NOVAK HD8 User manual

PRECAUTIONS
NEVER FREE-REV THE MOTOR!
Free-running your brushless motor in a no-load
condition can result in rotor failure and ESC transistor
damage. This includes holding your vehicle in the air,
and free revving the motor while installed into the
vehicle. This will void the product’s warranty!
• WATER & ELECTRONICS DON’T MIX Never allow water,
moisture, or other foreign materials to get inside motor.
• NOVAK ESC FOR BEST RESULTS Use Novak Activ8 V2 for best
performance & protection. Only use motors with the proper
Kv to match ESC’s rating.
• DO NOT OVERHEAT THE MOTOR Temperatures above 180°F
(82°C) will weaken the magnet and may melt the coils. This
voids the warranty and can damage the ESC.
• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent
shorts. Refer to ACCESSORIES for Novak heat shrink kits.
• NO SOLVENTS Do NOT expose the motor to any type of solvents.
• SET GEAR MESH PROPERLY Too tight of a gear mesh can
result in motor pinion shaft breakage--be sure to adjust the
gear mesh properly.
SPECIFICATIONS
Input Voltage ...................... 2S-4S LiPo/LiFe cells (7.4-14.8 max VDC)
Motor Kv ..............................................1,900 (#3810), 2,200 (#3811)
Design .......... Sensor-based (compatible with Sensored/Sensorless ESCs)
Motor Size ......................................1.57” D x 2.80” L x / 40 x 71mm
Weight .....................................................................11.8 oz / 334.5 g
Output Shaft Dimensions ........ 5mm Diameter; 19mm legth with flat
Rotor ................................ 4-pole, high-strength sintered Neodymium
Stator ....................................................................................... 12-slot
Max. RPM ................................................................................50,000
Mounting .................................M3x0.5 and M4x0.7 spaced at 25mm
Recommended ESC ......................................Novak Activ8 V2 (#1726)
1. Insert the motor mounting screws that came with your vehicle
through the motor mounting plate. Novak HD8 motors need
no more than 1/4” of screw extending past the vehicle’s
mounting plate (6.5 mm). Too little can strip motor’s threads.
Too much will cause internal motor damage and void warranty.
2. Attach the motor to the vehicle’s motor mount using one of
the sets of threaded mounting holes (M3x0.5 or M4x0.7).
Select a mounting position that keeps the solder tabs clear
of conductive surfaces like aluminum or graphite.
Note: An adhesive-backed foam pad is enclosed to be used to
support the rear of the motor to prevent flexing of the motor on
hard impacts. Use this if your vehicle does not have this feature.
STEP 1- INSTALL MOUNTING PLATE
A pinion gear with a 5mm bore is needed. Novak offers high-
quality Mod 1 (#5112-5124) and 32-Pitch (#5152-5161) gears.
1. Install pinion gear on the motors output shaft and test fit in
vehicle to align pinion and spur gears.
Refer to GEAR SELECTION (on the back) for additional
information on selecting the proper pinon gear.
2. Tighten pinion’s set screw on the flat of motor shaft.
3. Adjust the motor position for proper amount of free play.
It is important to have a small amount of play between the
pinion gear and the spur gear (about the thickness of piece of
paper) . Check the free play at several positions around the
spur gear to ensure a proper mesh .
MAKE SURE PINION/SPUR GEAR MESH IS NOT TOO
TIGHT! IF GEAR MESH IS TOO TIGHT, MOTOR SHAFT
BREAKAGE CAN OCCUR.
4. Tighten motor mounting screws. Avoid using excessive force,
as the threaded holes in motor could become stripped.
STEP 2- INSTALL PINION GEAR
I NSTALLATION
INSTRUCTIONS
HD8 1/8 SCALE
Motor Instructions
#55-3810M-1 Rev.1
4-2015
5351-4 Shielded Sensor Harness--Double-ended. Available in 4”, 6”, 9”, and 12”
5512 12GA Power Wire Set --3 feet each black, red, and blue
5654 High RPM Cooling Fan--30x30x10mm--With 2-pin JST connector.
5741 4mm Power Connectors/5pair --Gold plated low-loss high-amp connectors.
5832 Lead-Free 3% Silver Solder--15g Tube--Low-resistance, high-conductivity
5852 Heat Shrink Tubing--40pcs Blk/Red --1” pieces in 1/4” size--20 each
5860 Speed Lube--10ml --Premium American-made bearing oil with penetrative additives
The HD8 Motor is completely rebuildable, with full component availability.
Refer to website for component list. www.teamnovak.com
ACCESSORIES
The Activ8 V2 ESC (recommended) comes pre-wired with 12GA
silicone power wires. You will need a high-powered soldering
iron, solder (Novak #5832 or #5853), solder flux (Novak #5861)
and a pair of wire strippers (Novak #5880).
1. Determine the best routing in the vehicle for the motor’s
silicone power wires. Avoid any moving parts & suspension.
2. Prepare ends of power wires by stripping 3/16 - 1/4” of
insulation from end of wire. Tin wire ends with solder.
3. Lay tinned end of the wire flat on the proper soder tab (refer to
phase markings on the endbell) and solder wires to the motor.
Apply heat with a high-power soldering iron to the power
wire and solder tab- begin adding solder to tip of iron and to
wire. Add just enough solder to form a clean and continuous
joint from the solder tab up onto the wire.
Be sure no phase wires make contact with
an adjacet solder tab- this will cause short-
circuiting, damage electronics, & void warranty.
