Associated Electrics Team Associated RC10 DS DUAL SPORT User manual

. .
DUAL SPORT INSTRUCTION MANUAL
Associated Electrics, Inc., 3585 Cadillac Ave., Costa Mesa, CA 92626
I
DO HOT DISCARD THIS MANUAL!
Use with current catalog for future,
hassle-free re-ordering
of parts
=:-- -== ~ ~
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MOLDEDCOMPOSITE SHOCK TOWER
STEALTH TRANSMISSION
WITH ATC SLIPPER
MOLDED SUPER-STIFFER
COMPOSrrE
SUSPENSION ARM , FRONT AND REAR
ADJUSTABLE REAR TOE IN
BLACK ANODIZED ALUMINUM TUB CHASSIS
SCALE BBS STYLE , CHROMED FRONT AND REAR WHEELS ________ _.._,
PROLINE M2 COMPOUND SCALE RACING
TIRES WITH
FOAM INSERTS
DAM
-·-

I
ADJUSTABLE FRONT
ANTI-ROLL BAR
ADJUSTABLE
SERVO SAVER
BELLCRANK STEERING
LOW KICK-UP ANGLE FOR
SUPERIOR STEERING RESPONSE
HIGH
IMPACT FRONT BUMPER
ADJUSTABLE HEIGHT BODY MOUNTS

_,;: ~ ~~:.IIIIF'~
CONCERNING YOUR
NEWRC10DS
We congratulate you on purchasing the ACt ODS Dua l
Sport kit. lfs a unique and fun vehicle thatisbased on themost
durable and provencaron themarket, theoriginal ACtO.Itdoes
notmatterif youhave thecomplete kit
or oneof theconversion
kits(thatconverts your ACtOorRCtOTto
the OS), you willfind
the ACt ODS to be afun, easy-to-dri ve and competitivecar.The
feature thatmakes ourcardifferent from ourcompetitofs
is the
d ua lsport aspect. This means we are offering two different s ty l es
ofbodies,for German DTM tou ring, or IMSATr ans Am rac ing .
T
he kits come with our race proven Stealth transmls·
sion,Associated'simpr oved shoc ks ,special Proline semi-pn~u
matic rubber on road tires with new scale chrome wheels (w1th
BBS style hub caps), and our special dual sport suspension
parts. Our two bushing kit sport versionsincludea mechani·
calspeedcontrol, stock motor,bronzebushings, and oneof two
body styles.
The racing version has ball bearings, hard anodi
zed
Teflon sealed shocks, and universal dogbane rear axles, but does
not includea
body, motor or speed control.
In add itionto th e above, the ACt ODS featur es: new front
and rear suspension arms, front and rear anti-ro ll bars, f ron t
and r ea rshockstruts, new body mounts, new chassis no se plate,
and aluminum tu bchassis.
M
any racers have olderACtO 's or RC1 ors Ihatare used
less often because th ey have switched to our ACtOB2 or
ACtOT2.Some may also justbelooki ng for someth ingdifferent
to run. The ACt ODS conversion kit allows you to convert toon
r
oad racing byusingyourexisting off road AC10orRCtOTchas·
sis,yourStealth tranny (or evan youroriginalAC10 tranny) and
a few otherpartsfromyouroldcar. (You cannotconvertfrom an
AC10B2 or AC10T2 .)
All of thiscombines tomakeoneof the mostversatile
and enjoyable cars we have everproduced. When you are fin·
ished you will find what 12 years ofAssociated off road history
has done foryourhobbyenjoyment.
PLEASE READ THIS BEFORE
YOU BEGIN
OurI nst ru ction manuals have been considered some of the best
IntheIndustryby both hobbyists and RIC magazine reviewers.
M
any ofourcustomers will feel they can build theirkit from the
photos alone. This is not true. In addition
to the detail in the
photos
you willlind importantassemblyinformation. While you
hav e one of our top quality kits the only way to have an as·
sembled carof top qualityIstofollow the Instructionsas well
as t he photos.
Step 1 OPE NEACH PART S BAG WHENTHEINS TRU C..
TIONS IN DIC ATE ,NOT BEFORE.Thisis to preventparts from
one bag gettingmixed upwith parts fromanother bag andhelps 4
make the assembly easier. Check the parts bags against the
parts li st el sewh e re in your kit. Many of your parts bags are
numberedor
named to help you match it to the appropriate sec-
tion on the parts li st or in the manual steps. Anybagsinsidea
labeled or numbered bag will sharethe samepartsbag name01
numberasthe one itcame out of.
Step 2 CHECK EACH BAG F OR SUPPLEMEN TARY
S HE ETS. Becau se Associated isalways working on new ideas
for designs or materials to imp r ove ourproducts, we will occa-
sionally make updates or changes to our kits.These changes
usuallydon'tappearinthe manualbecausethey were not avaJ.
able when the manual was printed. 1) Inspect each bag upoa
opening nfor the first time. Look for any sheets that Indicate
changes made to the kit. 2)When you find one, locate the sec-
lionof the manual and parts li st where this change applies. Use
the supplement or updatesheetto marka ny changestoa parts
bag inventoryli
st and then 3) secure the supplementary sheet
to the appropriate step in the manual. This will guarantee thai
you have th e in fo rmation concerning the change wh~n you be-
gin this step and will save time sothat you arenotlooking for the
wrong part in the partsbag.
Step 3 KEEP YOUR PA RTS SEPAR ATE. While building
yourcarit will
be necessary to have more than one parts bag
open at a
time. In order to prevent confusion we recommend
usinglarge paperplates(especially picnicplateswithpartitions)
to keep theparts from eachbag spread out so th at you can find
them easily. Markeach plate withbagnumbersbefore you place
the parts in th em.When you have used all the parts fr om abag
you can then rel abe l thepl ate so that It canbe used foranoth er
bag.
Step 4 ADDmONAL ITEM S NEE DED TO OPE RATEYO UR
CAR:
Q 2 Channel RIC surface frequency radio system. (Bush ing
kits requ i re two servos but ball bearing kits require only one
servo)
Q Battery pack (6cell) .
Q Batterycharger (we recommend theuseof a peak detection
charger)
THE
FOLLOWING ADDIT IONAL IT EMSARE NEEDED IFYOU
HAVE A BALL BEARING TEAM KIT:
Q El ect ronic Speed Control (also know asan ESC)
Q RIC elec tri c motor
Q Pini on Gear (48 pitch); size to be determined by type and
wind of
moto r you will be using.
Step 5 TOOLS. This kit contains the shock/turnbuckle
wrench
and the four Allenwrenches you will need to assemble
your car. You will need to supply the following tools and adhe-
sives:
0 Phillipsscrewd river, 12 tip(#SP-76)
Q 1/8"straightblade screwdriver,for bushing kits only
Q Need lenosepliers
Q Hobby knife, such as an X·actoC knife with a #11 pointed
blade.
Q Soldering iron (40 to so watt s), and a sma ll amountof rosi n
(not
aci d) core 60 /4 0 solder. We have found from experience

thatapencil type solderingironworks betterthan the more com·
monsoldering guns.While the gunsgeneratea lotofheat,they
have a hard time keepingthe heat at the tip.
0 Superglue (cyanoacry1ic glue) with safetyglolles and goggles
Your k~ can beassembled easi er and faster with the following
Assoc iated tools or their equivalents:
0 Allen drivers (straight Allen wrenches with hex shaped alu·
mlnum handle s), such as the follow ing by Associated:
#6957 .050'
#69581/16'
#69595/64'
116960 3132'
116961 2.5mm
0 3116' nu1 driver will make installing the S.S. ball ends and
small pattern 4-40
nu1s easier(IISP-86).
0 1/4' nut driverwi ll speed up installing the 1/4'1ocknu1s and
front wheel nuts (#SP-85).
