Jconcepts BJ4 User manual

A
2. REAR TRANSMISSION SLOT: THE PURPOSE OF THIS STEP IS TO FILE THE REAR TRANSMISSION SLOT TO
ALLOW THE REAR TRANSMISSION CASE TO SIT FLAT ON THE CHASSIS. (REFER TO PICTURES BELOW)
FILE
FILING BATTERY SLOTS:
FILE
FILING TRANSMISSION SLOT:
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.
TOOLS NEEDED TO BUILD THIS KIT:
1. ALLEN WRENCHES
A. .050"
B. 1/16"
C. 5/64"
D. 3/32"
E. 2.5mm
CHASSIS PREPARATION:
2. NUT DRIVERS
A. 3/16"
B. 1/4"
C. 11/32"
BAG "A" INCLUDES:
CHASSIS x 1
TOP DECK x 1
FRONT SHOCK TOWER x 1
REAR SHOCK TOWER x 1
BEARING BLOCK x 2
STEERING RACK x 1
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
F. 7/16" OPEN END WRENCH
4. HELPFUL TOOLS (NOT REQUIRED)
A. VERNIER CALIPERS
B. HOBBY SCISSORS
C. 2.5mm BALL END HEX DRIVER
ITEMS NEEDED TO COMPLETE YOUR CAR:
1. R/C TWO CHANNEL SURFACE FREQUENCY RADIO SYSTEM.
2. BATTERY PACK (6 CELL)
3. BATTERY CHARGER (PEAK DETECTION CHARGER)
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: HOLESHOTS)
8. 1/10TH SCALE BUGGY REAR TIRES (BOX ART SHOWN: HOLESHOTS)
1. BATTERY SLOTS: THE PURPOSE OF THIS STEP IS TO FILE THE BATTERY SLOTS SO THAT WHEN THE BATTERY PACK
IS IN THE CAR, THE BOTTOM OF THE BATTERY IS ALMOST EVEN WITH THE CHASSIS. (REFER TO PICTURES BELOW)
NOTE: FILE 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.
A PROPERLY FILED BATTERY SLOT SHOULD ALLOW THE
BATTERY TO SIT ALMOST EVEN WITH THE BOTTOM OF THE
CHASSIS. CHECK THE FIT USING A BATTERY PACK, AND
REMOVE A SMALL AMOUNT OF MATERIAL AT A TIME UNTIL
THE PROPER FIT IS ACHIEVED.
NOTE: PROPER FIT
BATTERY PACK
TOOLS
BAG A
STEP 1

REAR SUSPENSION MOUNT (BACK) x 1
NOTE MOUNTING DIRECTION IN DRAWING
BELOW
REAR SUSPENSION MOUNT
4-40 x 5/16" x 4
MOTOR MOUNT
4-40 x 5/16" x 3
FRONT BULKHEAD
5-40 x 5/16" x 2
4-40 MINI LOCKNUTS
x 2
1. ATTACH FRONT BULKHEAD TO CHASSIS WITH TWO 5-40 X 5/16" FLAT HEAD SCREWS.
2. ATTACH BEARING BLOCK TO CHASSIS WITH TWO 4-40 X 3/8" FLAT HEAD SCREWS. SECURE WITH TWO 4-40 LOCKNUTS.
3. ATTACH MOTOR MOUNT TO CHASSIS WITH THREE 4-40 X 5/16" FLAT HEAD SCREWS. LEAVE SCREWS LOOSE SO THE
MOTOR MOUNT HAS SOME MOVEMENT FRONT TO BACK. SCREWS WILL BE TIGHTENED LATER IN THE ASSEMBLY.
4. ATTACH REAR SUSPENSION MOUNT (FRONT) WITH TWO 4-40 X 5/16" FLAT HEAD SCREWS. NOTE DIRECTION
5. ATTACH REAR SUSPENSION MOUNT (BACK) WITH TWO 4-40 X 5/16" FLAT HEAD SCREWS. NOTE DIRECTION
1. 1/16" ALLEN WRENCH
2. 5/64" ALLEN WRENCH
3. 3/16" NUT DRIVER
APPLY BLUE THREAD LOCKING COMPOUND
WHERE NOTED. (JUST A SMALL AMOUNT)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
BEARING BLOCK
4-40 x 3/8" x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
FRONT BULKHEAD
x 1
REAR SUSPENSION MOUNT (FRONT) x 1
NOTE MOUNTING DIRECTION IN DRAWING
BELOW
ASSEMBLING CHASSIS COMPONENTS:
MOTOR MOUNT
x 1 4-40 x 3/8" FLAT HEAD x 2
HARDWARE INSIDE BAG "B"
SCALE: 1:1
4-40 x 5/16" FLAT HEAD
x 7
5-40 x 5/16" FLAT HEAD
x 2 4-40 MINI LOCKNUT
x 2
BEARING BLOCK AND
CHASSIS FROM BAG "A"
BAG B
STEP 1
TOOLS USED

