Thank you for choosing a Magnum XLS series aircraft engine. The XLS .61A is a single cylinder, two-cycle engine incorporating ABC (Aluminum piston, Chrome plated Brass sleeve) technology for long life, high power output and easy break-in. A dual needle valve carburetor with a remote high speed needle valve for precise fuel/airflow metering is standard. The XLS .61A also features a dual ball bearing-supported crankshaft, a dual bushing-supported connecting rod and a high-flow, noise-reducing muffler. Your Magnum XLS series engine was designed by expert engineers and built by master craftsmen using only the highest quality materials and CNC machinery. These qualities provide the long life and dependability you have come to expect from an engine of this caliber. ● Keep spectators, especially small children, at least 20 feet away from the engine while it is running.

● Mount the engine securely in the airplane or on a suitable engine test stand to run the engine. Follow the mounting instructions in your kit's instruction manual or on the plans for individual mounting recommendations. Do not clamp the engine in a vise to test-run it.

● Use the recommended size propeller and follow the proper procedure for mounting the propeller. Use the correct size wrench to tighten the propeller nut. Do not use pliers.

● Inspect the spinner, propeller, and propeller nut on a regular basis, looking for any signs of nicks, cracks or loosening.

● To stop the engine, adjust the throttle linkage to completely close the throttle barrel and therefore cut off the fuel/air supply. You can also pinch the fuel line to stop the engine, but only if it is accessible. Do not throw anything into the spinning propeller or attempt to use your hands to stop the engine.

● While the engine is running, stand behind the engine to make any adjustments to the needle valves. Do not reach over or around the propeller. Do not lean toward the engine. Do not wear loose clothing or allow anything to be drawn into the spinning propeller while the engine is running.

● If you need to carry your model while the engine is running, be conscious of the spinning propeller. Keep the airplane pointed away from you and others at all times.

● Do not use a tight-fitting cowling over the engine. It can restrict air from flowing over the engine, which could result in engine damage from overheating. For proper cooling, the total cowling air-exit area should be 30% greater than the total air-intake area.



### 1 Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: (714) 963-0329 Fax: (714) 964-6236 Email: service@globalhobby.net Displacement

................................................................ 9.94cc (0.607ci)
Bore

.............................................................................. 24mm
Stroke

........................................................................... 22mm
Practical RPM

..................................................................... 2,000 - 16,000rpm Weight w/Muffler

........................................................... 22.5oz

l ABC Piston and Sleeve

l Dual Ball Bearing-Supported Crankshaft

l Dual Bushing-Supported Connecting Rod

l Lightweight, High Power Output

l Rear Needle Valve Assembly for Safe Tuning

Engine Orientation Your XLS series engine can be oriented in any position on the firewall. Keep in mind that when the engine is mounted inverted, carburetor adjustments will need to be made differently and the fuel tank may need to be lowered. (See fuel tank size and orientation to carburetor on the next page.)
Engine Bolts and Firewall Requirements The engine should be mounted to either a glass-filled nylon engine mount, a machined aluminum engine mount or an integrated hardwood beam mount. Use only high-quality 5/32" (4mm) steel cap screws and related hardware to mount the engine to the engine mount. The firewall in the airplane should be aircraft grade plywood no less than 1/4" (6mm) thick and the firewall should be reinforced to meet the torque and weight of the engine. SPECIFICATIONS AND FEATURES

INTRODUCTION

BECOMING FAMILIAR WITH YOUR ENGINE If you are familiar with the operation of model engines or just can't wait to run your new engine, please read through the included Quick Start Guide. This guide will help you get started right away and also includes some good recommendations. We do recommend reading through these operating instructions in their entirety to familiarize yourself with the features and operation of your new engine. We have also included a Troubleshooting Guide should you encounter any problems.

ENGINE INSTALLATION 

# XLS .61A

Rear Needle Valve

Aircraft Engine

P/N 210770

Muffler Muffler Cone

Cylinder Head

Carburetor Assembly

Crankshaft

Propeller Nut and Washer Drive Washer Crankcase Fuel Nipple

Idle Stop Screw Throttle Arm Detent Spring High Speed Needle Valve

Low Speed Needle Valve

Due to running manufacturing changes and improvements, your engine may

differ slightly from that shown. Fuel Nipple Needle Valve Plug

CAUTIONS AND WARNINGS Magnum XLS series model airplane engines will consistently give you dependable performance and reliability and will be a source of satisfaction and pleasure if you follow these instructions as to the engine’s proper and safe use. You alone are responsible for the safe operation of your engine, so act sensibly and with care at all times. This Magnum XLS series model airplane engine is not a toy. It is a precision-built machine whose power is capable of causing serious injury to yourself and others if abused or misused, or if you fail to observe proper safety precautions while using it. CAUTIONS AND WARNINGS, CONTINUED.... 