0 11132" nul driverwill speed up insta ll ing the 8·32 rear axle
nuts (#SP·82).
0 Precision steel rule (optional), Vernier or dia l calipers (with
decimal
or metric measure).
WARNING /I Do not usea powerscrewdriver to installscrews
into plastic, nylon
or ccmposite parts. The rotation speed is to
fast, causing
the screws to heat up when being installed in to
these mat11rials and theycanstrip out or brea k.
Final Notes: (1)Experiencedbuilders or racers: please
buildthe car accor ding to the InstructionsflrstllThe OS isa
rema r kab ly fast carright outofthe box. There isa good reason
for everything on the car. Build itaccording
to the instructions
first.
Then you will have a solid performance base to use as a
comparison forwhen
you do make changes;thenyoucancheck
whereyou are gaining
or loosing performance.(2)At the begin·
ning of each step you will find a box (0 ). When you havefin·
ished that stepput a check markin the box. When you stop for
any reason during assembly it will be easier to find where you
need tocontinue from.
(3)Occasionallyan actual
size drawingwillaccompany
th e photo to he lp you identify certain parts. You can place the
part on top of the drawing to be su re you have picl<ed up the
right one. Also you will most likely end upwith some extra parts
and fasteners, sodonotworry. WARNI NG /Onlythedraw ing s
at the bottom of the photos are to true scale. None of the
phot os are actual size . Even though you may see dimen·
sions markedInthe photos , the photos aresUI/ not to scale
or actus /size.
(4)The following typesof specialInstructions,in oblique.
will beused throughou1 the manua l:
• Racer's Tip:This Is a trickusedby some of the Team Drivers
to Improve th eircar's handling, performance andmaintenance.
• Note: Alternate ways to assemble the kit, including tips for
smoothing outdifficultassemblies.
• WARNI NG / This alerts you to be careful in order to prevent
damaging the parts, and warns against using wrong parts or
doing an inccrrectassemblythat cculddamage or reduce the
parts'parformance. -
SAVETHISMANUAL! Thisismore than an instruction
manual .lt Is alsoahandysupplementto the Assoc iated RC1 ODS
5
parts catalog. You can use the manual photostohelpyou iden·
Iffypart numbers
and part names when orderingparts. In add/·
lion, themanualcan
be usedduringa technicalassistancecall
to the factory it )IOU arehaving assemblyproblems or haveany
questions.ContactCustomerService
at nuso-9342. Please
remember, it's not a race to see how fast you can put this car
together;
rather, it's how well you put this cartogether that will
determinehowwell
you race .DON'TRUSH.TAKEYOURTIME.
Now clear off your workbench, line up some paper
pl
ates. graba drink and sandwich, and lefsbeginI
_..~~~~:.-
FRONT END ASSEMBLY
tb Fig. 1Beforewestal1toassemblethefrontend, remove
the 118416 shock/turnbuckle wrench and the 116950 tool bag
(which contains the four Allen wrenches) from the
k~ master
bag. Set them aside for
now; we will be using these as we go
through the assembly.
.050" 1N6"
Fig. 1
TUR NBUCKLE
Ql(b! o . /
8416
ii Fig. 2 Nowlet'sstart by opening bag 118-1 and N8 ·14.1)
From bag NB-1 remove the 116210 ao• casterfrontcarrier blocks.
Both lheright and leftcarrierblocks are con nect ed as shownIn
fig. 2. 2) U se your X ·ac t ~ knife to separate the bl ocks and
carefully trim off all the runner materi al and between the two
steering block mounts. WARNING / Any flashingmaterielre-
maining between the two kingpin mountin g points can
cause t
he steering to bind.
3) Now you will need to remove two 116273 long S. S.
ball ends, two 117260 4-40 small th inplain nu1s. and the //6272
foam strip from bag
118-14 .
4) Lay out your carrier blocks as shown in the middle
part of fig. 2. Ifyou havetroubleseeing the difference,
the re Is
a ''L.:' and an "R" scribed into thelong sideofeach carrierblock.
5)
Th read the 116273 long ball end Into each carrierblock from
the outside, as itshows In the photo. There is a 3/16' wrench
areaon the
118416 shockturnbucklewrenchwhich you can use
to Install all of the ball ends
or the 4-40 small thin plain nuts.
No te : You canalsouse your needlenosepliers, but if you want
to
speed up theassembly we suggestthatyou use a 3/16" nut
driver(Associated
IISP-86) or socket If you useasocketvsea
screwdriverstylehandle, notaratchethandle. 6)Afteryou have

installedthe #6273 longballend thread onthe 117260 4·40 nuts
an d tighten.
7) Fourteen smalldonutshapes are cut In to the116272
foam strip. Wecall these ball end dust covers. Remove two of
thecovers and push the centerholeovertheballportion of the
116273 ball end. These help keep the dirt out of the ball end
cups, reducing the wear that normally occurs when dirt gets
inside.
,7260
rrlhnmn #6273 @ 4-40
~ 4-40 plain nut
Fig. 2
£Fig. 3 1) Goi ng back to bag 118 ·1 wewill nowremove the
two
11622 1 nylon steering bl ocks. 2) From bag 118 · 14 we will
need to remove two 116270 short S.S. ball ends, two #7260 4·
40 small thin pattern plain nuts, and two #6272 loam ball end
dust covers. The
116221 steering blocks will be the same until
we installtheball ends, then there willbearight and leftside. 3)
Thread one 116270 ball end into each steering block, but on
oppositesides.4) Nowthread on the two
4-40 nuts and tighten
them down.5) Nowinstall two
of theloam ball end dustcovers
overtheballsthe same as
we didin fig. 2.Whenyou are done,
yoursteering blocks will looklike ftg .3 and you will now havea
left
and rightsteeringblock. 6) Placethe rest olthe dustcovers
aside,lorthemoment,with bag
#8 - 14 ; we willusethem laterin
otherparts
of the manual.
@
#7260
rTflmn. #6270 4·40
'--'iF" 4· 40 plain nut
Fig. 3
6
~ Fig. 4 1) In bag 118 ·1 y ou will find two 116220 aluminum
inline front axles. The hole drilled in the axle is lor the steel
kingpin which you will insta ll in a couple of steps.2) In order to
install the kingpin easily, useyour X ·actO:O knffe to deburr and
bevel the outeredge of both sides of the hole.
3) Nowwe want to take one axle and litk Into one a1
the steering blocks. Do oneaxle, then theother. Makesure lhe
hole in theaxlelinesupwiththe holein the steeringblock. The
partsshould pushtogetherwith your fingerswith firm prBSSU'e';
if theydonot, then youmaylita3/16" nut driveroverthe threaded
end of the axle and use the driVer to push it all the way in.
W AR NING !! The thre ads on the end of t he sx le ere 11lu,.
numa nd can be eas il y damagedby the nu t dri v er. Theaxle
will be fairty tight
in the steering block so try hard to al ign lhe
two holes as you are assembling the parts. WARN ING/I Do
not use p li e rs on t he bea ring surf a ce of t he axle, for this
can dama ge th e axle surface so that t he bearings w ill no
longer fit A small part of the la rge diameter of theaxle will be
exposed outside the steering block. This is okay; just make
sure the holes nne up.
Fig. 4
$ Fig. 5 1) Remove two of the 116223 steel pins from bag
#8·1. You will find two differentlengths of steel pins In this bag..
2) Matchtheproperpinsagainst the actualsizedrawing below.
Becausethe116223 pins are heattreated they will be darker in
colorthan theotherpinsin thebag.Thesetwo pinswill become
ourkingpins. 3) Nowcheck to makesure thatboth k ingpins~
go through the steering blocks and axles. Ifyou do not do this
now , it willbealmostimpossibleto getthe kingpin togo thr~
the 116210 front carrier block and the steering block/axle as-
sembly in the next step. 4) Once you have checked the align-
ment and lit, remove the kingpins so we are readylorthe nell!
step.