DIFF THRUST WASHER
x 2
DIFF SPRING
x 1
1. 5/64" ALLEN WRENCH
2. NEEDLE NOSE PLIERS
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)
SCALE: 1:1
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
TOOLS USED

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

3/8 X 5X8 BEARING
OUTDRIVE SHIM
VERY IMPORTANT
* (E-CLIPS ARE LOCATED IN THE SHOCK BAG)
FINAL OUTDRIVE ASSEMBLY:
3/8 x 5X8 RUBBER
SEALED BEARING
x 4
1. PRESS ONE OUTDRIVE SHIM ON THE LONG HUB.
(NOTE CORRECT DIRECTION ON DRAWING)
2. PLACE ONE 3/8 X 5/8 BEARING OVER EACH
OUTDRIVE HUB.
SCALE: 1:1
DOWEL PIN
x 2
ATTENTION!
FRONT INPUT SHAFT BAG CONTENTS
SCALE: 1:1
* SMALL E-CLIP
x 1 INPUT SHAFT SHIM
x 3 4-40 X 3/16"
BUTTON HEAD SCREW
x 1
DRIVE PINON
x 1
FRONT INPUT SHAFT ASSEMBLY:
3/16 X 3/8 RUBBER
SEALED BEARING
x 2
FRONT INPUT SHAFT
x 1
DRIVE CUP
x 1
1. INSTALL AND CENTER THE DOWEL PIN INTO THE FRONT INPUT SHAFT. (FIGURE 1)
2. TRIM BURRS FROM THE DRIVE PINION EDGE WHERE SHOWN BELOW.
SLIDE THE DRIVE PINION ON TO THE INPUT SHAFT. MAKE SURE THE
DOWEL PIN ALIGNS PERFECTLY WITH THE SLOT IN THE PINION.
3. ADD THE SMALL E-CLIP.
4. SLIDE TWO INPUT SHAFT SHIMS AND ONE 3/16 X 3/8 BEARING ONTO
THE INPUT SHAFT.
5. SLIDE THE SECOND BEARING ONTO THE INPUT SHAFT, THEN ONE INPUT
SHAFT SHIM. (FIGURE 2)
6. INSTALL AND CENTER THE DOWEL PIN INTO THE INPUT SHAFT.
7. SLIDE A DRIVE CUP ONTO THE END OF THE INPUT SHAFT.
8. TIGHTEN IT DOWN WITH ONE 4-40 x 3/16" SCREW.
FIGURE 1 FIGURE 2
SECOND BEARING
IN POSTION SCALE
1.5 : 1
FRONT INPUT SHAFT ASSEMBLED
(PLEASE COMPARE YOUR ASSEMBLY CAREFULLY)
CAREFULLY TRIM ANY BURRS
FROM THIS EDGE OF THE DRIVE
PINION WITH A HOBBY KNIFE.
STEP 6
BAG C
STEP 7