### Visit Our Website at http://Magnum.GlobalHobby.com 

# OPERATING INSTRUCTIONS

### 2 Using a 5/16" (8mm) drill bit or a propeller reamer, enlarge the hole in the propeller hub to fit the crankshaft. The diameter of the crankshaft is 5/16" (8mm). Slide the propeller onto the crankshaft, up against the drive washer, then slide the propeller washer up against the propeller and thread the propel

ler nut into place. Tighten the propeller nut firmly to secure the propeller into place. When tightening the nut, use an adjustable wrench. Do not use pliers.

WARNING If you are installing a spinner onto your engine, the spinner cone must not rub against the propeller. Allowing the spinner cone to rub against the propeller could lead to propeller damage and eventual propeller failure. NOTE: PROPELLER SHAFT THREAD SIZE IS 5/16-24. Fuel Tank Size and Orientation to Carburetor Ideally, the stopper in the fuel tank should be level with the high speed needle valve or just slightly below it. Some models will only allow the fuel tank to be mounted higher than the ideal location. A fuel tank that is positioned higher than the ideal location usually doesn’t pose any problem except when it is mounted excessively higher and/or is used in conjunction with an inverted mounted engine or during extreme aerobatic flight. If you mount the engine inverted, we strongly suggest lowering the fuel tank so the stopper assembly is slightly below the high speed needle valve. Doing this will prevent fuel from siphoning into the engine and flooding it when the fuel tank is full. If you cannot lower the fuel tank far enough, we suggest lowering it as far as can be allowed in your particular application.
The size of the fuel tank used should be 10oz. - 14oz., depending on the model and the length of flights desired. Use of a 14oz. tank will provide approximately 15 minutes of run time at full throttle. Use of a fuel tank any larger than 14oz. can lead to excessive leaning of the engine during flight and is not recommended.

Carburetor Installation Slide the base of the carburetor into the crankcase, being careful to line up the mounting holes in the carburetor with the holes in the crankcase. Push down firmly on the carburetor so that the base of the carburetor sets completely into the crankcase. An o-ring is installed on the carburetor throat to seal the joint. While holding the carburetor down firmly, install and gently tighten the two socket-cap

screws (A) to hold the carburetor securely in place.

Muffler Installation The muffler is mounted to the engine using the two long socket-cap screws, two split washers and one of the two gaskets provided. The second gasket should be kept as a spare. Tighten both screws firmly to prevent the muffler from loosening during flight. The exhaust cone on the back of the muffler can be adjusted to better match the installation of your particular application. To adjust the exhaust cone, loosen the retaining nut (A) , rotate the exhaust cone to the desired angle, then tighten the retaining nut firmly while holding the axial bolt (B) in place from the front of the muffler. It is important to tighten the retaining nut firmly to prevent the exhaust cone from loosening during flight. Adjusting the Idle Speed (Idle Stop Screw) The idle stop screw adjusts the closure of the carburetor barrel. The idle stop

screw (A) should be adjusted so that the carburetor barrel is allowed to close completely, so that the engine can be shut off using your transmitter. To adjust the idle stop screw, first loosen the hex nut, then turn the idle stop screw clockwise to make the carburetor barrel stay open more or turn the idle stop screw counterclockwise to make the carburetor barrel close more. When satisfied with the setting, tighten the hex nut firmly to lock the idle stop screw in place.

Needle Valve Extension If an extension is required to adjust the high speed needle valve, use a 1.5mm diameter wire of the necessary length (not included). Loosen the grub screw in the side of the needle valve using a 1.5mm hex wrench, insert the wire into the end of the needle valve, then tighten the grub screw firmly. If the extension is more than a few inches long we recommend supporting the outer end of the extension to prevent excessive vibration.