OCI• = ===m ul rs223
$
6223
Fig. 5
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i\l Figs. 6, 7 & 8 Now we aregoingtoinstallthe steer-
ing block/axleassemblies into the carrier blocks. 1) If you look
closelyat the front of the carri er blocksyou willseethe"A" and
"C' that are scribed Into them. 2) Look back at fig. 3 and install
the left steering block Into the left carrier block, then do the
samefor the right side blocks. Makesurethattheball ends on
the assembly will be on thesameside (in this caseboth facing
up) . 3) Now reinstall the two kingpins into each assembly as
shown infig. 6.
4) In fig. 7 weare goingto install the 116299 E-clips. In
this photo you will see the roll of E-clips along with two i nd l·
vidual clips to giveyou a size comparison. As you cansee,the
clipsare not much bigger than the steel pins they fitonto. Infig.
8 youwillseeanenlargedview of theroll ofE-clipsand a single
E-clip. The roll isheld together with
wMe tape thatgoes most
of the way around the E-cllps. The roll is so small and so
easy to miss that you should look for the white tape In-
stead of the actual E-cllps. Take out four E-cllps. 5) Install
one onto each end of bothkingpins. Try to center thekingpins,
for this will make the installation
of the E-dips easier. We will
use the lemalni ng E- cl ips In the fo llowing steps. Note: ff you
lose to many during assembly of this section you w ill find
more In the shock sea/ bag (Ins id e the shock maste r bag)
and the rear end bag /18-8. 6) Place the rest of the E-clips
back in the bag we will use them in a fewminutes.
!Pl..#6299
I;) Cl a-clip
1/8 shaft
Fig. 6
•
) '
f.
~·
Fig. 7
6299
6299
Fig. 8
,
7
Fig. 9 1} Look into bag 118 ·1again and takeoutthe two
116951 4-40x 1/8'socket setscrews. 2) Now we need to open
up the
116950 tool bag we took out In fig. 1. Inside you will find
four differentsize"l:' shaped Allenwrenches.Thesmallestone
will be the .050'All en wrenchwhich weneedforth isstep.Note:
An Assoc iated 16957 .oso• A llen driver or sim il ar driver
wo uld make this assembly easter and qu ic ker. 3) If you ro-
tate the steering block in the carri er block so that the two ball
end are as far apart
as possible, then it will expose the back
side
of theaxlewhich hasa small threaded holein it . Useyour
.050' Allen wrench toinsta ll a set screw Into each axle, then 4)
tightenthe setscrewagainstthekingpin.5)Makesurethe stee r-
ing block pivots smoothly inside each of the carrier blocks.
am #6951
setscrew
6950 ,. 050 "
Fig. 9
lji Figs. 10 & 11 1) Remove the two 11881 o molded
front suspension a-arms, two
118834 front arm shock mounts
and
two 116918 4-40x 1/2'buttonheadsocketscrews from bag
118 -1. (One arm and shock mountwill be attached to thesame
runner,
so therewill be two sets becausethe arms and mounts
areinterchangeable-left
or right side-until we fasten theshock
mounts in place.)
2) Trim the arms and mounts from the run-
nersinthelocationsshown.3)Plaoetheshockmount ontop of
the leftarm intothe recess in thearm, makingsuretheangled
side
of the mount is on the inside of the arm. 4) Now tum the
armupsidedownandthreadin the4-40buttonheadscrewwith
the 1/16'Allen wrench (second sma
ll est) from your 116950 tool
bag. Note:
An Associated 116958 1/16' Allsn driver or simi·
tar driver would make this assembly easter and quicker. 5)
Assemble the right arm the sameway. The armswill be mirror
Images of each oth er.
QnDUJDU!U I! !~1d ~ 1/2
Fig. 10
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LEFT
6918 1
6950, 1/ 1 6"
Fig. 11
"3t Fig. 12 1) Nowwe need thetwo remaining 116223 steel
pins (heat treated) and the two
118825 steel pins. We wi ll be
using these pins as our front outer and inner hinge pins. 2)
Before we can install them we want to check the pin fi t in the
suspension
arm holes. The 116223 pins will be theouter hinge
pins, socheckthe
ir fit intheouterholesof the suspensionarms.
Slide the pin through thearm holes. 3) Now hold the pin onthe
ends
and liftthe otherend of thesuspensionarmuntil itis level,
as shown in fig. 12. When you let go of the arm it should drop
and swing freely on
th e hinge pin. 4) Nowusethe 118825 hinge
pins
and chad< theirfrt ontheinnerarmholes.
IC===]JII116223 II II 118825
Fig. 12
i;Lf lg. 13 1) Now we need to remove four of the 116299 E-
ollps we put back in bag 118·1. We are nowgoing to attach the
front axle assembly
to the front suspension arm. The shook
mount will
be onthe front side of the armand wewillwantthe
front
of the axle assembly on the same side. 2) We will start
with the leftside. Usethe block carrierwith the •t: scribed in to
thefront. Take one of t he 116223 hardened steel pins and slide it
through the rear
ho le of th esuspension arm, then the axle block
carrier,and finallythrough thefronthole
of thesuspensionarm.
We want the pin to be tight when goingthrough the axle block
carrier, but not the arm. 3) Now center the pin and instell a E·
clip ontoeach end of thepin. 4) Repeat the above steps for the
right arm and axle block carrier. Rememberto keep the
"A " to
thefront
of thearm. Fig. 19 showsbothfront arms with the ax le
block carrierassembliesinstalled.
116299
I 116223 ~ e-<:fip
1/8 shaft
8
6299
........... (J
~
c '----6223
6299
Fig. 13
~ Fig. 14 & 15 1) lnthesamebag 118-1 youwillfindthe
118824 front bulkhead blocks, the /17208 aluminum front bulk-
head support, and the last four 116299 1/8" E·clips (it's okay if
you have extras). There Is both a leftand right bulkhead block.
2) Une up the left bulkhead with the left arm in ner mounting
ho les. 3) Now do the same for the right bulkhead and arm. 4)
The 117208 front end brace will go in front of the bulkhead but
behind both front arm Inner mounting holes. Place the block
between theinnermounting holes of thearm. 5) Now.slide the
118825 frontinnerhingepins(wetookthese out infig.12) through
the back arm hole, the bulkhead, thealuminumfrontbrace, and
outthroughthefrontarmmounting hole. 6) Nowcenterthehinge
pins
and installa E-cl lp ontoeachend of eachpin.Rg. 15 shows
botharms and bulkheadsassembled.
#6299
~a-clip [11= ====]) 11 118825
1/8 shaft
8824
LEFT
7208
c..- - 6299
RIGHT
LE'FT
•• 0
Fig. 14
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0
Fig. 15
~ Figs. 16 & 17 1)Aemovethell8832fiberglassfront
shock strut from bag 118 ·1. 2) Now go back to bag 118·14 and
remove two
116270 shOrt ball ends,two 117260 small 4-40plain
nuts,
and two 116272 foam ballend dustcovers. 3) Layout your
strut so that the long flat side matches the photo. This will be
the bottom
of the shockstrut.4) On thesidesofthe front shock
strut
you will see two holes. Install the ball ends into the lower
holeas shown.
5) Now, thread the4·40 nutonto the en d ofthe
threads
on the other side of the shock strut. 6) Now installthe
foam ball
end dustcovers over the ball ends.