*SMALL E-CLIP
x 1 INPUT SHAFT SHIM
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
3/16 X 3/8 RUBBER
SEALED BEARING
x 2
4-40 X 3/16"
BUTTON HEAD SCREW
x 2
ONE-WAY HUB
x 1
72 TOOTH SPUR GEAR
x 1
DOWEL PIN
x 2
INNER SLIPPER HUB
x 1
DRIVE PINON
x 1
OUTER SLIPPER HUB
x 1
3/16 x 3/8 BUSHING
x 1
SLIPPER THRUST
RETAINER
x 1
* (E-CLIPS ARE LOCATED IN THE SHOCK BAG)
1/4 X 28 LOCKNUT
x 1
ONE-WAY SLIPPER SHAFT
x 1
SLIPPER PAD
x 1
SMALL C-CLIP
x 1
OUTER SLIPPER HUB ASSEMBLY:
1. 1/16" ALLEN WRENCH
2. 7/16" OPEN END WRENCH
3. NEEDLE NOSE PLIERS
1. PLACE BUSHING IN RECESS OF OUTER SLIPPER HUB.
2. SLIDE SPUR GEAR ONTO BUSHING AND FASTEN TO OUTER
SLIPPER HUB WITH TWO 4-40 X 3/16" BUTTON HEAD SCREWS.
(APPLY THREAD LOCKING COMPOUND TO SCREWS)
1. IN ORDER, SLIDE THE SLIPPER THRUST RETAINER, OUTER SLIPPER HUB ASSEMBLY,
SLIPPER PAD, AND INNER SLIPPER HUB ONTO THE SLIPPER SHAFT.
2. INSTALL DOWEL PIN AND SLIDE ENTIRE SLIPPER ASSEMBLY BACK
SO IT CAPTURES THE DOWEL PIN.
3. SLIDE SLIPPER SPRING AND LOCKNUT ONTO THE OPPOSITE END OF THE SHAFT.
4. TIGHTEN THE LOCKNUT UNTIL THE SLIPPER SPRING COMPRESSES
TO APPROXIMATELY 0.25" IN LENGTH.
ATTENTION!
THE NYLON INSERT IN THE LOCKNUT IS VERY TIGHT ON THE
SLIPPER SHAFT THREADS. IN ORDER TO TIGHTEN THE LOCKNUT
TO THE GIVEN LENGTH, INSERT A .050" ROD THROUGH THE SHAFT
AND TIGHTEN THE LOCKNUT WITH A 7/16" OPEN END WRENCH.
(DO NOT USE PLIERS ON THE SLIPPER SHAFT!!!)
REAR INPUT SHAFT/SLIPPER ASSEMBLY:
4-40 x 3/16" x 2
USE SHORTER 1/4" DOWEL PIN
LOCATED SEPARATELY
SLIPPER SPRING
x 1
REAR INPUT SHAFT BAG CONTENTS
BAG C
STEP 8
STEP 9
TOOLS USED

1. SLIDE ONE BEARING AND TWO INPUT SHAFT SHIMS ONTO THE SLIPPER SHAFT.
2. INSTALL AND CENTER A DOWEL PIN INTO THE SLIPPER SHAFT.
3. SLIDE A DRIVE PINON ONTO THE END OF THE INPUT SHAFT. MAKE SURE THE
DOWEL PIN ALIGNS PERFECTLY WITH THE SLOT IN THE PINION.
4. ADD A SMALL E-CLIP.
REAR INPUT SHAFT/SLIPPER ASSEMBLY:
COMPARE REAR INPUT SHAFT/SLIPPER ASSEMBLY
4-40 X 3/8"
BUTTON HEAD SCREW
x 4
4-40 X 3/8"
BUTTON HEAD SCREW
x 4
4-40 X 3/8"
FLAT HEAD SCREW
x 6
1. 1/16" ALLEN WRENCH
2. 3/32" ALLEN WRENCH
3. .050" ALLEN WRENCH
TRANSMISSION COMPONENTS
8°
FRONT TRANSMISSION HOUSING REAR TRANSMISSION HOUSING
4-40 x 1/8"
SET SCREW
x 2
DRIVE SHAFT
4-40 X 3/8"
SOCKET HEAD SCREW
x 8
STEP 10
STEP 11
BAG C TOOLS USED