Adjusting the Throttle Arm Position The throttle arm angle can be adjusted to better suit your particular application. Loosen the throttle arm retaining nut with an adjustable wrench, adjust the angle of the throttle arm either forward or backward, then firmly tighten the retaining nut. Propeller Installation

WARNING Before installing the propeller it must be balanced. Running your engine using an out-of-balance propeller can lead to excessive vibration, which will result in excessive stress and wear on both the engine and the airframe. Balance the propeller using the method recommended by the propeller manufacturer. Several products are available to properly balance propellers. Ask your local retailer for more information about these items. Optional Standard Needle Valve Installation It is not necessary to use the rear-mounted needle valve assembly with your engine. You can mount the needle valve into the side of the carburetor if you wish. Using an adjustable wrench, carefully loosen and remove the plug from the side of the carburetor. Carefully loosen and remove the needle valve assembly (including the clear gaskets) from the rear needle valve mount. Carefully thread the needle valve assembly (with the clear gaskets in place) into the side of the carburetor and tighten it securely using an adjustable wrench.

Rear Needle Valve Assembly Installation Mount the rear needle valve assembly to the back of the engine, using the two longer socket-cap screws and split washers (A) packaged with the rear needle valve assembly, then install the length of silicon fuel line (B) between the rear needle valve assembly and the carburetor. The fuel pick-up line from your fuel tank will connect to the larger brass nipple on the rear needle valve assembly.

Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: (714) 963-0329 Fax: (714) 964-6236 Email: service@globalhobby.net

### 3 Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: (714) 963-0329 Fax: (714) 964-6236 Email: service@globalhobby.net Your XLS series engine can be started using an electric starter or it can be started by hand. For safety and ease of starting, especially when the engine is new, we recommend using an electric starter. The following two procedures should be done with the power to the glow plug off.

WARNING ABOUT ENGINE HYDRO-LOCKING If the engine becomes hydro-locked, do not force the propeller through the compression stroke. The excess fuel should be expelled from the engine.

● Completely close the high speed needle valve until it bottoms out, then remove the glow plug from the cylinder head.

● With a rag over the top of the engine, turn the crankshaft several times, using your electric starter or flipping the propeller by hand. The excess fuel will be expelled out of the engine and into the rag.

● Check to make sure that the glow plug has not been fouled, then reinstall it and reset the high speed needle valve. PROPELLER, GLOW PLUG AND FUEL
Propeller Recommendation The diameter and pitch of the propeller needed for the XLS .61A engine will vary greatly depending on the application the engine is used in. The weight, drag, type of model, and how you intend to fly it are all factors in determining the correct size propeller to use. Experimentation will be necessary to find the optimal size propeller for your particular application. Ideally you want a propeller that the engine will turn in the 10,000 - 14,000 rpm range on the ground, yet power the airplane sufficiently. Using a propeller that is too small will cause the engine to run at too high an rpm. Using a propeller that is too large will cause the engine to run at too low an rpm, cause it to lug down too much and make tuning difficult. In both instances this can lead to premature engine wear and eventual failure.

P ropeller S ize R ecommendations



### Use for Break-In 11 x 7 11 x 8

12 x 6 12 x 7

13 x 4

Glow Plug Recommendation
Glow plugs can make a big difference in the performance of your engine. We recommend using a long-reach, hot heat-range glow plug intended specifically for two-stroke engines. Do not use a cold heat-range plug. This can lead to erratic engine runs, difficult tuning and eventual engine
wear and failure.

Fuel Recommendation Fuel can make a big difference in the way your engine performs. We recommend using two types of fuel with the XLS .61A engine. For the break-in period you should use a fuel containing no more than 15% nitro methane and no less than 18% Castor/synthetic blend lubricant. Use of fuel containing more than the recommended percentage of nitro methane or only synthetic lubricants will cause the engine to run too hot and result in excessive wear and engine failure in a very short period of time. Once the engine has been adequately broken in (about 1/2 gallon of the recommended break-in fuel), we still suggest using 15% nitromethane fuel, although a fuel containing up to, but no more than, 30% nitro methane and no less than 18% Castor/synthetic blend lubricant can be used. Remember though, when using higher nitro-content fuels, the engine will run hotter and its useful life will be shortened. You must also be careful when leaning out the engine.