7) Nextremove two
116924 4· 40 x3/8' socketheadcap
screws from bag
118·1 .8) Theball endswill be on theback side
of thefront shock strut. Line up the strut with th e two mounting
hol
es in the back of the front bulkhead blocks. Use the 3/32'
Allen wrench (the largest In the tool bag) to fasten the front
shock strut to the bulkhead with the
two /16924 screws. Not e:
AnAssociated 116960 3/32' Allendriver, or similardriver, would
make this assemblyeasier
and quicker.
~# 6270
~4-4 0
6272
\.._....
62 70 ,
©
7260
117260
@ 4-40 Qnmmn #6924
plainnut 4·40x
318
~-------- ' ------~------~-
Fig. 16
9
Fig. 17
Figs. 18 & 19 1) In bag 118 ·1youwillfindthe two #8812
tumbucldes.
2) Now go to bag 118·14 and remove tour of the
11627 4 plastic ball end cups. (There are a total of 14 ballend
cups on themoldedparts tree,
as shownIn the photo.) When
assembled these will become the front camber links.We sug·
gestyou readinstructionfigs. 18-19allthe way through before
beginning.
3) Nowwe want to thread theballend cups ontothe
turnbuckles.Thebest wayto dothis
is to holdthecenter of the
tumbucklewith the
118416 shock/tumbucklewrench.4)Thetum-
buckleshavelefthandthreads on oneend and righthandthreads
on the other,
so the cups will screw on In different directions.
(This feature helps
to simplify adjusting camber. After It is in·
stalled,you can tu rn theturnbuckle with the wrench to lengthen
or shortenthecamber rod without removing it.)
Install bothball end cups aseven ly as you can.5) Fin ·
Is htheinstallation byusingthe smoothpart of yourneedlenose
plie
rs to holdthecup still and the usethe 118416 wrench to turn
the turnbuckle. Racer's
Tip : To prevent damaging t he ball
end cup, rotate only the turnbuckle , no t the ball cup . TIJrn -
lng the ba ll cup w ill likely damage lt .
6) Thread the cups on until you reach a length of 1
9/ 32' (1.28' or 32.5mm) THESE DIMENSIONS ARE M EA ·
SURED TO THE CENTERS
OF THE BALL CUP SOCKETS,
NOT THE ENDS OF THE SOCKET$, as shown In the scale
drawing below. When assembl
ed and adjusted correctly both
ball end cups will be fa
ci ng the samedirectlon. 7) Now look at
fig. 19 and use your needlenose pliers to snap the turnbuckle
ball endcups onto the fourball ends.
Cl I (l lt s274 118812
19/32'
f--- 1. 28 " ----1
32.5mm
((£~~~) Fig. 18
lt6274
116274
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\
627 4
8812
Fig. 19
Fig. 20 The plastic ball end cups can be removed from
the S.S. ball ends by hol ding the cups next to the ballwith your
needlenose p li ers and tw isting the cup off of the ball end.
I
Fig. 20
n
~ Fig. 21 1) Go back to bag 118 -1 and remove the 118820
front aluminum kick up and tour 116292 4-40 x 3/8' flat head
socket screw . 2) We are now going to attachthefrontbulkhead
to the aluminum kick up . Place the front end ove r the kick up,
th en holding both parts, turn them over . 3) On the bottom side
you will find tour countersunk holes. Locatet he bulkhead over
the four holes and then thread the 116292 sc re ws into the four
holes with your 1/16' A llen wrench. 4) After allfour screwshave
been installed, go ahead and tighten them down.
~\-.,.,., #6292
V'"'""'"" 4-40X 3/8
10
8820 6292
Fig. 21
_..
SERVO SAVER ASSEMBLY
$ Figs. 22 & 23 1) Fr om th e kit box remove your
116301 blackanodizedaluminumchassis. 2) Remove the 116931
8-32 x 1/4' steel fla t head mach i ne screw from bag 118-1. 3)
Place the nose plate and front end assembly over the front ol
the chassis as shown. There are three hol es in the nose plate
thatneed to line up withthethree countersunk ho l es Inthefront
of thechassis. 4) Take the 8-32 x 1/4' machine screw and th read
it intothe center hole from the bottom of the chassis. Just lightly
secure the nos e pl ate so tha t th ere is not a l ot of space be-
tween thetop of the chassis and the bottom of the nose plata
We will tightenthis screw later.
5) We are going to leave bag 118-1 for a moment and
open bag 118 -2. Remove the two 117306 specia l servo saver
moun ting sc rews. The long screw is for the servo saver side of
the st ee ring and the short screw is tor the be ll cr ank side of the
steering. On the Dual Sportthe long screw will be on the left(or
dri ve r's) side and the short screw will be on the r ight (o r pas-
senger) side. 6) I nsta ll these screws from the bottom of the
chassis. 7) After both sc rews have been installed, go ahead
and tighten them and the 116931 screw.
I\
\
6931
Fig. 22
D.,.m.- --- -,mu=m, r~~s ~mu r- -,,mmmm ;;;os
specia l special
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7306
L ONG
fmm #6931
l)lllll 8· 32 X 1/4
steel Fig.
23
~ Fig. 24 Inside the same bag you will find the 117531
plas1lc servo saver parts tree and the 119156 aluminum servo
savertube. The namesofthe parts on thepartstree are: (1) left
upper servo saver arm, (2) lower servo saver bushing, (3) up-
pe r servo save r bushing, (4) left lower servo saver arm, (5)
rightsidebellcrank. Removethe two servo saverbushingsand
install theminto
the servo saver tube.T he upper bushinggoes
into the threaded end
of t he tube and the lower bushing goes
into t he hex end of the tube.
0 ®
Fi g. 24
$ Fig. 25 & 26 1) Take out the #9157 servo saver
spring and
the #9157 aluminum sp ri ng adjusting nut from bag
#8 -2. 2) Now remove the lower left servo saver arm from the
partstree. 3) Before we install t he lower servo saverarm over
t he aluminumtube, look at the bottom of thearm. You will find a
r ec essed hex shaped areathatwill match up with the hex por-
tion at the bottom of the aluminum tube. Sl ide the lower servo
sa ve r ar m ove r the al um i num tube and push it down until the
tube he x fi ts in to the he x shaped recess. 4) Next we need to
re move the upper servo saver arm. Install it over the tubewith
the "V" shaped portion facing down into the 'V" groove of the
lowerarm. Make sure
the upperarm is facingto the right (with
the lower arm faci ng away from you) as shown in the photo.
Racer's Tip: Tea m driv er s coat the V-groove portion of the
s
erv o sav er w ith a s mall amount of t he 116588 black gr ease
11
to improve th e servosaver perform ance.
5) If you look at thetop of the upperleftservosaverarm
(afternisinstalledonto the aluminumtube) you will seethereis
a recessed area. Sl ide the spring over the aluminum tubeand
into the recessed area. 6) L ook closely at the spring adjusting
nut. You will see that one side of this nut al so has a recessed
area.Sli de the nutover the tube, recessed si de first, andthread
it onto the tube.7) Tighten the nut until1/32' of the tubethreads
is exposedabove the adjusting nut. Racer's Tip: You canad-
ju st theservo sa v er tension by tigh t ening or looseningthe
aluminum adjusting nut. This changes
th e tension on the
serv o saver spring. The more you tighten the servo saver
spring, themore
load you trans fer to the servo gears. The
adjus ting nut should only bebelow the initial senlngunder
limitedracingconditions on an extremely high bite trac k.
91 57
I\
H ~
Fig. 25
Fig. 26
Fig. 27 Now we need to go back to bag #8-14 and
remove five #6270shortballendsandfi ve #6272foam ba ll end
dust covers. Layout the left servo saverarm assembly and the
rightbellcrank as shown in the photo. Now we need to thread
the fiveball endsinto the servosaverand bellcrank. After all of
the ball ends are installed you can then push t he 116272 foam
dust covers over the ball ends. Note: You do not need to
install nuts on the bottom of these ff ve ba ll ends.
tT1\mrn #6270
'-'iF"' 4·40
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6270
6270
6272
Fig . 27
$ Fig. 28 From bag #8·2 remove the new 116265 molded
draglink.Wewant to install
the draglink by snapping it over the
two center balls on both the servosaver arm and the belletank
as shown in the photo.