FRONT TRANSMISSION ASSEMBLY, LOWER HALF:
1. ATTACH THE LOWER FRONT 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.
4-40 x 5/16"
BUTTON HEAD
x 2
FRONT TRANSMISSION ASSEMBLY:
1. INSTALL THE FRONT DIFF ASSEMBLY AND FRONT INPUT SHAFT
ASSEMBLY IN THE LOWER TRANSMISSION CASE.
2. ADD A SMALL AMOUNT OF STEALTH LUBE TO THE FRONT SIDE
OF THE RING GEAR AND PINON GEAR.
3. ATTACH THE UPPER TRANSMISSION CASE TO THE LOWER 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
APPLY A SMALL AMOUNT
OF STEALTH LUBE
REAR TRANSMISSION ASSEMBLY, LOWER HALF:
1. ATTACH THE LOWER REAR TRANSMISSION HOUSING
TO THE REAR OF THE CHASSIS USING FOUR 4-40 x 3/8"
FLAT HEAD SCREWS.
2. TEMPORARILY SCREW THE 4-40 x 1/8" SET SCREWS INTO
THE REAR SUSPENSION MOUNT (FRONT) ON BOTH SIDES.
LATER IN THE CAR ASSEMBLY IT WILL BE NECESSARY TO
TIGHTEN THE SET SCREWS AGAINST THE HINGE PINS.
A SMALL AMOUNT OF THREAD LOCKING COMPOUND
WILL BE USED AT THAT TIME.
4-40 x 1/8"
SET SCREW
x 2 4-40 x 3/8"
FLAT HEAD
x 4
4-40 x 3/8"
FLAT HEAD
x 2
STEP 12
STEP 13
STEP 14

1. UNBOLT THE MOTOR MOUNT FROM THE CHASSIS WHERE IT WAS LOOSELY ATTACHED IN CHASSIS ASSEMBLY STEP 1.
2. SLIDE THE SLIPPER SHAFT ASSEMBLY THROUGH THE BACKSIDE OF THE MOTOR MOUNT. SLIDE ONE 3/16 x 3/8 BEARING
ONTO THE SLIPPER SHAFT, MAKING SURE IT SETS NICELY INTO THE COUNTERBORED SIDE OF THE MOTOR MOUNT.
3. PRESS THE SMALL C-CLIP ON THE GROOVE LOCATED ON THE SLIPPER SHAFT AND SNAP INTO PLACE.
4. SLIDE THE ONE-WAY HUB ONTO THE SLIPPER SHAFT ASSEMBLY. TIP - SPINNING THE ONE-WAY HUB
WHILE PRESSING IT ON THE SHAFT MAKES IT EASIER TO INSTALL.
5. INSTALL THE REAR DIFF ASSEMBLY IN THE LOWER REAR TRANSMISSION CASE.
REAR TRANSMISSION ASSEMBLY:
SMALL C-CLIP
3/16 X 3/8
BEARING
ONE-WAY HUB
FRONT SIDE
OF GEAR
REAR TRANSMISSION ASSEMBLY:
4-40 x 5/16"
FLAT HEAD
x 3
1. LOCATE THE DRIVE SHAFT AND LINE UP THE SLOT ON THE FRONT TRANSMISSION CUP AND PIN
ON THE DRIVE SHAFT AND SLIDE IT INTO PLACE.
2. HOLD THE MOTOR MOUNT AND REAR SLIPPER ASSEMBLY ABOVE THE CHASSIS SURFACE WHILE
HOLDING THE DRIVE SHAFT AT AN ANGLE WHERE THEY PROPERLY SLIDE TOGETHER.
3. LOWER THE MOTOR MOUNT AND SLIPPER ASSEMBLY, WITH THE DRIVE SHAFT INSTALLED,
DOWN TO THE CHASSIS SURFACE. ROTATING THE GEARS MAY BE NECESSARY TO
GET THEM TO MESH AND FOR THE ENTIRE ASSEMBLY TO FIT INTO PLACE.
(ADD A SMALL AMOUNT OF STEALTH LUBE AS NOTED)
4. SECURE THE MOTOR MOUNT TO THE CHASSIS WITH
THREE 4-40 x 5/16" FLAT HEAD SCREWS.
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
APPLY A SMALL AMOUNT
OF STEALTH LUBE
STEP 15
STEP 16

