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What I wrote above is incorrect about the fuel returning to tank. Read here: MEP 002A and 003A - Steel Soldiers::Military Vehicles Supersite Have you checked the check valve?

Is the fuel shutoff solenoid working correctly? I thought the return line was on the output side of the injector pump. You might just have air in the system or your injector pump might need attention. I haven't gotten that far with my 003, yet, but will soon.

In theory, you SHOULD be able to disconnect all the wires from the head and not do any harm. But, I cannot be 100% sure about not damaging the VR. If it starts, though, it should be fine. Just don't let it run slow for any length of time. Start it, give it a few seconds to get up to 1800 or...

If the batteries can start your Deuce, then they should be able to spin the 003 with no problems. Make sure your wiring and connections are good. A bad wire or connection can cause similar symptoms. I'm still pretty sure the gen head should spin freely at startup. Even if the field is...

I don't think you should get any kind of drag on the gen head at starting speeds. Maybe a shorted field coil or something was drawing too much current and making the starter turn slower? I think every time you start a MEP genset if sends 24V to the field to "field flash" the set. I do not...