly the muffler (silencer), cylinder head or exhaust header pipe – could
result in a serious burn. Avoid contact with the engine until it has cooled.
• Protect onlookers – especially small children – by making sure that
they remain at least 20 feet (60 meters) away while you start the engine.
• This engine was designed only to power R/C model vehicles and
should not be used for any other purpose.
• Never pull the starter cord out more than 10 inches (25cm). To rewind
the cord, continue holding the handle and let the recoil action pull it
smoothly back into the starter unit. Do not abruptly release the handle.
The High-Speed Needle
The “high-speed” needle is sticking up from the side of the carb. It is
located in the brass housing, just above the fuel inlet. It controls the fuel
to air mixture of the carb. The needle is pre-set for break-in from the fac-
tory at 2-3/4 turns out from the fully closed position of the carb. Once the
engine is broken-in, the high-speed needle would typically run from
CARBURETOR SETTINGS
ADDITIONAL PRECAUTIONS
FOR YOUR SAFETY
INTRODUCTION
®
ENGINE INSTRUCTIONS
ENGINE INSTRUCTIONS
Warranty
• DuraTrax®will warranty this engine for 90 days after the pur-
chase date from defects in materials or
workmanship. DuraTrax
will either repair or replace, at no charge, the incorrectly made
part.
• Make sure you save the receipt or invoice you were given
when you bought your engine! It is your proof of purchase and
we must see it before we can honor the warranty.
• To return your Torq 16 for repairs covered under warranty you
should send your engine to:
Hobby Services
1610 Interstate Drive
Champaign, Illinois 61822
Attn: Service Department
Phone: [phone]:00 am - 5:00 pm Central Time M-F
E-mail: [email protected]
Repair service is available anytime.
• After the 90 day warranty, you can still have your Torq 16
repaired for a small charge by the experts at DuraTrax’s
authorized repair facility, Hobby Services, listed above.
To speed up the repair process, please follow these instruc-
tions:
Send written instructions which include: a list of all items returned,
a THOROUGH explanation of the problem, the service needed
and your phone number during the day. If you expect the repair to
be covered under warranty, be sure to include a proof of date of
purchase (your store receipt or purchase invoice). Also be sure to
include your full return address.

2 to 2-1/2 turns out from closed, depending on the weather, humidity and
altitude above sea level. To richen turn the needle counterclockwise, to
lean turn the needle clockwise.
The Low-Speed Needle
The “low-speed” needle is the screw in the middle of the throttle arm (see
picture on previous page). It controls the fuel to air mixture at low throttle
settings. There is a simple way of adjusting the low-speed needle cor-
rectly called the “pinch test.” With the engine at idle, pinch the fuel line
and listen to how the engine speeds up or slows down. If the engine
increases its speed for about 2 or 3 seconds and then loses speed, the
needle is set correctly. If the engine loses RPM quickly, it is set too lean
and the low-speed needle needs to be opened (counterclockwise) to
richen the mixture. Pinch again to check the mixture. If the engine takes
longer than 4 seconds to slow down, lean (clockwise) the low-speed
needle and then pinch again to check the mixture.
The Throttle Stop Screw
On the front of the carburetor, there is a black screw
(see picture on previous page). This is called the idle
stop screw. This increases or decreases the idle
RPM without changing the fuel to air mixture. The barrel should be approx-
imately 1.5mm (between 1/32" and 1/16") from fully closed.
To insure long life and good performance from your Torq 16 engine, you
MUST break-in the engine. The break-in period is critical for long life of
the internal parts of the engine. This should be done over the first 5 or
6 tanks of fuel.
Some Things To Remember During Break-In
1. Run with the body off. This will keep the engine cooler.
2. Keep the air cleaner on at ALL times
3. Run on a smooth, hard surface. An empty parking lot is perfect.
4. Use the same fuel that you will use for normal running.
5. Resist the urge to accelerate and decelerate the vehicle quickly.
6. Break-in puts stress on the glow plug and you can burn it out dur-
ing break-in. Make sure you have an extra plug or two on hand.
7. Do NOT overheat the engine. You can check the head temperature
by using one of the temperature gauges that are available or by
putting a drop of water on the top of the cylinder head. If the water
boils away immediately, shut off the engine and allow it to cool. If it
takes more than 5 seconds to boil away, the engine is at proper run-
ning temperature for break-in.