WARNING We do not recommend using fuels that contain only synthetic lubricants. Synthetic lubricants have a much lower flash point than Castor Oil lubricants. Flash point is the point at which the lubricant begins to actually burn and lose its lubricating qualities. Using fuels containing a blend of Castor Oil and synthetic lubricants results in an engine that runs cooler and lasts longer. One lean run using a fuel containing only synthetic lubricants can cause engine failure. Using fuels with a Castor Oil and synthetic blend of lubricants greatly reduces this chance.

HIGH AND LOW SPEED NEEDLE VALVES
High Speed Needle Valve The high speed needle valve is used to meter the air/fuel mixture at full throttle. Turn the needle valve clockwise to lean the mixture or turn the needle valve counterclockwise to richen the mixture. When you start the engine for the very first time the needle valve should be turned in completely, then backed out 2-1/2 turns. When you start the engine after that, leave the needle valve in the same position it was in when you shut down the engine. Low Speed Needle Valve The low speed needle valve is preset from the factory for initial starting and break-in. Do not adjust it until after the engine is broken in. The low speed needle valve regulates the air/fuel mixture at idle and during transition from idle to full throttle. Turn the needle valve clockwise to lean the mixture or turn the needle valve counterclockwise to richen the mixture. The low speed needle valve is preset from the factory, but minor adjustments may need to be made after the engine is broken in. To reset the low speed needle valve to the factory setting, follow these procedures:

● Open the carburetor barrel completely.

● While holding the carburetor barrel open, turn the low speed needle valve IN ( clockwise) GENTLY until it stops. From this point, while still holding the carburetor barrel open, turn the low speed needle valve OUT (counter-clockwise) 5 full turns. This is the factory setting.

WARNING It is possible to adjust the low speed needle valve so lean that the engine will not draw fuel. The low speed needle valve should not need to be adjusted more than one full turn in either direction from the factory setting. If the engine does not idle or transition, reset the low speed needle valve to the factory setting.

STARTING PROCEDURE

Starting Using an Electric Starter
When using an electric starter it is not necessary to choke and prime the engine. The starter turns the engine over fast enough that the engine draws fuel on its own. Priming the engine prior to using an electric starter can cause the engine to "hydro-lock" or flood. This is a result of too much fuel in the engine before it actually fires. Turning the engine over with an electric starter while the engine is flooded can cause extreme damage to the engine and/or cause the propeller assembly to come loose. Turn the propeller through the compression stroke one time by hand to check for a hydro-locked state before applying the starter.
Starting by Hand
When starting the engine by hand always use a chicken stick or a heavy leather glove. Never just use your bare hand or serious injury could result. To make the engine easier to start by hand it should first be primed. This is done by opening the carburetor barrel completely and covering the tip of the muffler with your finger. Fuel can then be drawn into the engine by "pulling" the propeller through the compression stroke 2 - 3 times. This will draw fuel into the engine. After fuel begins to enter the carburetor, remove your finger from the muffler and pull the propeller through the compression stroke once to check for a hydro-locked condition.

### 4 IMPORTANT Your XLS series engine is an ABC engine. The cylinder sleeve is tapered at the top, causing severe resistance when the piston moves through the top of the stroke. This is normal. When the engine heats up to operating temperature, this resistance will decrease and the proper clearance will be achieved. The break-in procedure will guide you through the steps necessary to properly break in your new ABC engine. Please follow the steps in this section closely.
The break-in process allows the engine parts to perfectly fit each other and properly protect each part from premature wear. The engine should be broken in using a fuel that contains 15% nitro methane and no less than 18% Castor/synthetic blend lubricant. Fuel containing only synthetic lubricants should not be used during the break-in procedure. For the break-in procedure we recommend mounting the engine into the airplane it will be used in. This way the muffler, fuel tank and throttle linkage can all be tested in combination with the engine. If your airplane uses a cowling, it should be removed during the break-in procedure.

❑ 1) Turn the high speed needle valve out 2-1/2 turns from the fully closed position.

❑ 2) If you are using an electric starter to start the engine, follow the procedure in the previous section. If you are starting the engine by hand, follow that procedure in the previous section.

❑ 3) Open the throttle barrel to approximately 1/4 throttle. Connect the power to the glow plug. Start the engine using an electric starter or by hand. If starting by hand you will need to vigorously flip the propeller through the compression stroke several times before the engine will start.

❑ 4) Once the engine starts, open the throttle barrel to about 1/2 throttle. You may need to lean the high speed needle valve in about 1/4 turn to keep the engine running at half throttle.

