Jconcepts BJ4 User manual

ITEMS NEEDED TO COMPLETE YOUR CAR:
1. R/C TWO CHANNEL SURFACE
FREQUENCY RADIO SYSTEM
2. BATTERY PACK (6 CELL SADDLE PACK)
3. BATTERY CHARGER (PEAK DETECTION)
4. ELECTRONIC SPEED CONTROL
5. R/C ELECTRIC MOTOR
6. PINON GEAR (SIZE TO BE DETERMINED
BY MOTOR CHOICE)
7. 1/10TH SCALE 4WD FRONT TIRES
(BOX ART SHOWN: BLOCKHEAD)
8. 1/10TH SCALE BUGGY REAR TIRES
(BOX ART SHOWN: X-2000)
4. HELPFUL TOOLS (NOT REQUIRED)
A. VERNIER CALIPERS
B. HOBBY SCISSORS
C. 2.5mm BALL END HEX DRIVER
3. MISC. TOOLS
A. NEEDLE NOSE PLIERS
B. THREAD LOCKING COMPOUND (BLUE)
C. HOBBY KNIFE (DANGER!) THIS KNIFE CUTS
PLASTIC AND FINGERS WITH EQUAL EASE
D. PRECISION RULER
E. FLAT FILE
2. NUT DRIVERS
A. 3/16"
B. 1/4"
C. 11/32"
1. ALLEN WRENCHES
A. .050"
B. 1/16"
C. 5/64"
D. 3/32"
E. 2.5mm
TOOLS NEEDED TO BUILD THIS KIT
CHASSIS PREPARATION:
CHASSIS
x 1 TOP DECK x 1
(2 PIECES)
STEERING RACK
x 1 BATTERY TRAY x 2
BATTERY STRAP
x 2
BEARING BLOCK
x 2
FRONT SHOCK
TOWER x 1
REAR SHOCK
TOWER x 1
CHASSIS COMPONENTS
FILE
NOTE CHASSIS
ORIENTATION
NOTE: THIS IS A CLEARANCE FOR THE BOTTOM OF THE REAR
TRANSMISSION CASE. A PROPERLY FILED CHASSIS WILL ALLOW
THE REAR TRANSMISSION CASE TO SIT FLAT ON THE CHASSIS.
FILE CAREFULLY! USE THE PROPER CASE TO CHECK THE FIT
WHILE REMOVING A SMALL AMOUNT OF MATERIAL AT A TIME.
1. FILE REAR TRANSMISSION SLOT WITH
THE BOTTOM SURFACE OF THE FILE.
FILE AT THE GREATEST ANGLE POSSIBLE
WITHOUT THE TOP SURFACE OF THE FILE
HITTING THE OTHER SIDE OF THE SLOT.
SEE FIGURE 1.
2. REFER TO FIGURE 2 FOR COMPLETED COMPARISON.
FIGURE 1
FIGURE 2
TOOLS
BAG A
STEP 1
PAGE 1

ASSEMBLING CHASSIS COMPONENTS:
1. ATTACH FRONT BULKHEAD TO CHASSIS WITH TWO 5-40 x 5/16" FLAT HEAD SCREWS.
2. ATTACH BEARING BLOCK WITH TWO 4-40 x 3/8" FLAT HEAD SCREWS. SECURE WITH TWO 4-40 LOCKNUTS.
3. ATTACH CENTER MOTOR MOUNT TO CHASSIS WITH THREE 4-40 x 5/16" FLAT HEAD SCREWS.
4. ATTACH CENTER BULKHEAD TO CHASSIS WITH TWO 4-40 x 5/16" FLAT HEAD SCREWS.
5. ATTACH REAR SUSPENSION MOUNT (FRONT) WITH TWO 4-40 x 5/16" FLAT HEAD SCREWS. NOTE DIRECTION
6. ATTACH REAR SUSPENSION MOUNT (BACK) WITH TWO 4-40 x 5/16" FLAT HEAD SCREWS. NOTE DIRECTION
APPLY BLUE THREAD LOCKING
COMPOUND WHERE NOTED.
(JUST A SMALL AMOUNT)
FRONT BULKHEAD
5-40 x 5/16" x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
BEARING BLOCK
4-40 x 3/8" x 2
BEARING BLOCK AND
CHASSIS FROM BAG "A"
4-40 MINI
LOCKNUTS
x 2
CENTER MOTOR MOUNT
4-40 x 5/16" x 3 CENTER BULKHEAD
4-40 x 5/16" x 2
REAR SUSPENSION MOUNT
4-40 x 5/16" x 4
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND) (APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
FLAT EDGE OF FRONT MOUNT
SHOULD FACE FORWARD
REAR SUSPENSION MOUNT (FRONT) x 1
NOTE MOUNTING DIRECTION IN
ASSEMBLY BELOW
REAR SUSPENSION MOUNT (BACK) x 1
NOTE MOUNTING DIRECTION IN
ASSEMBLY BELOW
CENTER MOTOR
MOUNT x 1 CENTER BULKHEAD
x 1 CENTER BULKHEAD
CAP x 1
FRONT BULKHEAD
x 1 BATTERY POST
x 4
4-40 x 5/16"
FLAT HEAD
x 9
5-40 x 5/16"
FLAT HEAD
x 2
CHASSIS COMPONENTS
4-40 x 5/16"
SOCKET HEAD
x 8
4-40 MINI
LOCKNUT
x 2
4-40 x 3/8"
FLAT HEAD
x 6
#4 WASHER,
ALUMINUM
x 4
PAGE 2
BAG B
STEP 1