Before running, please, read this manual thoroughly to familiarize your-
self with this engine.
There are several simple steps to starting the engine:
1. Install a glow plug. This threads into the top of the cylinder head.
2. Fill the tank - Fill the tank almost to the top. Leave a little air at the
top of the tank.
3. Prime the engine - Use the primer button on the fuel tank to force
the fuel through the fuel line. Watch the fuel go through the line and
when it gets to the carburetor, press the primer button once more to
get fuel into the engine.
4. Open the high speed needle valve exactly 2-3/4 turns out (coun-
terclockwise) from fully closed. The high-speed needle is stick-
ing up from the carburetor inside the brass housing. All of the
carburetor settings are adjusted with a flat bladed screwdriver. If
you have previously run the vehicle, keep the same needle valve
setting that you used on your last run.
5. Start the engine by pulling the recoil - Use short, quick pulls. DO
NOT pull the recoil starter’s string to the end. You only need 10 inch-
es of pull to start the engine.
Sometimes it is helpful to start the engine at around half throttle. Have
a friend pull back on the throttle some while you start the engine. This
may be an indicator that the low speed needle setting needs to be
adjusted. When the engine starts, immediately return the throttle to idle.
If this is not done the engine can over-rev and cause engine damage.
If the engine is difficult to turn over with the recoil starter, espe-
cially if it is brand new, loosen the glow plug a half turn before
starting the engine. This allows some compression to escape, but
the engine will still start. Make sure you tighten the glow plug after
the engine starts. If the recoil starter is still difficult to pull, the engine
is flooded – there is too much fuel inside the engine. Remove the glow
plug and air cleaner, then turn the engine upside down and pull the
recoil 5 or 6 times. This will clear the engine of fuel, and you will notice
the recoil pulls easier. Replace the glow plug and repeat the starting
procedure.
Fuels
Use fuels that are specially formulated for car and truck engines. DuraTrax
Red Alert fuel is specially formulated for engines like the Torq 16.
How To Stop Your Engine
You may have been wondering how to stop the engine. All you have to
do is pinch the fuel line that runs to the carburetor and from the bottom
of the fuel tank. Pinching this will restrict the fuel flow and the engine
will quit within a few seconds.
The First Tank
Your first tank of fuel should be running the vehicle at a very rich high-
speed needle valve setting. This allows the fuel to carry as much oil as
possible into the engine to lubricate the internal parts during the break-in.
1. Open the needle valve 2-3/4 turns from fully closed (counterclock-
wise). This is factory set already, but check it to make sure. When
closing the high-speed needle, close the needle until you feel
some resistance. DO NOT overtighten or you will damage the
engine.
2. Start the engine.
3. Once the engine is started, open the high-speed needle valve
around 1/8 turn at a time, finding the setting where the engine just
barely runs. This may take a few times adjusting the needle, run-
ning the vehicle away from you and back, then adjusting the nee-
dle. The vehicle will perform sluggishly and stall from time to time
- that is normal.
4. Run the vehicle back and forth at medium speeds, slowly acceler-
ating and decelerating the vehicle.
5. After a minute or two of running, make sure the engine is not over-
heating by putting a drop of water on the cylinder head and watch-
ing it boil away. If it boils away immediately, stop the engine and
allow it to cool. Open the high-speed needle around a 1/4 turn
before starting again. This is a good habit to get into every time
you run to ensure that the engine does not overheat during any
run. Looking at the smoke that comes out the exhaust is also an
indicator of how rich or lean the engine is running. If there is a
good amount of smoke coming out of the exhaust, then chances
are good that you are running rich.
6. Run the vehicle back and forth at a medium speed until the tank is
almost out of fuel. Do not allow the tank to run out of fuel. This
leans out the engine and can cause overheating (See How To Stop
Your Engine).
7. Stop the engine and allow the engine to cool before the second
tank. This normally takes around 10 minutes.
Tanks 2-6
Turn in the needle valve (clockwise) around 1/12 turn from the previous
setting. Run the vehicle back and forth. You should notice that the vehi-
cle will perform better during each run. Stop the vehicle periodically to
check for overheating. If it is too hot, stop the engine. Wait for it to cool,
then open up the needle valve 1/4 turn and restart. After the 6th tank,
you should be near to the peak performance of the engine.