❑ 5) After the engine has been running about 1 minute, remove the power from the glow plug and slowly advance the throttle barrel to full throttle. Adjust the high speed needle valve so that the engine is running very rich. You should notice excessive white smoke coming from the exhaust. Let the engine run for approximately 10 minutes then stop the engine.

❑ 6) Let the engine cool for approximately 10 minutes then restart it. Set the high speed needle valve mixture to a slightly leaner setting, about 1/4 turn more in. Let the engine run for about 5 minutes at this setting, then stop the engine and let it cool for approximately 10 minutes.

❑ 7) Repeat the procedure in step # 6, while leaning the needle valve slightly more each time. In all, you should run the engine about a total of 45 minutes of actual running time. After 45 minutes of run-time the engine is ready for flight. Fly the airplane with the engine set as rich as possible, but with adequate power to fly the airplane. After each flight, lean the mixture slightly. Continue to do this for about 5 flights. 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.

Now that your engine is broken in, you can set the high and low speed needle valves for optimum performance.

WARNING Be careful never to lean the engine out too much. Remember that the lubricants for your engine are suspended in the fuel. If you lean out the fuel mixture too much you will also be lowering the amount of lubricant entering your engine. Less lubricant means more chance of your engine overheating and possible engine failure. Information about returning your engine for warranty service, can be found on the separate sheets packaged with these Operating Instructions.
Magnum XLS series engines are distributed exclusively in North America and South America by Global Hobby Distributors 18480 Bandilier Circle, Fountain Valley, CA 92708
All contents copyright © 2006, Global Hobby Distributors Revision 1 November 2006 BREAK-IN PROCEDURE

OPTIMIZING THE MIXTURE SETTINGS Setting the High Speed Needle Valve

❑ 1) Start the engine and remove the power from the glow plug. Allow the engine to warm up for about 30 seconds.

❑ 2) After the engine has warmed up, slowly lean the high speed mixture until the engine reaches peak rpm. After reaching peak rpm, richen the mixture slightly until an audible drop in rpm is heard. If you are using a tachometer this should be between a 200 - 300 rpm drop.

❑ 3) With the engine running at full power, carefully lift the nose of the airplane about 45o into the air. The mixture should not become too lean, but you may hear a slight increase in rpm. If the engine sags, or loses rpm when you hold the nose up, the mixture is too lean. If this is the case, slightly richen the mixture and follow the test once more.

IMPORTANT Rpm will increase about 10% - 30% in the air. This is due to the forward motion of the aircraft as it is flying. Because of this, more air is entering the carburetor, at a higher force, which causes the mixture to lean out. Additionally, as the fuel level in the fuel tank goes down, fuel draw becomes more difficult for the engine, especially during aerobatics, thus causing the mixture to go lean. It is imperative that you set the mixture rich while on the ground to compensate for the leaning tendencies that will happen in the air. Always watch the exhaust during your flight. The engine should leave a noticeable white smoke trail at all times. If there is no smoke trail, the engine is running too lean. You should land immediately and reset the mixture.

Setting the Low Speed Needle Valve

❑ 1) Start the engine and lean out the high speed needle valve as per the previous steps. Close the throttle until the slowest reliable idle is reached. Allow the engine to idle for about 15 - 20 seconds.

❑ 2) Quickly advance the throttle to full. If the engine just stops running as soon as the throttle is advanced, the idle mixture is too lean. With the engine stopped, richen the idle mixture about 1/8 of a turn.

❑ 3) Repeat steps # 1 and # 2 until the engine will transition from idle to full throttle smoothly. Minor hesitation in the transition is normal.

❑ 4) If you quickly advance the throttle from idle to full and the engine seems to be very rich during transition (i.e., lots of smoke coming from the exhaust), the mixture is too rich. With the engine stopped, lean the idle mixture about 1/8 of a turn.

❑ 5) Repeat steps # 1 and # 4 until the engine will transition from idle to full throttle smoothly. Minor hesitation in the transition is normal.

● Avoid running the engine under dusty conditions. If you are in a dusty environment we suggest using an air filter over the carburetor.

● At the end of every flying day, purge the engine of fuel by disconnecting the fuel line and allowing the engine to run dry of fuel.