COMPARE TRANSMISSION ASSEMBLY
REAR TRANSMISSION ASSEMBLY:
1. ATTACH THE UPPER TRANSMISSION CASE TO THE LOWER
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"
SOCKET HEAD
x 4
STEP 17
STEP 18

COMPARE DRIVETRAIN ASSEMBLY
1/8 x 1/4
BEARING
x 4
STEERING AND TOP DECK COMPONENTS
1. 1/16" ALLEN WRENCH
2. NEEDLE NOSE PLIERS
3. 3/16" NUT DRIVER
LONG STEERING
BELLCRANK
x 1
SHORT STEERING
BELLCRANK
x 1
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 2
4-40 X 1/4"
BUTTON HEAD
x 4
TRANSMISSION
SPACER
x 2
LONG
BALL END
x 6
.030 ALUMINUM
WASHER
x 11
4-40 x 1/2" SOCKET
HEAD WITH HOLE
x 2
SHORT
BALL END
x 1
4-40 X 1/2"
FLAT HEAD
x 2
4-40 X 3/8"
FLAT HEAD
x 9
4-40 X 3/8"
BUTTON HEAD
x 3
.030 NYLON
WASHER
x 2
BATTERY POST
x 2 REAR TOWER
MOUNT
x 1
4-40 X 1/4"
FLAT HEAD
x 6
BATTERY
RETAINER
x 1
STEP 19
BAG D TOOLS USED

STEERING ASSEMBLY:
1. THREAD BOTH STEERING POSTS INTO THE STEERING BELLCRANKS AS SHOWN.
(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. 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 3/8" 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)
COMPARE STEERING ASSEMBLY
APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND
NOTE DIRECTION
APPLY A SMALL
AMOUNT OF
THREAD LOCKING
COMPOUND
NYLON
STEERING AND CHASSIS COMPONENT ASSEMBLY:
1. ATTACH EACH BATTERY POST TO THE CHASSIS
WITH ONE 4-40 X 3/8" FLAT HEAD SCREW.
(APPLY THREAD LOCKING COMPOUND)
2. THREAD ONE SOCKET HEAD CAP SCREW WITH
HOLE INTO THE TOP OF EACH BATTERY POST.
(LENGTH WILL BE ADJUSTED LATER)
3. ATTACH THE BATTERY RETAINER USING TWO
4-40 X 1/4" FLAT HEAD SCREWS.
(APPLY THREAD LOCKING COMPOUND)
4. INSERT TWO 1/8 X 1/4 BEARINGS INTO THE
BEARING BLOCK ON THE CHASSIS.
5. SLIDE THE STEERING ASSEMBLY
INTO THE BEARINGS.
6. SLIDE ONE 1/8 X 1/4 BEARING
ONTO THE TOP OF EACH
STEERING POST.
4-40 X 3/8"
FLAT HEAD SCREW
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
4-40 X 1/4"
FLAT HEAD SCREW
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
SPECIAL 4-40 SOCKET
HEAD WITH HOLE
x 2
1/8 X 1/4 BEARING
x 4
STEP 1
STEP 2
STEP 3