DIFF BOLT
THRUST WASHER
FEMALE SLIPPER
OUTDRIVE
SLIPPER PLATE
ALIGN HEXES
1. STACK THE FOLLOWING PARTS ONTO THE PARTIAL
ASSEMBLY IN THIS ORDER:
A. SLIPPER PAD
B. 78 TOOTH SPUR GEAR (ALIGN WITH SLIPPER PAD)
C. SLIPPER PAD (ALIGN WITH SPUR GEAR)
D. SLIPPER PLATE
E. MALE SLIPPER OUTDRIVE (ALIGN WITH SLIPPER PLATE)
2. CAREFULLY ALIGN ALL THE HEX SHAPED PARTS WHILE THE
SLIPPER PADS REST IN THE SPUR GEAR.
3. INSERT THE SLIPPER SPRING INTO THE MALE SLIPPER OUTDRIVE.
4. INSERT THE T-NUT INTO THE MALE SLIPPER OUTDRIVE UNTIL IT
TOUCHES THE DIFF SPRING. (APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND WHERE SHOWN)
5. TIGHTEN THE SLIPPER USING THE 5/64" ALLEN WRENCH,
BUT NOT COMPLETELY. JUST TIGHT ENOUGH TO HOLD
THE COMPONENTS IN PLACE.
SLIPPER ADJUSTMENT:
1. HOLD THE DIFF BOLT WITH A 5/64" ALLEN WRENCH.
2. SLIDE ONE THRUST WASHER ONTO THE DIFF BOLT.
3. SLIDE THE DIFF BOLT WITH THRUST WASHER INTO
THE FEMALE SLIPPER OUTDRIVE.
4. WHILE ALIGNING THE HEXES ON EACH PART, SLIDE
THE SLIPPER PLATE ONTO THE FEMALE SLIPPER OUTDRIVE.
5. HOLD THE PARTIAL ASSEMBLY WITH THE 5/64" ALLEN
WRENCH SO THAT THE SLIPPER PLATE IS FACING UP.
SLIPPER ASSEMBLY:
PARTIAL ASSEMBLY
SLIPPER PAD
SPUR GEAR
SLIPPER PAD
SLIPPER PLATE
MALE SLIPPER
OUTDRIVE
ALIGN HEX
WITH FEMALE
OUTDRIVE HEX
ALIGN HEXES
SLIPPER SPRING
T-NUT
APPLY A SMALL AMOUNT OF THREAD LOCKING
COMPOUND TO THE THREADED, ALUMIUM PORTION
SLIPPER OUTDRIVE
MALE x 1
78 TOOTH SPUR GEAR
x 1 OUTDRIVE SHIM
x 2
SLIPPER PAD
x 2 SLIPPER PLATE
x 2 3/8 X 5/8 BEARING
x 2
SLIPPER OUTDRIVE
FEMALE x 1
CENTER SLIPPER PARTS
DIFF T-NUT
x 1
SLIPPER SPRING
x 1
DIFF THRUST WASHER
x 1
DIFF BOLT
x 1
PAGE 3
BAG B
STEP 1
STEP 2

#4 WASHER
x 4
BATTERY POST
x 4
BATTERY TRAY
FROM BAG "A"
4-40 x 3/8"
FLAT HEAD
x 4
1. SLIDE ONE OUTDRIVE SHIM AND ONE 3/8" x 5/8" BEARING ONTO EACH SIDE OF THE SLIPPER ASSEMBLY.
2. SLIDE THE COMPLETE SLIPPER ASSEMBLY DOWN INTO THE CHANNELS OF THE CENTER BULKHEADS.
3. ATTACH THE CENTER BULKHEAD CAP WITH FOUR 4-40 x 3/8" SOCKET HEAD SCREWS.
4. ALIGN EACH BATTERY TRAY WITH THE SLOTS IN THE CHASSIS, AND SNAP INTO PLACE.
5. ATTACH EACH BATTERY POST WITH A 4-40 x 3/8" FLAT HEAD SCREW. MAKE SURE TO ALIGN THE HEX
ON EACH BATTERY POST WITH THE CORRESPONDING HEX IN THE BATTERY TRAY.
6. SLIDE THE BATTERY STRAPS ONTO THE BATTERY POSTS AS SHOWN BELOW.
7. ATTACH EACH BATTERY STRAP WITH TWO 4-40 x 5/16"
SOCKET HEAD SCREWS AND TWO #4 WASHERS.
ASSEMBLING CHASSIS COMPONENTS:
4-40 x 5/16"
SOCKET HEAD
x 4
1. THE SLIPPER IS ONE OF THE MOST CRITICAL ADJUSTMENTS ON THE BJ4. REMEMBER,
THE SLIPPER IS DESIGNED TO ABSORB IMPACTS FROM THE DRIVETRAIN. SETTING THE
SLIPPER TOO TIGHT WILL ONLY CAUSE PREMATURE DAMAGE TO THE DRIVETRAIN.
IN ADDITION, HAVING THE SLIPPER TOO LOOSE WILL NOT HELP CREATE TRACTION.
2. SCREW IN THE DIFF BOLT UNTIL THE SPRING IS FULLY COMNPRESSED. PAY CLOSE
ATTENTION TO THE ALIGNMENT OF THE PARTS. DO NOT OVERTIGHTEN THE BOLT.
WHEN YOU FEEL THE SPRING COMPRESSED, LOOSEN THE DIFF BOLT ONE TURN.
3. AFTER YOU HAVE DRIVEN THE CAR FOR ONE BATTERY PACK, CHECK THE SLIPPER
ADJUSTMENT. IF NECESSARY, REPEAT STEP 2 ABOVE.
4. IF MORE SLIP IS DESIRED, LOOSEN THE DIFF BOLT 1-1/4 TURNS FROM BOTTOM.
IF LESS SLIP IS DESIRED, LOOSEN THE DIFF BOLT 3/4 TURNS FROM BOTTOM.
SLIPPER ADJUSTMENT:
CENTER BULKHEAD CAP
4-40 x 3/8" x 4
OUTDRIVE SHIM
x 2
3/8" x 5/8" BEARING
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
COMPARE ASSEMBLY:
PAGE 4
STEP 3
STEP 4