RUNNING THE ENGINE
BREAKING-IN THE ENGINE
1/32" TO 1/16" GAP

10 Ways To Ensure A Long Life From Your Engine:
1. Keep your engine clean. Dirt will act as insulation on an engine. It
will not be able to shed heat as easily. Use a good air filter to keep
dirt out of your engine and clean it often.
2. Do not over-lean your engine.
3. Do not run your engine with little or no load. Don’t throttle up the engine
to full throttle when the wheels are not in contact with the ground.
4. Do not overheat the engine. This goes along with keeping it clean
and not over-leaning the engine.
5. Do not use a fuel with a low oil content. Make sure you use a fuel
from a reputable manufacturer, such as DuraTrax Red Alert.
6. Avoid using old fuels in the engine. Always run all of the fuel out of the
engine. After running for the day, use an after-run oil and work it into
the engine by turning the flywheel or pulling the engine recoil slowly.
7. Do not use a fuel with a nitromethane (often called nitro) content
over 20%.
8. Do not scratch the piston or cylinder sleeve. Avoid jamming some-
thing into the exhaust port when removing or re-installing the
clutch or flywheel. Use a special tool called a crankshaft locking
tool (not included), which is installed in the glow plug hole.
9. Do not use silicone sealer on the engine joints. Silicone sealer
contains acetic acid, which is corrosive if it gets inside your engine.
10. Do not allow any water inside the engine. This sounds easy, but
temperature changes can cause
condensation inside the engine.
This is a good reason to use an after-
run oil. Store your engine
inside the house, not in a garage
or shed where there will be tem-
perature
extremes.
If you are having problems with your engine consult the engine
troubleshooting flow chart shown. The following are some poten-
tial problems.
Glow Plug
The glow plug is an item that will wear out and need replacement from
time to time. It is a good idea to remove the glow plug before your first
run, heat it and see how well it glows. You should see a bright orange
glow from the filament. If a coil or two will not glow or the plug will not
glow at all, replace the plug. If the engine quits when you remove the
glow starter, the plug might need to be changed, although this may be
because you are running too rich and need to screw in your high-speed
needle some. Look at the glow plug when you are running the engine.
If you see some bubbles coming from around the plug, replace the glow
plug (copper) gasket, or both the plug and gasket. The only real way to
test a glow plug is to replace it. Make sure you have a spare plug or two
on hand when you run the Torq 16.
Fuel
Fuel can go bad. The main ingredient in model fuel is methanol, which
is basically an alcohol. Alcohols can absorb water out of the air, so keep
your fuel jug capped at all times. Store your fuel out of the sunlight and
in a cool place. Bad fuel is one of the most difficult problems to diagnose
in engines. If you have tried everything you can think of to remedy an
engine that is not running correctly, try using some fresh fuel.
Fuel line is susceptible to pinhole leaks. You cannot see the hole in the
fuel line, but if you see air bubbles in the line going to the carburetor,
replace the fuel line. Another symptom of a leak in the fuel line is a
surging engine. The properly tuned engine will surge when the air bub-
bles hit the carb. It is basically leaning out the mixture.
To keep dirt out of the engine, use an inline fuel filter on the fuel line
running from the fuel tank to the carburetor. Dirt can get caught in the
needle seat and cause an inconsistent running engine. If you suspect
that some dirt has lodged itself in the carb, remove the needles and
clean the carb
with denatured alcohol or fuel. It can help to use com-
pressed air to blow out the fuel passages as well. Dirt can get into your
carburetor and engine through the air filter. Ensure that your air clean-
er has a good seal to the top of the carb. Periodically wash the air
cleaner foam element and re-oil the filter. Any air cleaner that has a torn
element or a bad seal should be replaced immediately.
Overheating
One of the worst things you can do to your engine is overheat it. The
oils that lubricate the engine are carried in the fuel. If your engine is set
too lean, there will not be enough oil in the engine to lubricate the inter-
nal parts. This will cause premature wear in the engine and cause dam-
age. We have talked about overheating in other parts of this manual,
but we want to stress the proper techniques to check for overheating.