TOP DECK ASSEMBLY:
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
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 ONE 4-40 x 3/8" BUTTON HEAD SCREW.
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)
4-40 x 3/8"
BUTTON HEAD
4-40 x 3/8" FLAT HEAD
x 2
4-40 x 1/4" FLAT HEAD
x 2
4-40 x 1/4" BUTTON HEAD
x 2
4-40 x 1/4"
BUTTON HEAD
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
LONG BALL END WITH ONE
.030" ALUMINUM WASHER
x 4
FILE EDGE AS
SHOWN BELOW
FILING TOP DECK EDGE:
EDGE
COMPARE STEERING AND CHASSIS ASSEMBLY
4-40 x 1/4" FLAT HEAD
x 2
STEP 4
STEP 5

TOP DECK ASSEMBLY:
TRANSMISSION
SPACER
TRANSMISSION
SPACER
1. ATTACH THE TOP DECK BY FIRST LINING 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.
2. SLIDE THE TWO ALUMINUM TRANSMISSION SPACERS BETWEEN THE TRANSMISSION CASES AND THE TOP DECK.
INSERT TWO 4-40 x 1/2" FLAT HEAD SCREWS AND TIGHTEN. REFER TO ILLUSTRATION BELOW FOR LOCATION
OF SCREWS.
3. SECURE THE TOP DECK IN FRONT WITH THREE 4-40 x 3/8" FLAT HEAD SCREWS. SECURE THE TOP DECK TO THE
MOTOR MOUNT WITH USING TWO 4-40 x 5/16" FLAT HEAD SCREWS. (APPLY A SMALL AMOUNT OF THREAD
LOCKING COMPOUND) FINISH WITH TWO 4-40 x 3/8" FLAT HEAD SCREWS IN THE REAR.
4-40 x 1/2"
FLAT HEAD
4-40 x 1/2"
FLAT HEAD
4-40 x 5/16"
FLAT HEAD
x 2
4-40 x 3/8"
FLAT HEAD
x 3
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
4-40 x 3/ 8"
FLAT HEAD
x 2
COMPARE TOP DECK ASSEMBLY
STEP 6
STEP 7

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:
1. .050" ALLEN WRENCH
APPLY A SMALL AMOUNT
OF BLACK GREASE
CVD FRONT BONE
x 2
CVD FRONT AXLE
x 2
CVD COUPLING
x 2
REMOVE THESE PARTS FOR THE REAR CVD'S
CVD CROSS PIN
x 2 CVD SET SCREW
x 2 BEARING SPACER
x 2
1. .050" ALLEN WRENCH
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
REMOVE THESE PARTS FOR THE FRONT CVD'S
CVD BAG TOOLS USED
STEP 1
TOOLS USED
CVD BAG

FRONT A-ARM
x 2
4-40 MINI
LOCKNUT
x 2
2-56 x 1/8"
BUTTON HEAD
x 4
FRONT HINGE
PIN BRACE
x 1
PIVOT SLEEVE
x 2
FRONT SHOCK TOWER
x 1
STEERING AND CASTER BLOCK ASSEMBLY:
NOTE: USE COMPLETED FRONT CVD'S FOR THIS STEP
KING PIN
x 4 .030 ALUMINUM
WASHER
x 4
STEERING BLOCK,
LEFT & RIGHT
x 1 EACH
4-40 x 1/4"
BUTTON HEAD
x 2
CASTOR BLOCK,
LEFT & RIGHT
x 1 EACH
BALL CUP
x 12
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
1. .050" ALLEN WRENCH
2. 1/16" ALLEN WRENCH
3. 5/64" ALLEN WRENCH
4. NEEDLE NOSE PLIERS
5. 3/16" NUT DRIVER
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 FASTEN 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 CASTOR 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. CHECK TO MAKE SURE STEERING BLOCK PIVOTS FREELY.
10. REPEAT FOR THE OPPOSITE SIDE ASSEMBLY.
ATTENTION! NOTE DIRECTION OF STEERING BLOCK AND CASTOR BLOCK
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 RUBBER
SEALED BEARING
x 4
REAR SHOCK TOWER
x 1
FRONT END COMPONENTS
BAG E TOOLS USED
STEP 1