DIFF THRUST WASHER
x 2
DIFF SPRING
x 1
SHORT OUTDRIVE HUB
x 1 LONG OUTDRIVE HUB
x 1
DIFF BOLT
x 1
3/16 X 5/16
DIFF BEARING
x 2
DIFF T-NUT
x 1
5/64 THRUST BALL
x 6
3/32 DIFF BALL
x 12
DIFFERENTIAL RING GEAR
x 1 DRIVE RING
x 2
DRIVETRAIN COMPONETS (DIFF x 2)
THRUST BALL ASSEMBLY:
1. HOLD THE DIFF BOLT WITH THE 5/64" ALLEN WRENCH
AND SLIDE ONE THRUST WASHER ONTO THE DIFF BOLT.
2. APPLY A GENEROUS AMOUNT OF BLACK GREASE TO THE
WASHER ON THE SIDE FACING AWAY FROM THE BOLT HEAD.
3. PLACE SIX THRUST BALLS INTO THE GREASE AGAINST THE BOLT
AND WASHER. ADD THE OTHER THRUST WASHER. THE GREASE
WILL HOLD THE BALLS IN PLACE DURING ASSEMBLY,
SANDWICHED BETWEEN THE WASHERS.
APPLY GENEROUS AMOUNT OF BLACK GREASE
HOLD WITH 5/64" ALLEN
WRENCH
DIFF BOLT
THRUST WASHERS
5/64
THRUST
BALLS
x 6
SHORT HUB ASSEMBLY:
1. INSERT THE THRUST ASSEMBLY INTO THE SHORT OUTDRIVE HUB.
2. ADD A LIGHT COAT OF STEALTH LUBE TO THE SHORT HUB FACE
WHERE SHOWN.
3. PLACE A DIFF DRIVE RING ONTO THE FACE OF THE SHORT HUB.
4. SLIDE A DIFF BEARING ONTO THE PROTRUSION OF THE SHORT HUB.
SMEAR A SMALL AMOUNT OF STEALTH LUBE
HERE TO HOLD THE DIFF DRIVE RING IN PLACE
THRUST ASSEMBLY
SHORT OUTDRIVE HUB
3/16 x 5/16 DIFF BEARING
DIFF DRIVE RING
NOTE: REMOVE ANY OIL RESIDUE FROM OUTDRIVE
HUB THOROUGHLY BEFORE APPLYING STEALTH LUBE
OUTDRIVE SHIM
x 1
BAG C
STEP 1
STEP 2
PAGE 5

1. TRIM ANY BURRS FROM THE INSIDE OF THE GEAR WITH A HOBBY KNIFE.
2. ADD A GENEROUS AMOUNT OF STEATLH DIFF LUBE TO THE RING GEAR
BALL HOLES AND PUSH IN THE TWELVE 3/32 DIFF BALLS. THEN PUSH IN
THE LUBE THAT CAME OUT.
TRIM ANY BURRS FROM THE INSIDE
OF THE GEAR WITH A HOBBY KNIFE
STEALTH DIFF LUBE
AFTER APPLYING THE STEALTH DIFF LUBE,
SNAP THE 3/32 DIFF BALLS IN PLACE
SHORT HUB ASSEMBLY
LONG HUB ASSEMBLY:
1. INSERT THE DIFF SPRING INTO THE LONG OUTDRIVE HUB.
2. INSERT THE T-NUT INTO THE LONG HUB UNTIL IT TOUCHES
THE DIFF SPRING.
3. ADD A LIGHT COAT OF STEALTH LUBE TO THE LONG HUB FACE.
4. PLACE A DIFF DRIVE RING ONTO THE FACE OF THE LONG HUB.
5. INSERT THE 3/16 x 5/16 DIFF BEARING INTO THE LONG HUB. NOTE: REMOVE ANY OIL RESIDUE FROM OUTDRIVE
HUB THOROUGHLY BEFORE APPLYING STEALTH LUBE.
3/16 x 5/16 DIFF BEARING
DIFF DRIVE RING
LONG OUTDRIVE HUB
DIFF SPRING
T-NUT
DIFF ASSEMBLY:
1. INSERT THE LONG HUB ASSEMBLY INTO THE SHORT HUB ASSEMBLY,
MAKING SURE YOU LINE UP THE BOLT IN THE HUB AND THE BOLT
THREADS INTO THE T-NUT.
CHECK ALIGNMENT OF THE HUBS
2. TIGHTEN THE DIFF WITH YOUR 5/64" ALLEN WRENCH, BUT NOT COMPLETELY.
3. SCREW IN THE DIFF BOLT A FEW TURNS THEN STOP TO ROTATE THE DIFF HUBS
IN OPPOSITE DIRECTIONS. THEN SCREW IN THE BOLT SOME MORE. FOLLOW
THIS PROCEDURE TO CHECK PROPER ALIGNMENT OF THE PARTS. THE
FOLLOWING NOTE CLARIFIES THIS.
READ THE FOLLOWING CAREFULLY
AS YOU TIGHTEN THE DIFF BOLT, PAY CLOSE ATTENTION TO THE FEELING WHEN THE SPRING IS FULLY
COMPRESSED. DO NOT OVERTIGHTEN THE BOLT. WHEN YOU FEEL THE SPRING COMPRESSED,
LOOSEN THE DIFF BOLT 1/4 TURN. NO MORE, NO LESS. AFTER YOU HAVE DRIVEN THE CAR FOR ONE
BATTERY PACK, RECHECK THE DIFF ADJUSTMENT AS ABOVE SO THAT WHEN YOU FEEL THE SPRING
FULLY COMPRESSED, LOOSEN THE DIFF BOLT 1/4 TURN. NEVER ADJUST THE DIFF ANY OTHER WAY.
NOW ASSEMBLE THE SECOND DIFF THE SAME WAY
TIGHTEN USING 5/64" ALLEN WRENCH
DIFFERENTIAL RING GEAR:
STEP 3
STEP 4
STEP 5
PAGE 6