6265
Fig. 28
&; Fig. 29 1)1n order to install the servo saver assembly
youwill need to start with the leftside. Tum theassembly to the
right. Slide the arm assembly down over the long mounting
setew. When the arm Is at the bottom of the setew, rotate it to
theleftso that youcan Install the rightbellcrank assembly over
the short setew. The areas that you have to
wor1< around are
the front shock strut mounting screw and
the left upper servo
saver
arm. Movethebellcrankaround to clearthese as needed .
2) Now remove the two #6222 4·40/5·50 black self
threading nylon locknuts (frombag 118·2) and thread them onto
the
117306 servosaver mounting screws. 3) Tighten the nutsto
take
up any vertical free play or movement of the servo saver
or bellcrank but
not so light that It causes binding.Wewant
the servosaverarm and bellcrank to beableto swing freely to
both
the leftand right. Note: When you threadth& 116222 ny-
lon locknut over the left servo saver, the bottom of the nut
will be going down over an unthreaded portion of thescrew.
Do
not w orry; th is w ill not affect the holding power of the
nut.
1"::\ 16222
\:::..1 4-4015-40
ny1on locknut
12
Fig. 29
$ Figs. 30 & 31 1) Now from bag 118 ·1 take out the
two 118822 aluminum nose brace tubes, two #6285 4·40 x 1/ 4'
socket head cap screws, and two 1#6g1g 4·40 x 5/16" button
head socket screws. 2) Nowlook at
the two 118822 nose bra&
tubes. You will see that on one end thereisa holedrilledthrough
the sidethatis threaded. Th is will be theback end of the tube .
It you look at the front end of the tube you wmsee that the
insideholeisthreaded.3)1nstallthebutton head screwinto the
front of theshock strut. Usetheright side hole of thestrut (next
tothe ball end) so thatthe screwthreads comeouttheback ol
the shock strut. 4) Now line up the threaded end of the nose
brace tube and thread the tube onto the button head screw.
Leave a littleplaysowecan lineupthe other end easily. 5) Now
Install one of the 4-40 x 1/4" socket head cap screws through
the hole in
the side of thechassis and t hread It Into theside ol
the nose brace tube. You may have to rotate the nose brace
tube sothat the screwand hole can line up correctly.Aga in, do
not tighten this sc rew Just yet. 6) Now repeat the above steps
and installthe second nose brace tube on the otherside
of the
chassisand shockstrut.Makesure you sti ll leavethese setews
a littlelooseuntilbothsides areinstalled,thenyou can go bad<
andtighten al l four screws.
116285
[)umm 4-40 X 1/4 n., #6919
steel II'""""" 4·40 x5/16
-
8822 sg1g
Fig. 30
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6285
Fig. 31
$ Figs. 32 & 33 1) Nowremove the #6260 turnbuck-
les from bag #8-2(thelasttwo ~e ms in thebag). 2) You willalso
need to go back to bag #8-14 and r
em o ve four more of the
#627 4 plasticballendcups. These turnbuckl es will become the
two steering tie-rods.Weareagain goingtothread theballcups
onto
the twoturnbuckles.3)_Theturnbuckleshave both leftand
ri ght handed threads on them. All adjustments are measured
from the center of one ball cup hol e to the center of the other
ball cup hole, as shown inthedrawing below. Goback to fig. 18
for procedures on putting ball cups onto the turnbuckles.
Thread on
the ball end cups equally until you achievea
length
of 1 11/16" (1.69" or 17. 5mm). 4) Snapthe turnbuckles
onto
the steeri ng ball ends using your needlenose plier s. On
these turnbuckles both ball cups wi ll be facing thesame di rec-
ti on. To make it easier to insta ll t he i ns ide ball cup, rotate the
servosaverso thatthe insideball is exposedasmuch as pos-
sibl e. Reverse the servo saver directi on when you have to in-
sta ll the otherturnbuckle on theother side of the car.
C1 I~#627 4 IIIIUUH!Q!!IIIIIIIID ~~0 ~
60
111/16 "
1+- -- 1.69" --+!
42.9mm
~~ Wlll~a) Fig. 32
#6274
#6274
Fig. 33
13
_,. ~ ....,~ _....,_:..-
FRONT ANTI ROLL/SWAY
BAR
ASSEMBLY
1$ Fig, 34 Nowopen bag #8-3 and remove the two #6270
short ball ends. Ifyou look at the front of the car you willsee a
hole on theleadingedge
of each of the front arms.Thread one
of theshortball ends into each of the twoholes. Because ofthe
shape of the arm
you may not be able to fully install the ba ll
ends w~h a nut driver or socket. Use your 118416 shock/tum-
buckle wrench or needlenose pliers to finish the job.
rrllmrn #6270
'-"it""" 4-40
627D
Fig. 34
Iii Fig. 35 Go back to bag 118-3 and remove the parts tree
containing
the #8828 mo lded roll bar ball cups, and two 118828
4-40 x5/16' socket set screws. If you l ook at the ba ll cups you
wi ll find two with an open cupand two that have a closed cup.
Thread oneopen
cup and one closed cup ontoeach ofthe5/16"
set screws. Do your best to thread them on equally and
then
makesure theygo on until theybottomout against each other.
This will nowbecome the adjustable pivotlink. Because of the ir
small si ze you can use your .050' Allen wrench tothread one
cupontothe set
screw. Afterone is installedthread on theother
oneuntil it bottoms out.
•
Ill
- .- -.- -.-
~t rFig.3s
8828
~ Fig. 36 we can now take outthe 118826 roll ba rwire and
the two #6920 4-40 x3/ 16 ' button head socketscrews. Look at
the front sideof the front bulkhead. At thetop
of eachbulkhead
section, nextto the shock strut,you will fi
nd asmallrecess and
a hol
e. Lay the wi re in the two recesses with the ends going
towards the front of the car. Now use the two
116920 screws to
hold the wire in place by threading them into
the two holes at

the top of the bulkhead. Carefully tighten them afterboth have
beenInstalled.
1\nno 116920
IJ""" 4-40 X3/16
Fig. 36
Ill Figs. 37 & 38 1)(Rg. 37 .) Now wecan remove the
two #8830 aluminum roll bar pivots and two #6951 4-40 x 1/8"
socket setscrews. 2) There is a hole through thecenter of the
pivots. Slide the roll
bar wire through the hole (collar side first)
until thewire jus t comes out t he front of the pivot. 3) Now take
the set screw and thread
it into the collar. Just lightly snug It
downfornow.Wewill makesomeadjustments in a moment. 4)
Install the otherpivot ball on the oppos~e end of the roll bar.
5) (R g. 38 .) Now go back and pick up the #8828 ad-
justablepivotlinks (weassembled them in fig. 35) andsnapthe
closed ball
en d cup onto the ball end of the front suspension
arm, and 6) the open ball end onto the roll b~r pivot. 7) After
bothadjustablelinks havebeenInstalledwe
w111 need to setthe
roll bar pivot position. Looking at the front end assembly from
the front
of the car. adjust the pivot balls so that both of the
adjuS1abte links are close to vertical. We want to make sur~
thatthepivot balls are not binding but sllll remainclose toverti-
cal. B) Oncethey arelined up correctlyandpivoting freel y, tighten
the setscrews. 9) Make sure that the spacing
on both roll bar
pivots Is the same. If the spacing is not the same, the car's
handling characteristics will
be different for both right and left
tums.