● Use a high quality after-run oil in the engine after you have purged the engine of fuel. Inject the oil into the engine through the carburetor and through the glow plug hole. Rotate the crankshaft several times to distribute the oil throughout the engine. This will prevent the engine from forming rust.

● Periodically check to make sure all of the engine bolts are tight. ENGINE MAINTENANCE

Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: (714) 963-0329 Fax: (714) 964-6236 Email: service@globalhobby.net For service in other countries, please contact your local dealer or Magnum Engines Agent in your country.OUR RECOMMENDATIONS
The following items are recommended for use with your Magnum XLS series aircraft engine. These items are recommended for initial start-up and running. Please read through the Operating Instructions for further
details.



### Fuel: We suggest Power Master 15% 2-Stroke Blend (P/N 275198) for break-in.
We suggest Power Master 15% 2-Stroke Blend (P/N 275198) for normal use.
We suggest using Power Master brand fuels. Power Master fuel comes in many different nitromethane contents that can be used in your XLS series engine. Power Master fuels are blended using only high-quality nitromethane, methanol, Castor Oil and synthetic lubricants to provide high power output, along with easy starting and unmatched lubricating and heat dissipation qualities. For the lower nitro content necessary for break-in and for normal use, too, use 15% 2-stroke blend. After break-in, for extra performance, you can use up to 30% 2-stroke blend. For more information about using 30% fuel, please refer to the Operating
Instructions.



### Fuel Tank: Dubro 14oz. Fuel Tank (P/N 568543)
Dubro fuel tanks are a perfect match for your XLS series engine. This size recommendation will give you about 15 minutes of run-time at full throttle. Dubro fuel tanks are possibly the easiest fuel tanks to assemble
and maintain.



### Glow Plug: Thunderbolt # 3 Glow Plug (P/N 115559)
The Thunderbolt # 3 glow plug is designed to be used in high-performance engines using fuels containing 10% - 30% nitro content and in any environment. It is a "hot" type of glow plug for easy starting, excellent transition and incredible top end. The glow plug is also very durable and able to withstand repeated use, day after day.



### Propeller: APC 11 x 7 Propeller (P/N 608570)
We have found that XLS series engines run best using APC brand props. They are designed to be very efficient and run quiet at high rpm’s, and they are also durable. Use this size prop to break in your engine, then change to the prop that best suits your application. Use the guide in the Operating Instructions to help you find the right size propeller.



### Glow Starter: Flight Leader Glow Starter w/Meter (P/N 404024)
The Flight Leader glow starter is an excellent choice for heating the glow plug. It uses a 2400mAH NiCD battery, includes a meter to determine the quality of your glow plug, and it also includes a charger to recharge the battery. It’s very economical and can be used with most glow aircraft engines. 

# XLS .61A AIRCRAFT ENGINE QUICK-START GUIDE

The following information is provided to get your new Magnum XLS series engine running right away with minimal effort. We have listed our recommendations for fuel, propeller, starting procedures and other recommended accessories. Also included is general information about the accessories needed for the engine that we hope you will find helpful.
This Quick-Start Guide should not be used as a replacement for the Operating Instructions included; rather, it should be used along with the Operating Instructions. We highly recommend reading through the Operating Instructions to familiarize yourself with each part of the engine, along with the proper procedures for engine break-in and tuning.



### Engine Mount: Magnum Adjustable Engine Mount (P/N 279951)
The Magnum Adjustable Engine Mount is a glass-filled reinforced nylon beam mount that mounts onto a plywood firewall in the model. It is lightweight, strong, easy to install and features adjustable width.

Engine Preparation

❑ 1) Mount the engine to the recommended engine mount. A wood beam mount built into the airframe would also be sufficient.

❑ 2) Install the carburetor, rear needle valve assembly and muffler onto the engine using the hardware provided. The muffler cone can be rotated to better suit the installation in your model. Be sure to tighten the nut securely to prevent the muffler cone from loosening.

❑ 3) Install the propeller to the engine using the propeller nut and washer provided. Tighten the nut securely using an adjustable wrench.

❑ 4) Connect the fuel lines from the fuel tank to the engine. The fuel pick-up line should be connected to the fuel nipple on the rear needle valve assembly and the pressure line should be connected to the pressure nipple on the muffler.

Engine Starting

❑ 1) Carefully turn the high speed needle valve in completely until it stops, then turn the needle valve out 2-1/2 turns. This is the mixture setting for initial starting. Do not readjust the low speed needle valve.