3/8 x 5/8 BEARING
OUTDRIVE SHIMS,
VERY IMPORTANT
FINAL DIFF ASSEMBLY:
3/8 x 5/8 BEARING
x 4
1. SLIDE ONE OUTDRIVE SHIM AND ONE
3/8 x 5/8 BEARING ONTO EACH SIDE
OF THE DIFF ASSEMBLY.
SCALE: 1:1
CVD SET SCREW
x 2
CENTER CVD BONE "FRONT"
x 1
CENTER CVD BONE "REAR"
x 1
CVD COUPLING
x 2
CENTER CVD INPUT SHAFT
x 2
1. SPREAD A SMALL AMOUNT OF BLACK GREASE ON THE OUTSIDE OF THE CVD COUPLING AND INSERT THE
COUPLING INTO THE AXLE AS SHOWN.
2. SPREAD A SMALL AMOUNT OF BLACK GREASE ON THE ROUND PORTION OF THE AXLE AND INSERT INTO THE
CVD BONE, ALIGNING THE CROSS HOLES.
3. INSERT THE CROSS PIN, MAKING SURE IT IS EVENLY SPACED ON BOTH SIDES OF THE CVD BONE.
4. APPLY A SMALL AMOUNT OF MIP THREAD LOCKING COMPOUND TO THE SET SCREW. ANGLE AND TURN
THE CVD SO THE SET SCREW CAN BE SCREWED IN WITH AN ALLEN WRENCH.
5. REPEAT THIS PROCEDURE FOR BOTH FRONT AND REAR CENTER CVD'S.
CENTER CVD ASSEMBLY:
CENTER CVD COMPONENTS
CVD CROSS PIN
x 2
APPLY A SMALL AMOUNT
OF BLACK GREASE
CVD CROSS PIN
SOLID
APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND
STEP 6
CENTER CVD BAG
STEP 7
PAGE 7

DOWEL PIN
x 2
ATTENTION!
* (E-CLIPS ARE LOCATED IN THE SHOCK BAG)
INPUT SHAFT COMPONENTS
SMALL E-CLIP*
x 2
INPUT SHAFT SHIM
x 8
DRIVE PINON
x 2 3/16 x 3/8
BEARING
x 4
CAREFULLY TRIM ANY BURRS
FROM THIS EDGE OF THE DRIVE
PINION WITH A HOBBY KNIFE.
1. SLIDE TWO INPUT SHAFT SHIMS AND TWO 3/16 X 3/8 BEARINGS ONTO
THE INPUT SHAFT.
2. SLIDE TWO INPUT SHAFT SHIMS ONTO THE INPUT SHAFT.
3. INSTALL AND CENTER THE DOWEL PIN INTO THE INPUT SHAFT.
4. TRIM BURRS FROM THE DRIVE PINION EDGE WHERE SHOWN.
SLIDE THE DRIVE PINION ON TO THE INPUT SHAFT. MAKE SURE THE
DOWEL PIN ALIGNS PERFECTLY WITH THE SLOT IN THE PINION.
5. ADD THE SMALL E-CLIP.
6. REPEAT THIS PROCEDURE FOR THE OTHER INPUT SHAFT.
COMPARE ASSEMBLY:
INPUT SHAFT ASSEMBLY:
INPUT SHAFT SHIM
x 4
DRIVE PINON
x 1
DOWEL PIN
E-CLIP
3/16" x 3/8" BEARING
x 2
INPUT SHAFT
1. COMPARE YOUR ASSEMBLY CAREFULLY!
2. COMPLETE OTHER INPUT SHAFT ASSEMBLY TO MATCH.
CENTER CVD BONE "FRONT"
(SHOWN)
CENTER CVD BONE "FRONT" (SHOWN)
BAG C
STEP 8
STEP 9
PAGE 8

TRANSMISSION COMPONENTS
8°
FRONT TRANSMISSION HOUSING REAR TRANSMISSION HOUSING
4-40 x 5/16"
BUTTON HEAD
x 2
4-40 x 3/8"
BUTTON HEAD
x 4
4-40 x 3/8"
FLAT HEAD
x 6
4-40 x 3/8"
SOCKET HEAD
x 8
4-40 x 1/8"
SET SCREW
x 2
1. ATTACH THE FRONT, LOWER TRANSMISSION HOUSING TO THE CHASSIS
AND FRONT BULKHEAD USING TWO 4-40 x 5/16" BUTTON HEAD SCREWS
IN THE FRONT AND TWO 4-40 x 3/8" FLAT HEAD SCREWS IN THE BACK.
2. ATTACH THE REAR, LOWER TRANSMISSION HOUSING
TO THE REAR OF THE CHASSIS USING FOUR 4-40 x 3/8"
FLAT HEAD SCREWS.
3. TEMPORARILY SCREW A 4-40 x 1/8" SET SCREWS INTO
EACH SIDE OF THE REAR SUSPENSION MOUNT (FRONT).
LATER IN THE ASSEMBLY, IT WILL BE NECESSARY TO TIGHTEN
THESE SET SCREWS AGAINST THE REAR HINGE PINS.
A SMALL AMOUNT OF THREAD LOCKING COMPOUND
WILL BE ADDED AT THAT TIME.
TRANSMISSION CASE ASSEMBLY:
4-40 x 3/8"
FLAT HEAD
x 2
4-40 x 5/16"
BUTTON HEAD
x 2 4-40 x 3/8"
FLAT HEAD
x 4
4-40 x 1/8"
SET SCREW
x 2
BAG C
STEP 10
PAGE 9