#6951
om set screw
14
8828~
8830
•
6951
Fig. 37
Fig. 38
...r :611/r....,....,...., ....
FRONT BUMPER ASSEMBLY
~ Fig. 39 1) Open bag #8-4, the front bumper bag, and
remove the #8816frontbumper,
two 116922 4-40x 1/2" flathead
socl<et screws,andtwo 116222 4-40/5- 40 blacknylonselfthread-
ing locknuts. 2) Near the center of the bumper there are two
mountingholes. Theyare
on thebackedge. The " AE " indicates
thetopofthebumper. Place the back edge
of the bumperover
thefrontaluminumkick
up thenline up theholesinthebumper
withthe holesin thekick up. In the bottom of thebumperthere
is a ridge designed to fit against the front
of the nose plate.
Install thetwo 116922 screwsthrough the bottom of thekick up
andthen thebumper. 3)
Now threadthe 116222 nylon nutson to
the threads and tighten both nuts to secure the bumper. After
the bumperisinstalledyoucansetyourchassisasi
de fora few
moments.
8816 Fig.
39
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I
~111 11 11111 #6922 0 ~l~~ - 40
4-40 x 1/2 nylon looknut
_.. ~ ~ ~ ...,.,_;.-
2.25:1 STEALTH
TRANSMISSION ASSEMBLY
You r new Dual Sport includes the originalrace proven
Stealth transmissi
on. It has been used to win many Nati onal
andWorld Championship Titles and is the des ign base for the
GT. T2, and B2 versions of the Stealth tranny.Th is l ow m ai nte-
nance, l ow drag t rans missi on gives you exce ll en t adju stabl llty
fo ralmostanyt rac kcondition.Youwill f ind that wh en assembled
correctly and properly ma intain ed , yourvehicle's performance
and re li abilitywillbeabout the bes t ar oun d.Thisalldepends,of
course, on howwell you assemble and maintain the transmis-
sion. So take your time during assembly and frequently cl ean
and re-lube your parts. Nota: All of the molded parts In th is
transmi
ss ion a re made of engineered materi als . This means
you have to use lubricat ion only where we in dicate in the as -
sembly man ual. Th e li fe of these parts aregreatlyaffected by
frequency of ma intenance. This does not mean you have to
replace partseach time, jus/that frequent cleaningandlublng
will increase part lif9 and performance.
Please no te that during the assembly of the lransmis·
sion wewill be usi ng the sa me instructions sh owing assembly
ofboth
th e bu sh ingand ba ll bearingkits.The on lypartst ha t will
be differentwill be either the bu shings or ball beari ngs , so th e
onlybag thatwill bedifferent will
be bag B. Ifyou are un ce rt ain
which kit you have, the descripti
on on the bo x end labelunder·
neaththe reta ilpr ic e and modelnumberwillindicateif you have
ballbearings.
iJt Fig. 40 1) Open the Stealth ma in bag. Inside you will
findseveral sma ll er bags. You will find bags marked A. B,C. D,
E, & F. You wi ll also find a couple that have no marki ngs and
two tubes oflub ri cants. Remove the tubeof #6591 Stealth diff
lube (this will be an almost clear lube) from the main
bag. 2)
Nowopen bag A and remove th e /16 580 di ff gear, and the bag
containi ng the twelve /16581 3/3 2' carbi de diffball s. There are
two bags with ba ll s In th is bag,wewant the ba gwith t he l arge r
ba ll s. These ca rb ide balls are the best avail able. T hey will out-
lastthe driverings atleast tentimes (if thedi ll iskeptclean and
lubed). WARNING
!/ NEVERreplace your 3/32' dlff balls with
any other balls except our /16581 carbide dlff balls . The
tolerances we use are ti ghter than any other company that
we know of. Due to these ti ght tolerances and carefu l pack ·
ag i ng of matched ba ll s, when replac i ng lost or wom 3/32'
dl ff balls , you MUST r eplace ALL 3/3 2" balls at the sa me
time wi th new ba lls f rom the same package . Th is me a ns
you cannot even mi x balls fr om two di fferent 11658 1 pack ·
ages . Not observ in g th is warn i ng will reduce your di ff con -
si stency and perfo r mance and could cause premature part
failure. 3)
Loo k atthe cen terhole ofthe /165 80diffge ar. Ifthere
isany
fl ashingonthein si de ho le(as indicatedinthephot o) you
15
must remove it, or the diffwi ll notwork orgo t oge ther co rr ect ly.
Use y
ou r X ·act~ knifetocarefully trimany flash from th ecen·
te r hole.Wesugge st using the tipofthe blade since it will tum
eas ierandfo ll ow the shape of the gearwith lesschance ofdam·
age to the gear. It isimportant to remove onlythe flashi ng and
not any ofthe gearmate ri al.
4) Therearetwelve holesinthe diffgear.Filleachhole
with
116591 siliconedifflube. WARNING /I DO NOT substitute
any other type of diff lube on t he balls . It took us count-
less hours of intense testing to fi nd the co"ect silicone
dl ff lube to make the dlff work co"ectly. Do you r self a fa.
vor : use what comes In your kit. While the ff6591 Is called
silicone dlff lube , it actually Ia a all/cone compound. It is
not used to ma ke the dlff slip , like mos t people would think ,
It Is used to control how fast the dlff locks up . Lube has
just become a standard descript i on for all greases and sill·
cone compounds. 5) Now genUy push the tw el ve 3/32' balls
intothe twelveholesaround the gear.6) Afterall oftheballsare
installedwipethe excesslube back intothe
bal lholes withyour
finger.
You willsee your di ff gearwithballs installedin the third
step ofthephoto.7) Cl
ea n thedifflube from yourhands. We do
not want to take a chance of this lube ge t1l ng mixed into the
116588 black greasethat we will use in a fewsteps.
FLASHING 6580
6591
6581
Fig. 40
l;i Figs . 41 & 42 Open bag Bof the St eal th mainba g.
(Th iswill be the only transmission bag that will be different be·
tween the two ki t ve rsi ons.) If you have a bal l beari ng kit, use
theparts and part numbers onthele ft sideof fig. 41. If youhave
a b
us hingkit, use the pa rt s andpartn umb ers on the ri ghtside.
All kits (bushi ng and ba ll bearing) will use a 1165 96 b ush ing fo r
the torque clutch.
If you have a ba ll bearing kit you will have
eight bearingsand one bushing. If you have a bushing kit you
willhaveninebushi ngs . Note : All of thebushingsused in thiskit
arepre-o il ed throughaspecialmanufactu ri ng process, so nooil
is neededon thebus hi ngs duringassemb ly.
4) Remove one ofthe /16589 5132 " x 51 16 ' unflanged
ballbearings or one ofthe 116597 5/32' x 51 1 6' unflanged bronze
bushings. WARNING /I On bush in g ki ts both th e 11 6596 and
11 6597 bushings have the same ou ts ide diamete r, only the
Ins ide diameter is different . Do not us e the l arger I ns ide
diameterb
ushing In this step. If you do , the torque clutch
will not go together later and you w/11 heva to takethetrans·

missi on enddifferentialapartagain to locatethet/6596bush-
ing. 5) Placethe 116589 bearingor 116597 bushi ng i nto thecen·
ter hole of the diff gear as shown.
@#6589 @#6597
5/32 )( 5/16 0 5/ 32 )( 5/16
unflanged bearing unllanged bushi ng . J.f'l')
tr\'1 N6596 4...'/J. , ;j ,C\
V8J 3/16X 5/16 /l:J:.\ Y ~\JI
unllanged bushi ng ~ ~ 'V ·
:-.r
,65 96 1
0 '0
6589 0 ~ @ 06597
6906
6906
© @65 99
@ @6599
-
I'.. O' d 6598
' :..o' ~
Fig. 41
Fig.