The easiest way of checking the temperature of the cylinder head is
using one of the available temperature gauges. This will give you a
direct reading of the cylinder head temperature. Do not let the head
temperature exceed 220° Fahrenheit (104° Celsius). Another way of
checking the head temperature is to put a drop of water on the cylinder
head. If it boils away immediately, the high-speed needle is set too lean.
If the water boils away in 3-5 seconds, the engine is within proper oper-
ating temperatures. If the water boils away longer than 5 seconds, the
mixture is set rich which is preferable when breaking in the engine.
Otherwise lean the mixture some and retest after a minute of running.
ENGINE MAINTENANCE
27
18
19
20
20
21
22
23
24
11
6
10
3
4
971
8212 13 14 15 16 17 15
29
26
25
32 31 32
5
30
33
Carburetor
Complete
Stock # Description ...........................Includes
DTXG0300 Air Filter
DTXG0350 Crankshaft Front Bearing .............7 x 1
DTXG0360 Crankshaft Rear Bearing..............8 x 1
DTXG0400 Carburetor Dust Cover ...............25 x 1
DTXG0420 Carb Needle O-Rings...........27, 28 x 1
DTXG0440 Carburetor Complete
DTXG0450 Carburetor Screw .......................32 x 2
DTXG0466 Carb O-Ring ...............................31 x 1
DTXG0471 Connecting Rod............................4 x 1
DTXG0492 Cover Plate...........................13, 14 x 1
DTXG0494* Cover Plate Standard
DTXG0500 Cover Plate Gasket ....................13 x 1
DTXG0510 Cover Plate Screw......................15 x 4
DTXG0512*Cover Plate Screws Standard
DTXG0521 Crankcase ....................................1 x 1
DTXG0534 Crankshaft ....................................2 x 1
Stock # Description ...........................Includes
DTXG0535*Crankshaft Standard
DTXG0551 Cylinder/Piston Assembly .............3 x 1
DTXG0560 Drive Hub......................................9 x 1
DTXG0583 Heatsink Head........................6, 10 x 1
DTXG0591 Heatsink Head Gasket................10 x 1
DTXG0600 Heatsink Head Screws .................11 x 4
DTXG0605 Idle Needle .................................26 x 1
DTXG0607 Idle Needle O-Ring.....................33 x 2
DTXG0615 Needle Set................19, 21 x 1, 20 x 2
DTXG0620 Needle Valve ..............................18 x 1
DTXG0641 Piston Pin .....................................5 x 1
DTXG0750 Recoil Starter........................16, 17 x 1
DTXG0760 Starting Shaft ..............................12 x 1
DTXG0800 Throttle Arm..........................29, 30 x 1
DTXG0810 Throttle Stop Screw ..........22, 23, 24 x 1
*Optional
Exploded View and Parts List

ENGINE TROUBLE SHOOTING
The engine starts
Does the engine
turn over easily?
Does it run con-
tinuously?
Is fuel getting to
the engine?
Check for clogging in
the carburetor or fuel
line. Press the
primer pump and
check for fuel spray-
ing out of the fuel
line. If so, replace
the fuel line.
Is fuel in the
fuel line?
Is the glow plug
red hot?
Check the high speed needle
setting and prime the engine.
Is foreign matter
clogging the fuel
tank or fuel line?
Is the battery for
the glow plug
clip charged?
It should be
ready to go.
Is the high
speed needle
setting 2 to
2-1/2 turns out
from closed (if
the engine is
broken-in?)
Try starting the
engine again.
NO
NO
NO
NO
YES
YES
YES
YES
YES
Does the engine
quit when the
glow plug clip is
removed?
YES
YES
Clear the engine
of fuel.
NO
Reset the high
speed needle.
YES
NO
Replace the
glow plug.
Check that the
pressure line is
connected to the
muffler. The fuel
may be bad.
The engine does not start
NO
Does the engine
turn over easily
with the glow
plug removed?
The engine may
be flooded.
Clear the engine
of fuel.
YES
Check that
nothing is
caught in the
engine. Check
that the the
pull starter
operates
smoothly.
NO
Press the
primer pump
and check for
fuel spraying
out of the fuel
line through a
small hole. If
so, replace
the fuel line. YES
Remove the
obstruction from
the fuel tank or
fuel line.
NO NO Charge or
replace the
batteries.
YES
Replace the
glow plug.
Try starting the
engine again.
Entire Contents Copyright © 2000 DTXZ2601 for DTXG0210