1. INSTALL THE FRONT AND REAR DIFF ASSEMBLIES IN THE LOWER
TRANSMISSION CASES AS SHOWN BELOW.
2. INSTALL THE FRONT AND REAR INPUT SHAFT ASSEMBLIES AS
SHOWN BELOW. BE SURE TO INSERT THE DOGBONE END OF
EACH CVD ASSEMBLY INTO THE CENTER SLIPPER OUTDRIVE.
3. ADD A SMALL AMOUNT OF STEALTH LUBE TO THE FRONT SIDE
OF THE RING GEAR AND PINON GEAR ON BOTH ASSEMBLIES.
4. ATTACH EACH UPPER TRANSMISSION CASE WITH FOUR
4-40 x 3/8" SOCKET HEAD SCREWS AND TWO 4-40 x 3/8"
BUTTON HEAD SCREWS.
4-40 x 3/8"
BUTTON HEAD
x 2
4-40 x 3/8"
BUTTON HEAD
x 2
CENTER CVD INPUT SHAFT
"REAR"
CENTER CVD INPUT SHAFT
"FRONT"
APPLY A SMALL
AMOUNT OF
STEALTH LUBE
TRANSMISSION ASSEMBLY:
APPLY A SMALL
AMOUNT OF
STEALTH LUBE
COMPARE DRIVETRAIN ASSEMBLY:
4-40 x 3/8"
SOCKET HEAD
x 4
4-40 x 3/8"
SOCKET HEAD
x 4
STEP 11
PAGE 10
STEP 12

LONG STEERING
BELLCRANK
x 1
SHORT STEERING
BELLCRANK
x 1
1/8 x 1/4
BEARING
x 4
STEERING AND TOP DECK COMPONENTS
STEERING
BUSHING
x 2 STEERING POST
x 2
4-40 MINI
LOCKNUT
x 8
FRONT BODY
MOUNT
x 2
ANTENNA
MOUNT
x 1
FRONT TOWER
MOUNT
x 1
4-40 x 5/16"
FLAT HEAD
x 4
4-40 x 1/4"
BUTTON HEAD
x 4
4-40 x 5/16"
BUTTON HEAD
x 2
TRANSMISSION
SPACER
x 2
LONG
BALL END
x 6
SHORT
BALL END
x 1
4-40 x 3/8"
FLAT HEAD
x 9
4-40 x 3/8"
BUTTON HEAD
x 1
4-40 x 1/2"
FLAT HEAD
x 2
.030" NYLON
WASHER
x 2
REAR TOWER
MOUNT
x 1
.030" ALUMINUM
WASHER
x 11
STEERING ASSEMBLY:
4-40 x 1/4"
FLAT HEAD
x 4
2-56 x 5/16"
BUTTON HEAD
x 2
1. THREAD BOTH STEERING POSTS INTO THE STEERING BELLCRANKS AS SHOWN.
PAY ATTENTION TO THE ANGLE ON THE LONG BELLCRANK. THE LONG SIDE OF
THE BELLCRANK SHOULD ANGLE AWAY FROM THE CENTER OF THE ASSEMBLY.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
2. SLIDE ONE .030" NYLON WASHER ONTO THE TOP OF EACH STEERING POST.
3. SLIDE ONE .030" ALUMINUM WASHER ON TO A SHORT BALL END AND
FASTEN IT TO THE LONG BELLCRANK AS SHOWN.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
4. SLIDE THREE .030" ALUMINUM WASHERS ONTO A LONG BALL END.
INSERT THE BALL END WITH THE THREE WASHERS INTO THE BACK
HOLE OF THE GRAPHITE STEERING RACK (THE FLAT EDGE OF
THE STEERING RACK IS THE BACK EDGE). SECURE THE BALL
END WITH ONE 4-40 MINI LOCKNUT. REPEAT FOR OTHER SIDE.
5. INSERT A STEERING BUSHING INTO THE GRAPHITE STEERING RACK
(NOTE DIRECTION). SLIDE ONE 4-40 x 5/16" BUTTON HEAD SCREW
UP THROUGH THE BOTTOM OF THE RACK AND TIGHTEN THE SCREW
INTO THE BELLCRANK. REPEAT FOR OTHER SIDE.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
BODY MOUNT
PAD
x 2
APPLY A SMALL
AMOUNT OF
THREAD LOCKING
COMPOUND
NYLON
NOTE DIRECTION
APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND
BAG D
STEP 1
PAGE 11

1. ATTACH THE FRONT TOWER MOUNT USING TWO 4-40 x 1/4" FLAT HEAD SCREWS.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
2. CAREFULLY FILE THE LEADING EDGE OF THE TOP PLATE SO IT IS AT THE SAME ANGLE AS THE FRONT TOWER
MOUNT WHEN VIEWED FROM THE SIDE. (REFER TO ILLUSTRATION BELOW)
3. SLIDE ONE .030" WASHER ON EACH OF FOUR LONG BALL ENDS. INSERT THE BALL ENDS, WITH WASHERS,
INTO THE HOLES SHOWN BELOW. SECURE THE BALL ENDS USING FOUR 4-40 MINI LOCKNUTS.
4. ATTACH THE FRONT BODY MOUNTS WITH TWO 4-40 x 1/4" BUTTON HEAD SCREWS.
5. ATTACH A BEARING BLOCK TO THE BOTTOM OF THE TOP DECK USING TWO 4-40 x 3/8" FLAT HEAD SCREWS.
SECURE WITH TWO 4-40 MINI LOCKNUTS.
6. ATTACH THE ANTENNA MOUNT TO THE TOP DECK USING TWO 2-56 x 1/4" BUTTON HEAD SCREWS.
7. ATTACH THE REAR TOWER MOUNT WITH TWO 4-40 x 1/4" BUTTON HEAD SCREWS FROM THE
BOTTOM OF THE TOP DECK. FINISH ATTACHING THE REAR TOWER MOUNT BY ADDING TWO
4-40 x 1/4" FLAT HEAD SCREWS. REFER TO ILLUSTRATION BELOW FOR LOCATION OF SCREWS.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
2-56 x 5/16"
BUTTON HEAD
x 2
ANTENNA MOUNT
4-40 x 3/8" FLAT HEAD
x 2
FILING TOP DECK EDGE
LONG BALL END WITH ONE
.030" ALUMINUM WASHER
x 4
FILE EDGE AS
SHOWN BELOW
4-40 x 1/4"
BUTTON HEAD
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
4-40 x 1/4" BUTTON HEAD
x 2
4-40 x 1/4" FLAT HEAD
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
4-40 x 1/4" FLAT HEAD
x 2
TOP DECK
DETAIL A (LEFT SIDE VIEW)
EDGE
TOP DECK ASSEMBLY:
STEP 2
PAGE 12