42
Figs. 43, 44, 45 & 46 1) Backinbag A youwill
find a mo ld ed parts tree containing the /16575 T-nul and diff
thrustboltcover.2)Trim thetwoparts from t he treeasshown In
fig. 43. WARNIN G/I Makesure you do not cut the "ears" off
the T-nut or thrust bolt cover. The ears ere needed to pre-
vent the parts from spinning freely In the outdr/ves. For
now
se t the diff thrust bolt oover aside; we will use it near the
end
of the transmission assembly.
3) Now remove the #6582 diff thrust spring and the
/16578 left diff outdri ve hub (the one with thesmall nipple on i t)
from thesame bag A. WARNING !! Please make sure you do
not get the 116582 dlff thrust spring mixed up w ith the 16587
torque control spring (f r om bag E) we w ill be Installing
later . The to rque control spring has a slight ly lar ger ou t·
side diam et er and w ill jam Ins i de the di ll ou td ri ve hub if
forced ln. Now check to make sure that there are no burrs or
residue on th e insi de or outside, of the diffoutdrive hub, which
coulddamage partsorreduce
the performance of the diff.Slide
thediffspring intothe left diff outdrive hub. It should s li de in or
16
go inwithvery light pressure until itreaches thebottom of the
outdrive. Next, aligntheT- nut With theslots in the outdrive and
push it. Make sure the steel insert side goes in first. This will
pl ac e theears on the outsi de awayfromthespring.S li de the T·
nut all the way down aga inst thespring.
(Fig.
45. ) The ea rs on theT-nutshould be approximately
3/32"ora littlelesst han .1 oo• from thebottom of the slot.Take
your X· acto<C knife and trim off any of the plastic T-nu t that ex·
tendsoutside bothsidesof theslot intheoutdrive hub. The di ll
outdrive hub will notslidethroughthe ball bearing laterif we do
nottakecare
of this now. WARNING/IBecarefulhere so that
you do no t cut yo urself , since y ou will be cutting towards
your thumb.
diffthrust '"
boltcover
'
65 5
6575 6582
3/ 32"
T·nut
Fig. 43
Fig. 44
Fig. 45
Fig. 46
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~ ig. 47 1) Still using bag A remove the small bag con-
taining the six 11657 4 5/64" dirt thrust balls, Remove another
smallbag thatcontainsthe two 116573 diff thrust washers (spe-
cialhardenedsteel washers)andthe 116575 diff thrustbon which
we alsoneedto remove. WARNING!! Again follow thesame
wamlng we explained
in fig. 40 about only using the balls
that came with the kit. These are special tight tolerance
balls that are not available from any other company that
we know of. Remember, the tolerance Is so tight that you
cannot even mix balls from two different bags of Associ ·
ated 116574 dlff thrus t balls. Y ou mus t replace all six at the
same time
or you will reducethe pe rf ormance and du rabll ·
lty of the dlff assembly.
2)
Now slide one of the #6573 diffthrust washers on to
the
/16575 dlff thrust bolt. Racer's Tip: Carefully look at the
center
hole of the first thrust washer; you will seethateach
side
Is beveled. One side is beveled more than the other;
this side
Is Installed towards the head of the thrust bolt.
This
will help to Insure that the thrust assembly will work
as smoothly es possible. 3) Go back to theStealth main bag
and remove the tube
of N6588blackgrease. 4) Openthe tube
andplacea smallamount on thewasher. Use justenoughgrease
to hold the six ballsyou
wtll place on the washer. WARNING !/
DO NOT use the 116591 Stealth silicone diff lube on the
/16574 dlff thrust bells . 5) Now carefullyplace six #6574 balls
Inthe greasearound the washer.
6) Slideon thesecondwasher
until it contacts the balls. WARNINGII Make sure that you
have exactly six thrust balls in sta ll ed between the wash·
ers. More than six will cause the di ff to back off and less
than
si x can causethe t hrust washers to crack.
6588
-- ~
0 . . . .
.. 0
6573 6574 6573 6575 Fig. 47
•
A SS EMBLED
@#6513 ()n mu!lll!llil!il@ll!!!!! !l ~ 6575
lit Fig. 48 Remove the /16577 right diff outdrive hub and
one
of the 116579 dirtdriveringsfrom bagA. Go back to bag B
and remove either the second
116589 5/32" x 5/16" unllanged
ballbearing or 116597 5/32"x 5/16"unllangedbushing(depend-
ing upon which kit you purchased). Now check to make sure
thatthere
are no burrs or residue on theinside or outsideof the
diff outdrive hub, which could damage parts or reduce the per-
formance of the dirt. Install the 11 6589 ball bearing or 116597
bushing into the cavity in thecenter of the #6577 right dirthub.
It should push In with your ling er . N eve r drive or Ior ee t he
bea ring or bushing Into the hub cavity. Now place th e 116579
17
drive ring on to the outdrive hub as shown. Racer's Tip: Our
Team drivers always check the diff drive rings tor the side
that is more rounded on the outer edge. They place this
side against the hub as It gives you a more consistent dlff
action. If you are on a budget you can still use both sides
of the drive rings to reduce your maintenance costs . DO
NOT try to pin thedrive rings to the dlff hubs as Isdone on
other designs. Our hub and drive rings are designed to
lock the dri ve ring without pinning . Please leave the diff
AS IS.
#6579
drive ring
@
#6597
5132 X 5116
unflanged bushing
6599
BUSHING KIT
6589
BEARING KIT
-:> '0
@
#6589
5/32 X 5/ 16
unf langed bearing
0 @
BUSHING
OR BEARING
6579 6577
Fig. 48
ig • 49 Go back toyour /16950 toolbag and removethe
5/64" Allen wrench. Slide the long leg of theAllenwrench in to
the head of the 116575 dirt thrust bolt. We will be inserting the
bolt,washers,andthrustballsi nto thecenter of the 116577 right
diff
outdrive.Note: An Associated N6959 ~·Allen driverwould
workwellhere.
1
6950 5/64"
l
-r:::::::: - ·-- -
'\
Fig. 49
Fi g. 50 With the Allenwrenchstill in the head of thediff
bolt. tum theright diff outdrive hubupright so thatthewrench is
on thebottom.Makesurethatthe 116579 d1rt drivering is still on
the hub and centered. Now pickup the/16580 diff gear(withthe
3/32' diff balls and ball bearing or bushing installed) and s li p it
over the diff thrustbolt. We want to center it onto the dirtdrive
ring
on the ri ght d iff outdrive hub.
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Go back to bag A and remove the second #6579 diff
dr ivering. Installthisringoverthediffthrustboltanddown over
the balls on the top side of the gear as shown In the photo. If
you are doing the racer setup, the rounded side will be up.
WARNING/I If you remove the dlff gear before you com-
pletely assemble the dlff halves , al ways double check to
see that you do not have both drive rings on the same
side . This can happen easily because one drive ring may
Slick to the diff gear and the other may stick to one hub . It
is easy to turn the dlff gear around w ithout realizi ng ft.
This situation would place both drive rings on the same
side and the dlff will not work co" ectly.
•
•
•
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Fig. 50
~ Figs . 5 1 & 52 Nowwearegoingtoinstallthelf6578
left diff outdrive assembly over the #6 575 diff thrust bolt. 1)
Slide the thrust
boll Into the hole of the nipple on the left out·
drive, then lightly push the nipple through the center of the dill
gear bearing or bushing. Make sure the outdrive hub centers
on t he top dilf dr ive ring when it fi ts into the center of th e dlff
gear. Note: When picking up the
left outdrive hub, place your
fingeroverthe slottedend
of the hubto preventanychance of
the T-nut and dilfspring from falling out during this assembly.