FRONT SUSPENSION ASSEMBLY:
1. USE REFERENCE ILLUSTRATION BELOW TO PREPARE THE TWO PIVOT SLEEVES.
2. INSERT BOTH PIVOT SLEEVES INTO THE FRONT BULKHEAD.
3. ALIGN THE FRONT A-ARMS WITH THE PIVOT SLEEVES AND PRESS THE FRONT INNER HINGE PINS INTO PLACE.
4. 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.
5. 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)
6. CAPURE THE FRONT INNER HINGE PINS BY INSERTING TWO 2-56 x 1/8" BUTTON HEAD
SCREWS INTO THE FRONT HINGE PIN BRACE.
7. CHECK TO MAKE SURE SUSPENSION ARMS PIVOT FREELY.
4-40 x 1/4"
BUTTON HEAD
x 2
FRONT INNER
HINGE PIN
x 2
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
2-56 x 1/8"
BUTTON HEAD
x 2
IF NECESSARY, REMOVE A
SMALL AMOUNT OF MATERIAL
FROM THE EDGE OF EACH PIVOT
SLEEVE UNTIL IT FITS FLAT AGAINST
THE FRONT BULKHEAD.
VERY CRITICAL FIT!
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
COMPARE FRONT SUSPENSION ASSEMBLY
4-40 x 3/8"
BUTTON HEAD
x 2
STEP 2
STEP 3

FRONT SUSPENSION AND REAR TOWER ASSEMBLY:
1. POSITION THE STEERING AND 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 SCREWS 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.
6. ATTACH THE REAR SHOCK TOWER USING FOUR 4-40 X 5/16"
SOCKET HEAD SCREWS. (APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
FRONT OUTER
HINGE PIN
x 2
2-56 x 1/8"
BUTTON HEAD
x 2
4-40 x 5/16"
SOCKET HEAD
x 4
(APPLY A SMALL AMOUNT OF
THREAD LOCKING COMPOUND)
FRONT TURNBUCKLE ASSEMBLY:
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.
1.30
FRONT CAMBER TURNBUCKLE 2.00": x 2
SCALE 1:1
1.05
FRONT STEERING TURNBUCKLE 1.775": x 2
SCALE 1:1
STEERING
TURNBUCLKE
CAMBER
TURNBUCKLE
STEP 4
STEP 5

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
1. .050" ALLEN WRENCH
2. 1/16" ALLEN WRENCH
3. 5/64" ALLEN WRENCH
4. NEEDLE NOSE PLIERS
5. 3/16" NUT DRIVER
.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 ON TO 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 LOCK NUT. REFER TO ILLUSTRATION FOR LOCATION.
6. REPEAT FOR THE OPPOSITE ASSEMBLY.
NOTE: USE COMPLETED REAR CVD'S FOR THIS STEP
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
ATTENTION! THIS IS A LEFT SIDE ASSEMBLY ILLUSTRATION, NOTE
DIRECTION OF HUB CARRIER AND SUSPENSION ARM
4-40 x 1/8"
SET SCREW
2-56 x 1/8"
BUTTON HEAD
1. 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)
2. 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.
3. CAPTURE THE OUTER HINGE PINS BY INSERTING A 2-56 x 1/8"
BUTTON HEAD SCREW INTO EACH A-ARM.
4. PUT BALL END DUST COVERS ON ALL OF THE REAR
SUSPENSION BALL ENDS.
5. MAKE SURE THE A-ARMS AND HUB CARRIERS PIVOT FREELY.
REAR SUSPENSION ASSEMBLY:
BAG F TOOLS USED
STEP 1
STEP 2