1. INSERT TWO 1/8 X 1/4 BEARINGS INTO THE BEARING BLOCK ON THE CHASSIS.
2. SLIDE THE STEERING ASSEBLY INTO THE BEARINGS.
3. SLIDE ONE 1/8 X 1/4 BEARING ONTO THE TOP OF EACH STEERING POST.
4. TO ATTACH THE FRONT PORTION OF THE TOP DECK, LINE UP THE BEARING BLOCK ON THE BOTTOM OF THE TOP
DECK WITH THE TWO BEARINGS ON TOP OF THE STEERING POSTS. PRESS THE TOP DECK DOWN INTO PLACE.
5. SLIDE ONE ALUMINUM TRANSMISSION SPACER BETWEEN THE UPPER TRANSMISSION CASE AND THE TOP DECK.
INSERT ONE 4-40 x 1/2" FLAT HEAD SCREW AND TIGHTEN. REFER TO ILLUSTRATION BELOW FOR LOCATION.
6. FINISH SECURING THE FRONT PORTION OF THE TOP DECK WITH THREE 4-40 x 3/8" FLAT HEAD SCREWS AND
TWO 4-40 x 5/16" FLAT HEAD SCREWS. REFER TO ILLUSTRATION BELOW FOR LOCATION OF SCREWS.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND TO THE 4-40 x 5/16" FLAT HEAD SCREWS)
7. POSITION THE REAR PORTION OF THE TOP DECK AS SHOWN BELOW, AND REPEAT STEP 5 ABOVE.
8. FINISH SECURING THE REAR PORTION OF THE TOP DECK WITH TWO 4-40 x 3/8" FLAT HEAD SCREWS AND
TWO 4-40 x 5/16" FLAT HEAD SCREWS. REFER TO ILLUSTRATION BELOW FOR LOCATION OF SCREWS.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND TO THE 4-40 x 5/16" FLAT HEAD SCREWS)
9. ATTACH ONE BODY MOUNT PAD ON EACH SIDE OF THE CHASSIS USING A 4-40 x 3/8" FLAT HEAD SCREW.
4-40 x 3/8"
FLAT HEAD
x 3
4-40 x 1/2"
FLAT HEAD
TRANSMISSION
SPACER
TRANSMISSION
SPACER
4-40 x 3/8"
FLAT HEAD
x 2
4-40 x 1/2"
FLAT HEAD
4-40 x 5/16"
FLAT HEAD
x 4
(APPLY A SMALL
AMOUNT OF THREAD
LOCKING COMPOUND)
TOP DECK ASSEMBLY:
4-40 x 3/8"
FLAT HEAD
x 2
STEP 3
PAGE 13

APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND
CVD CROSS PIN
SOLID
APPLY A SMALL AMOUNT
OF BLACK GREASE
1. SPREAD A SMALL AMOUNT OF BLACK GREASE ON THE OUTSIDE OF THE CVD COUPLING AND INSERT THE
COUPLING INTO THE AXLE AS SHOWN.
2. SPREAD A SMALL AMOUNT OF BLACK GREASE ON THE ROUND PORTION OF THE AXLE AND INSERT INTO THE
CVD BONE, ALIGNING THE CROSS HOLES.
3. INSERT THE CROSS PIN, MAKING SURE IT IS EVENLY SPACED ON BOTH SIDES OF THE CVD BONE.
4. APPLY A SMALL AMOUNT OF MIP THREAD LOCKING COMPOUND TO THE SET SCREW. ANGLE AND TURN
THE CVD SO THE SET SCREW CAN BE SCREWED IN WITH AN ALLEN WRENCH.
5. REPEAT THIS PROCEDURE FOR ALL OF THE CVD'S. SET THE COMPLETED CVD'S AND ADDITIONAL HARDWARE
ASIDE FOR LATER ASSEMBLIES.
FRONT/REAR CVD ASSEMBLY:
APPLY A SMALL AMOUNT
OF BLACK GREASE
CVD FRONT BONE
x 2
CVD FRONT AXLE
x 2
CVD COUPLING
x 2 CVD CROSS PIN
x 2 CVD SET SCREW
x 2 BEARING SPACER
x 2
CVD ROLL PIN
x 2
CVD FRONT HEX
x 2
REAR CVD COMPONENTS
CVD FRONT
WHEEL NUT
x 2
CVD ROLL PIN
x 2
CVD REAR BONE
x 2
CVD REAR AXLE
x 2
CVD CROSS PIN
x 2 CVD SET SCREW
x 2 CVD AXLE
SHIM (THIN)
x 6
CVD AXLE
SHIM (THICK)
x 2
CVD COUPLING
x 2
CVD REAR
WHEEL NUT
x 2
FRONT CVD COMPONENTS
CVD BAG
STEP 1
CVD BAG
PAGE 14