Makesureyousecurely
hOld theAllenwrenchinthehead of the
diffthrust bolt. This will prevent the bolt, washers, and thrust
balls from sliding
out durmg assembly and possiblylosing any
of the di/fthrust balls.
2) Tightent he boll usingtheAllenwrench,makingsure
that the hubs
and drive rings stay centered. 3) Once you have
lightly snugged the two halves together
you can tum the diff
assembly
on its side to make the final adjustment easier. Fig.
52.Holdtheleftoutdrive
and tighten the diffspring andthe screw
until
it stops. DO NOT OVERTIGHTEN. Correct adjustment Is
tightening the spring an d diff bolt until they stop, then backing
theboltoff 1
/8 of a turn.
The dlff
sho uld be tight but the operation shou ld feel
smooth when turning the
hub in opposite directions. Remem·
ber, this is not a free spinning component. We are looking for
the ball rolling motion to feel smooth,
not rough. Note: After
you have run the car once you will need to recheck the diff
adjustment.
The first run willmake sure all the partsseat cor·
rectly. After you have rechecked the diff it shouldonly be nee·
essaryto checkthe dilf adjustmentoccasionally.
ADJUSTING THE DIFF. As you are tightening the diff
boll, you will notice the ears on theT·nut moving closer to the
bottom ofthe slots
in the left diff outdrive hub . Thiscauses the
diff spring (behind the T·nut) to compress. The spring and diff
boftshouldstopaboutthesame lime astheT·nutearsreach the
bottom
of the slot (if It Is off by only a small amount there is no
18
problem). Bottoming out the spring and bolt Is very im portant
Th e tension of thespri ng can only beconsistentifyou startfrom
lhe same point. A fully collapsed spring Is your starting poi
nt
Thisway, whenyou backoffthebolt 1/8 of a turnyouwillalways
havethesamespringtension,
so yourdiffwill be consistent.We
again remindyouthatthisdiff
is notdesignedtoslip.We usethe
torqueclutch tocontrol
any slippagethecarneeds.Thisiswhy
the wrongdifflu be or evensiliconecompoundcanallowthediff
to slip, which would reduce transmissi
on performance and in-
creasepartswear.
Fig. 51
•
Fig. 52
ig. 53 OpenbagC andremove the/165651eft and right
casehalves.There
are fiveotherparts on the partstreesomake
sure you
put them back in bag C for now . Make sure thatyou
remove
any flashing near the bottom of the case halves. Go
back to bag B and remove four /16906 3/ 1 6" x 3/8" unflanged
ballbearings or four /16599 3/16"x 3/8"unflangedbushing. Also
remove two#6903
318" x5/8"unflangedTeflon sealedballbear-
Ings
or two /16 5983/8" x 5/8"unflanged bushings. (Bag B isthe
onlytrannybag thatwillvarydependinguponwhichkityou have.)
In t he photo we have installed bushings in one case half and
ball bearingsin the other casehalf. B ot h halveswill receive the
samebushings
or bearingsdependinguponwhichkityouhave.
3/8 X3/16 0
3116 X 318
@
#69 06 @#6599
unflanged bearing unflanged bushing
#6903
318 x 518
unllanged bearing
#6598
3/Sx 518
unf!angedbushing

6599
bushing kit
RIGHT bearing
kit
LEFT
Fig. 53
· s. 54 & 551)0 penbag0and r emovethe#6 571
rive gear/shaftassembly. 2) Carefully deburr the roll pin ho le
In the drive gear shaft. We are try ing to make sure the hole is
not bl oc ked and thatthere are no raised edgesaround the ho le
that will prevent the beari ng or bushing from sl iding onto the
shaft. Be su re to de burr both sides of the hole. 3) Now insert
the #6571
dr ivegear/sha ft through t he upper bearinginthe ri gh t
case half. The shaft will be on the o ut si de of the case and the
gear on the inside aga in st the ball bearing.
4) Now open bag E and remov e the#6572 ro ll pin. Us·
ing your needlenose pliers squeeze the roll pin into the hole of
th e drive gear/shaft. Do your b es t tocenter the ro ll pin.Racer's
Tip:
you can use your needlenose pliers to gently close
the
split on one end of the roll pin. This slightly smaller
end will then be easier to get started into the hole.
#6572
roll
pin
6571
( .
i.
•
'
·"
....
.,
•
, ,
';
Fig. 54
6572
=
19
Fig. 55
igs. 56 & 57 We nowneed tolnstallthedlffassem-
bly into the right case hal f. We need to ma ke sure that the diff
bolt head goes through the right case half. We want to end up
withboth adjustment po i nts on the same side (thetorq ue clutch
and diff bolt ). WARNING!/ If you install the diff bolt head so
that it is on the driver's side of the transmission, you may
have a problem with the diff adjustment backing off and
the diff then slipping.
Go bac k to bag 0 and removethe #6570idler gearand
shaft. Install the idl er gear into the center bearing on the right
case half. You may have to t urn t he gear so t ha t it will mesh
with the other two gears in the case. It does not matterwhich
way t he i dle r gear goes in, it will work correctly either way .
DIFF ASSEMBLY 6571
6570
Fig. 56
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Fig. 57
~ig. 58 Open bag F and remove the four #69284-40x
1 socketheadcapscrews.Threadthemintothe
bok hole loca-
tionsonthe lefthand case . T ake theleft hand case and installil
over the gears and differential, mak ing sure thateach gear fits
intotheappropriatebearing
or bushi ng .ThereIsalocatingridge
onthe
ins ide of the case to helpline up thecasehalves. Screw
the bo ll s In until theyextend out th e right si de of the case 1 /8 '.
Onommmmmnum\umo ~:5~
1
6928
Fig. 58
'rt Figs. 59, 60 & 61 1) Back in bag C you will lind
the lour #6569 motor plate spacers and the case dust end cap
on the remain in g partst re e. 2) Re move the live partsfrom the
tree.
Set t he end cap aside lor a moment. 3) In bag F you will
find the #6566ten dust seal.4) You willneed to carefullyremove
thethreefe
lt cutouts wh ere the motor platespacerswill go (fig.
59).
5) Wecan now install three of the motorplatespacers into
thefeltseallikethis: The feltseal willonlygo onone way , so li ne
it up over the holes in the case, before you start, so you will
know how II is Installed. Lay the fe lt sea l down with the case
side
up .Install the three #6569spacers so t ha t the small end is
pointing up. The small ends of the spacerswill lit into t he case
holesonthe ri ght side of thecase. The fourth spacerwill fit into
thebottomfront hole
wh i ch is not covered by thefelt dust seal.
6) Nowinstall t he felt sea landthreespacers over the driveshaft
and onto the case
as shown (fig. 60). The spacerswill a lso be
go ingovert he threadedends of the lou r #6928casescrews.7)
Installthefourth m otor platespacerin the front ho le.
B) Orientthetrannyas in fig. 61 . II youlookat the upper
part of the case you will see a ho le in the l eft side at the drive
gear/shaftlocation.You will
need to pressthe#6569 case dust
20
end cap Into the ho le in the case at the end of the d ri ve gear/
shall Youwill see anarrowpointing to the location lo r thecase
dust end cap. Note: On occas ion the case dust end cap w: J
break off the parts tree before the parts are packaged. IMlen
this occurs we willnormallyInstallthe end cap into one of the
casehalves
so that it cannot get lost. If it is InstalledInthe right
case
half push it out a nd insta ll itIn the left case half where it
belongs.
Fig. 59
Fig . 60
Fig. 61
• 6569
~ Fig. 62 In the Steanh main bag youwill find the #6604
black anodized m
otor m oun ting p la te. Place the mo to r plate
over the dr i ve gear /shaft. There are four ho l es around the mo-
to rplateshaftopening.You willneed to li ne up thefourthreaded
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