❑ 2) If hand starting, prime the engine by opening the throttle barrel completely, placing your finger over the carburetor opening and flipping the prop through compression 2 -3 times. If you will be using an electric starter, do not prime the engine. The starter will turn the engine over fast enough to draw fuel on its own.

❑ 3) Connect the glow starter to the glow plug. Open the carburetor barrel to about 1/4 throttle and start the engine. If you are starting the engine by hand, you will need to vigorously flip the prop several times before the engine will start. Once the engine begins running, immediately turn the high speed needle valve in about 1/4 turn to keep the engine running.

❑ 4) Advance the throttle to full while turning the high speed needle valve in to keep the engine running. The engine should be producing a very noticeable white exhaust from the muffler and sound like it is running rough. Allow the engine to run only for about 5 minutes, then shut the engine off.

❑ 5) Now that you have started your engine, it must be properly broken in. Proper break-in will seat all of the moving parts, particularly the piston and cylinder. This procedure takes about 20-30 minutes of run-time and is highly recommended. An engine that is properly broken in will produce more power, be more user-friendly and last much longer than an engine that does not receive a break-in period. For this reason we highly recommend following the break-in procedure detailed in the Operating Instructions before you run the engine further. QUICK-STARTING PROCEDURES

Troubleshooting and Warranty Information on Back

# XLS .61A AIRCRAFT ENGINE TROUBLESHOOTING GUIDE

This troubleshooting guide has been provided to help you diagnose and solve most problems that you may encounter with your XLS series engine. Most problems encountered can be solved by carefully following the problem-cause-solution sections below. If you cannot solve the problem using this troubleshooting guide, please feel free to contact us using the information below.



# WARRANTY INFORMATION

All Magnum engines returned for warranty service must be within the warranty terms as stated on the warranty card provided with your engine. Do not return the engine to the place of purchase. They are not authorized or equipped to perform warranty work on Magnum products. For warranty service in countries other than within North and South America, please contact your local dealer or Magnum Engines Agent in your country. When requesting warranty service, please observe the following guidelines:

● Always send the complete engine including the carburetor and muffler . The engine must be removed from the model.

● Include a note detailing the problem or service you are requesting. Service cannot be provided without this information. Include your Email address and daytime phone

number in the event we need more details pertaining to the service requested.

● You may request an estimate of services at the time you return your engine for service. An omission of this request implies permission for the Magnum Service Center

to service your engine at our discretion.

● Include a method of payment for any service charges.

● Send the engine to us by United Parcel Service, Federal Express or by Insured Mail. Postage is not refundable. Send to:

Global Services ● 18480 Bandilier Circle ● Fountain Valley, CA 92708 Phone (714) 963-0329 ● Fax (714) 964-6236 ● Email: service@globalhobby.net 1) Engine does not start A) Failed glow plug A) Replace glow plug with new one B) Glow starter not charged and/or faulty B) Fully charge glow starter and/or replace C) Engine not being turned over fast enough C) Use an electric starter to start engine D) Low speed needle valve set too lean D) Reset low speed needle valve to factory setting E) Old or contaminated fuel E) Replace with new fuel F) Engine flooded with too much fuel F) Remove glow plug and expel fuel from cylinder G) Faulty fuel tank and/or stopper assembly G) Check and/or replace fuel tank assembly H) Air leak in fuel system and/or engine H) Replace fuel lines and/or tighten all engine bolts

2) Engine does not draw fuel A) Air leak in fuel system and/or engine A) Replace fuel lines and/or tighten all engine bolts B) High speed needle valve fully closed B) Reset high speed needle valve to factory setting C) Low speed needle valve set too lean C) Reset low speed needle valve to factory setting D) Fuel lines kinked D) Check and straighten fuel lines E) Defective fuel tank E) Replace fuel tank

3) Engine vibrates excessively A) Propeller out of balance A) Balance propeller B) Engine and/or engine mount loose B) Tighten engine mounting bolts

4) Engine does not transition A) Failed and/or wrong type glow plug A) Replace with new recommended glow plug B) Old and/or wrong type fuel B) Replace with new recommended fuel C) High speed needle valve set too rich C) Set high speed needle valve to leaner setting D) Low speed needle valve set too lean D) Set low speed needle valve richer E) Low speed needle valve set too rich E) Set low speed needle valve leaner F) Air leak in fuel system and/or engine F) Replace fuel lines and/or tighten all engine bolts G) Propeller too large G) Replace with one size smaller propeller