KING PIN
x 4
STEERING AND CASTER BLOCK ASSEMBLY:
.030 ALUMINUM
WASHER
x 4
STEERING BLOCK
LEFT & RIGHT
x 1 EACH
4-40 MINI
LOCKNUT
x 2
4-40 x 1/4"
BUTTON HEAD
x 2
CASTER BLOCK
LEFT & RIGHT
x 1 EACH
BALL CUP
x 12
NOTE DIRECTION OF STEERING BLOCK AND CASTER BLOCK
ATTENTION!
TITANIUM TURNBUCKLE
2.00" (CAMBER)
x 2
HINGE PIN 1.55"
(FRONT INNER)
x 2
4-40 x 3/8"
BUTTON HEAD
x 2
SHORT
BALL END
x 4
FRONT A-ARM
x 2
PIVOT SLEEVE
x 2
BALL END DUST COVER
x 14
HINGE PIN 1.OO"
(FRONT OUTER)
x 2
TITANIUM TURNBUCKLE
1.775" (STEERING)
x 2
1. INSTALL ONE 3/16 x 3/8 BEARING ONTO THE CVD AXLE. SLIDE THE AXLE
ASSEMBLY INTO THE BACK OF THE STEERING BLOCK.
2. IN ORDER, SLIDE A BEARING SPACER, 3/16 x 3/8 BEARING,
AND CVD FRONT HEX ONTO THE CVD AXLE.
3. PRESS THE BEARING INTO THE STEERING BLOCK
AND INSERT A ROLL PIN THROUGH THE GROOVE
IN THE CVD HEX AND INTO THE AXLE.
5. PARTIALLY THREAD A FRONT WHEEL NUT ON THE AXLE.
6. SLIDE THE CVD BONE THROUGH THE CASTER BLOCK. WHEN ANGLED
CORRECTLY, THE CVD BONE WILL DROP THROUGH THE CASTER BLOCK
FREELY. FIT THE STEERING BLOCK OVER THE CASTOR BLOCK AND
SECURE IT USING TWO KING PIN SCREWS.
7. SLIDE ONE .030" WASHER ON EACH OF TWO SHORT BALL ENDS.
THREAD ONE BALL END WITH WASHER INTO THE CASTER BLOCK.
(APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
8. SLIDE ONE SHORT BALL END WITH WASHER INTO THE STEERING BLOCK.
SECURE IT WITH ONE 4-40 MINI LOCKNUT.
9. REPEAT FOR THE OPPOSITE SIDE ASSEMBLY.
3/16 x 3/8 BEARING
3/16 x 3/8 BEARING
KING PIN
x 2
4-40 x 5/16"
SOCKET HEAD
x 4
3/16 x 3/8
BEARING
x 4
2-56 x 1/8"
BUTTON HEAD
x 4
FRONT HINGE
PIN BRACE
x 1
FRONT END COMPONENTS
BAG E
STEP 1
PAGE 15

FRONT INNER
HINGE PIN
x 2
2-56 x 1/8"
BUTTON HEAD
x 2
4-40 x 3/8"
BUTTON HEAD
x 2
4-40 x 1/4"
BUTTON HEAD
x 2
FRONT SUSPENSION ASSEMBLY:
1. INSERT BOTH PIVOT SLEEVES INTO THE FRONT BULKHEAD.
2. ALIGN THE FRONT A-ARMS WITH THE PIVOT SLEEVES AND PRESS THE FRONT INNER HINGE PINS INTO PLACE.
3. SLIDE THE FRONT HINGE PIN BRACE OVER THE FRONT INNER HINGE PINS UNTIL IT PRESSES AGAINST THE FRONT
BULKHEAD. NOTE THE DIRECTION AND LOCATION OF THE 2-56 HOLES IN THE ILLUSTRATION BELOW.
4. ATTACH THE FRONT SHOCK TOWER USING TWO 4-40 x 3/8" BUTTON HEAD SCREWS AT THE BOTTOM AND TWO
4-40 x 1/4" BUTTON HEAD SCREWS AT THE TOP. (APPLY A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
5. CAPURE THE FRONT INNER HINGE PINS BY INSERTING TWO 2-56 x 1/8" BUTTON HEAD
SCREWS INTO THE FRONT HINGE PIN BRACE.
6. CHECK TO MAKE SURE SUSPENSION ARMS PIVOT FREELY.
FRONT SUSPENSION ASSEMBLY:
1. POSITION THE CASTER BLOCK ASSEMBLIES AS SHOWN
AND SLIDE THE FRONT OUTER HINGE PINS INTO PLACE.
2. CAPTURE THE FRONT OUTER HINGES BY INSERTING A
2-56 x 1/8" BUTTON HEAD SCREW INTO EACH A-ARM.
3. PUT BALL END DUST COVERS ON THE FRONT
SUSPENSION AND TOP DECK BALL ENDS.
4. MAKE SURE THE CASTER BLOCKS
PIVOT FREELY IN THE A-ARMS.
2-56 x 1/8"
BUTTON HEAD
x 2
FRONT OUTER
HINGE PIN
x 2
STEP 2
PAGE 16
STEP 3