DO NOT OVERHEAT SOLDER TABS
Prolonged/excessive heating will damage tabs
and void warranty
Refer to Novak’s Website for videos on soldering
STEP 3- SOLDER POWER WIRES

Sensor harness
connector (keyed)
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket on end of
Teflon sensor harness wires
1. Determine the best routing in the
vehicle for the motor’s sensor harness.
Securing the sensor harness to the
motor power wires with a tie-wrap can
provide a good location and also act as
a strain relief. Novak offers several sensor
harness lengths for various installations
(Novak #5351-5354).
2. Connect one end of the included
harness to the ESC and the other end
to the motor’s sensor harness connector
located on the back endbell (refer to
figure)- be sure to insert all the way.
STEP 4- CONNECT SENSOR HARNESS
!GEAR SELECTION (Important!)
Motor operating temperature is the ONLY
way to properly set the maximum vehicle gearing
The motor should be 180°F (82°C) MAX at end of run!
Temperatures above 180°F will weaken the magnet & may
melt the coils! This voids warranty & can damage ESC!
Change the gearing to avoid overheating.
Because of the potential danger of overheating, ESC/motor
damage & failure, you must start with VERY small pinion
sizes and check ESC & motor temperatures at multiple times
throughout a run. This is the only way to ensure that you
are not causing excessive heating.
If ESC & motor temperatures remain low and stable, you can
slowly increase the pinion size while again monitoring the tem-
peratures to determine the safe gearing for your vehicle, motor,
and climate/track conditions. Because these variables can change
or be modified, you MUST continually monitor ESC and
motor temps to protect your electronics from damage.
OVERHEATING -- WARNING !
The Novak HD8 Motor when used properly should not have an
issue of over-heating. However extended runtimes, gearing, ve-
hicle performance, and track conditions, can lead to overheating.
You must use extreme caution when setting up these
electronics and carefully test your application to avoid
overloading and overheating either the ESC or the motor.
Damage caused by excessive overheating WILL NOT be
covered under the product’s factory warranty.
Should any of the 28G Teflon wires pull out of the motor’s sensor
harness connector, re-insert them in the connector’s appropriate
slot. Check the plastic tab to make sure it has not deformed
excessively before inserting into the housing.
SENSOR HARNESS WIRING
MOTOR MAINTENANCE
• CHECK ALL MOTOR SCREWS for loosening at regular intervals,
just like other hardware on your vehicle. Note: The 3 main
socket head screws that hold the motor together may require
tightening after a few runs of the motor. Also check the 3 flat
head screws securing the end cap on the back of the motor.
If any of the motor screws are removed, it is important
to apply a thread locking agent for added strength.
• CHECK MOTOR BEARING WEAR after extensive use. The
motor’s closed design will keep most dirt and debris out, but
some will get in and eventually cause wear. If the shaft does not
spin freely, you may need bearing replacement. A small drop
of Novak Speed Lube (#5860) on the bearings periodically
can help extend bearing life. However, too much oil will attract
dirt and will cause problems, so apply sparingly.
• CLEAN INSIDE MOTOR periodically by removing front end
bell, removing the rotor, and blowing out the inside of the
motor with compressed air. Be sure not to lose any small shim
washers that may be on the ends of the rotor shaft, and keep
them in the correct location.
SERVICE PROCEDURES
After reviewing instructions, tech section and how-to video section of website,
if you feel your motor requires service (motor may appear to have failed when
other problems exist) , obtain the most current product service options and
pricing by one of the following methods:
WEBSITE: Print a copy of the product SERVICE FORM from the SERVICE
section of the Novak website. Complete form & return with the product.
PHONE/E-MAIL: Contact our customer service department by phone or
e-mail, and we will supply you with current service options.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on product SERVICE
FORM and include a valid, itemized receipt with the purchase date on it,
or an invoice from previous service work. If warranty provisions have been
voided, there will be a service fee.
Technical Support: [email protected]
Customer Support: [email protected] • [phone]
PRODUCT WARRANTY
Novak Brushless motors are guaranteed to be free from defects in materials or workmanship
for a period of one year from the original date of purchase (verified by dated, itemized sales
receipt). Warranty does not cover incorrect installation, components worn by use, cross-
connection of battery/motor power wires, overheating solder tabs, damage resulting from
thermal overload or operation above 180°F, use of excessive timing or overheating, splices or
damage to the sensor harness, damage from disassembling motor, tampering with internal
electronics, allowing water, moisture, or any other foreign material to enter motor or get
onto the PC board, short-circuiting of motor by allowing exposed wiring or solder tabs to
cross-connect or ESC applying simultaneous power to more than one phase at a time from
switching to Brush Mode, free-revving motor, or any damage caused by a crash, flooding,
or natural disaster. In no case shall our liability exceed the product’s original cost. We reserve
the right to modify warranty provisions without notice.
Because Novak R/C, Inc. has no control over the connection & use of motor or other related
electronics, no liability may be assumed nor will be accepted for damage resulting from the
use of this product. Every motor is thoroughly tested and cycled before leaving our facility and
is, therefore, considered operational. This product is not a toy, and is not intended for use by
children under 14 years of age without the strict supervision of an adult. Use of this product
in a uncontrolled manner may result in physical damage or injuries. Take extra care when
operating any remote control vehicle. By the act of connecting/operating speed control, the
user accepts all resulting liability.
©2015 Novak R/C, Inc. California, U.S.A. No part of these instructions may be
reproduced without the written permission of Novak R/C, Inc. All Rights Reserved.
Installation Photos for popular
1/8th Scale Vehicles are located
on the Novak Website
www.teamnovak.com