5) Throttle barrel does not A) Idle stop screw and/or throttle servo linkage out A) Adjust idle stop screw and/or throttle linkage to close close completely of adjustment throttle barrel completely

6) Engine overheats A) Engine running too lean A) Richen high speed needle valve B) Cowl too restrictive B) Open larger vents in cowling to allow air to exit C) Wrong type of fuel used C) Use fuel with recommended oil content D) Engine not fully broken in D) Allow engine further break-in time

7) Engine stops abruptly A) Engine running too lean A) Richen high speed needle valve B) Piston and sleeve out of tolerances B) Return engine to Global Services C) Engine Overheating C) See # 6 above PROBLEM CAUSE SOLUTION

# XLS .61A AIRCRAFT ENGINE EXPLODED PARTS VIEW

Revision 1 November 2006 Replacement parts can be ordered directly from your local Magnum Engine hobby retailer. If your hobby retailer does not stock Magnum engines, you can order direct from us.

Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: (714) 963-0329 Fax: (714) 964-6236 Email: service@globalhobby.net



### 282519 280155

Reference Numbers, Descriptions and a Dimensional Drawing are Listed on the Back Page280113 120609 Muffler Gasket Set (2)

280154 S61601 Muffler Assembly

280155 S61416 Gasket Set (Includes 281126 & 281218)

280214 61228 Propeller Nut and Washer Set

280308 61238X Drive Washer and Collet Set

280534 S61101 Crankcase

280616 S61102 Backplate

280947 S61203 Piston and Sleeve Set

281034 S61103 Cylinder Head

281126 S61112 Cylinder Head Gasket Set (2)

281151 400160 Sleeve Index Pin

281162 S91120 Muffler Bolt Set (2)

281163 91130 Split Washer Set (2)

281166 12862 High Speed Needle Valve Seat Assembly

281168 46871F Rear Needle Valve Plug

281173 32H811 Throttle Arm Retaining Nut

281218 S61111 Backplate Gasket

281412 61109 Front Ball Bearing

281421 S61210 Crankshaft

281504 61123 Rear Needle Valve Mounting Bolt Set (2)

281603 28134 Carburetor Retaining Bolt Set (2)

281715 120616 Muffler Axial Bolt and Nut Set

281811 46861F High Speed Needle Valve with O-Ring

281812 46860F High Speed Needle Valve Assembly

281814 61874F Rear Needle Valve Assembly ORDER # REFERENCE # DESCRIPTION

281815 61873F Rear Needle Valve Assembly Bracket

281901 12833 Detent Spring

281903 12847 High Speed Needle Valve Seat Gasket

282002 12819 Fuel/Pressure Nipple with Fiber Washer

282004 12114 Fuel/Pressure Nipple

282130 46814A Throttle Barrel Spring

282159 S32868F High Speed Needle Valve Plug

282202 12812 Throttle Arm

282310 46810F Low Speed Needle Valve with O-Ring

282405 91816 Carburetor Base O-Ring

282412 40845 Low Speed Needle Valve O-Ring

282452 46845F High Speed Needle Valve O-Ring

282501 91137 Fuel Nipple Fiber Washer

282511 61134 Backplate Bolt Set (4)

282519 120901 Screw Set (Includes 283123 & 282511)

282608 46837F Idle Stop Screw Set

283025 S61801F Carburetor Assembly - Complete

283026 S61863F Carburetor Body with Spray Bar

283027 61813F Throttle Barrel

283123 120123 Cylinder Head Bolt Set (6)

284037 400110 Rear Ball Bearing

284206 12830 High Speed Needle Valve Seat

284264 80204 Connecting Rod

280821 61213 Wrist Pin and Retainer Set ORDER # REFERENCE # DESCRIPTION 

# XLS .61A AIRCRAFT ENGINE PARTS LIST

XLS .61A AIRCRAFT ENGINE DIMENSIONAL DRAWING

A B C D E F G H I J K L M



### 3-13/16" 5" 3-5/32" 4" 15/16" 1-7/16" 1-5/8" 2" 2-3/8" 1-3/32" 1-5/8" 2" 1/2"