LONG BLACK
BALL END
x 2
REAR A-ARM
LEFT & RIGHT
x 1 EACH
REAR END COMPONENTS
HUB CARRIER
LEFT & RIGHT
x 1 EACH
2-56 x 1/8"
BUTTON HEAD
x 2
HINGE PIN 1.O6"
(REAR OUTER) x 2
TITANIUM TURNBUCKLE
2.00" (CAMBER) x 2
.030 NYLON
WASHER
x 4
4-40 MINI
LOCKNUT
x 2
HINGE PIN 2.00"
(REAR INNER) x 2
BEARING
SPACER
x 2
HUB CARRIER ASSEMBLY:
1. SLIDE TWO SMALL AXLE SHIMS AND ONE 3/16 x 3/8
BEARING ONTO THE CVD AXLE. SLIDE THE AXLE
ASSEMBLY INTO THE BACK OF THE HUB CARRIER.
2. IN ORDER, SLIDE A BEARING SPACER, 3/16 x 3/8
BEARING, AND ONE THICK AXLE SHIM ONTO THE
CVD AXLE.
3. PRESS THE BEARING INTO THE HUB CARRIER AND
INSERT A ROLL PIN INTO THE AXLE.
4. PARTIALLY THREAD A REAR WHEEL NUT ON THE AXLE.
5. THREAD ONE LONG BLACK BALL END INTO THE MIDDLE
HOLE ON THE HUB CARRIER. SECURE IT USING ONE 4-40
MINI LOCKNUT. REFER TO ILLUSTRATION FOR LOCATION.
6. REPEAT FOR THE OPPOSITE ASSEMBLY.
ATTENTION!
LONG BLACK
BALL END
THIN AXLE SHIMS
x 2
ROLL PIN
THIS IS A LEFT SIDE ASSEMBLY ILLUSTRATION, NOTE
DIRECTION AND CONFIGURATION OF HUB CARRIER
3/16 x 3/8
BEARING
x 2
1.30
FRONT CAMBER TURNBUCKLE 2.00": x 2
SCALE 1:1
1. TWIST THE BALL CUPS ON TO EACH BLUE TITANIUM TURNBUCKLE
UNTIL YOU GET THE DIMENSION SHOWN FOR EACH PART.
2. LOCATE THE NOTCH ON EACH TURNBUCKLE AND ROTATE
THEM SO THAT IT IS LOCATED ON THE OUTSIDE OF THE CAR
ON THE LEFT AND THE INSIDE ON THE RIGHT. SNAP ALL OF
THE FRONT TURNBUCKLES INTO PLACE WHERE SHOWN.
MAKE SURE THAT ALL OF THE CVD BONES ARE IN THE SLOTS
OF THE OUTDRIVE HUBS.
FRONT TURNBUCKLE ASSEMBLY:
1.00
FRONT STEERING TURNBUCKLE 1.775": x 2
SCALE 1:1
STEERING
TURNBUCKLE
CAMBER
TURNBUCKLE
STEP 4
BAG F
STEP 1
PAGE 17

1.25
REAR CAMBER TURNBUCKLE 2.00": x 2
SCALE 1:1
1. TWIST THE BALL CUPS ONTO EACH BLUE TITANIUM TURNBUCKLE
UNTIL YOU GET THE DIMENSION SHOWN FOR EACH EACH PART.
2. LOCATE THE NOTCH ON EACH TURNBUCKLE AND ROTATE THEM
SO THAT IT IS LOCATED ON THE OUTSIDE OF THE CAR ON THE
LEFT AND THE INSIDE ON THE RIGHT. SNAP ALL THE REAR
TURNBUCKLES INTO PLACE WHERE SHOWN. MAKE SURE
THAT ALL THE CVD BONES ARE IN THE SLOTS OF THE
OUTDRIVE HUBS.
REAR TURNBUCKLE ASSEMBLY:
COMPARE SUSPENSION ASSEMBLY:
ATTENTION! THIS IS A LEFT SIDE ASSEMBLY ILLUSTRATION, NOTE
DIRECTION AND CONFIGURATION OF HUB CARRIER
2-56 x 1/8"
BUTTON HEAD
4-40 x 1/8"
SET SCREW
1. ATTACH THE REAR SHOCK TOWER WITH FOUR 4-40 x 5/16"
SOCKET HEAD SCREWS. (APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
2. ALIGN THE REAR A-ARMS BETWEEN THE REAR SUSPENSION
MOUNTS. SLIDE THE REAR INNER HINGE PINS INTO PLACE
AND SECURE THEM WITH WITH THE 4-40 SET SCREWS. (APPLY
A SMALL AMOUNT OF THREAD LOCKING COMPOUND)
3. POSITION THE HUB CARRIER ASSEMBLY AS SHOWN AND
SLIDE THE REAR OUTER HINGE PINS PARTIALLY THROUGH
THE HUB CARRIERS. POSITION TWO .030" NYLON WASHERS
BEHIND EACH HUB CARRIER AND CONTINUE TO PUSH THE
HINGE PIN THROUGH THE WASHERS INTO THE A-ARM.
4. CAPTURE THE OUTER HINGE PINS WITH A 2-56 x 1/8"
BUTTON HEAD SCREW INTO EACH A-ARM.
5. PUT BALL END DUST COVERS ON ALL OF THE REAR
SUSPENSION BALL ENDS.
6. MAKE SURE THE A-ARMS AND HUB CARRIERS PIVOT FREELY.
REAR SUSPENSION ASSEMBLY:
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
4-40 x 5/16"
SOCKET HEAD
x 4
REAR INNER
HINGE PIN
x 2
REAR OUTER
HINGE PIN
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
STEP 2
STEP 4
PAGE 18
STEP 3

4-40 x 3/4"
BUTTON HEAD
x 4
SHOCK COMPONENTS
THREAED SHOCK
COLLAR
x 4
.030 TRAVEL
LIMITER
x 2
SHOCK
BUSHING
x 4
SPRING CUP
x 4
SHOCK COLLAR
O-RING
x 4
SHOCK PIVOT
BUSHING
x 4
SHOCK
NUT
x 4
FRONT SHOCK
SHAFT (.89")
x 2
SMALL SHOCK
SPACER
x 8 (TREE)
GOLD
WASHER
x 4
SHOCK CAP
x 4
SHOCK PISTON
#1, #2, #3
x 1 (TREE)
LARGE SHOCK
SPACER
x 4 (TREE)
E-CLIP ROLL
x 1
SHOCK
O-RING
x 8
SHOCK SNAP
RETAINER
x 4 (TREE)
4-40 x 1/2"
SOCKET HEAD
x 4
4-40 PLAIN
NUT
x 4
FRONT SHOCK
BODY (.89")
x 2
REAR SPRING (BLACK)
x 2
FRONT SPRING (SILVER)
x 2
SETUP NOTES:
SHOCK EYELET
x 4
REAR SHOCK
BODY (1.18")
x 2
REAR SHOCK
SHAFT (1.02")
x 2
SHOCK CAP
O-RING
x 4
SPRING RETAINER
x 4
SHOCK BAG
PAGE 21