Team Losi JUNIOR TWO User manual

instructions to familiarize yourself with the
parts, construction, techniques, and tuning tips
outlined in this manual. Being able to grasp the
overall design of the Junior Two before construction
will ensure a smooth assembly.
~ Take your time and pay close attention
to details. Keep this guide for future reference.
TEAM LOSI, INC.
OWNER'S GUIDE
13848 Magnolia, Chino, CA 91710 P/N 800-0026 (Revision A)

WELCOME JUNIOR TWO OWNER
TheJuniorTwo should makegetting invol ved Inentrylevelradiocontrolledracing easier. Although
thiskitIslowerinpricethanthealloutracers, themostImportantfeaturesare incfuded.
We feelthiskit is competitiveoutofthebox,and with very minorchanges it can be updatedwith a ll
thehi-performance Team Loti parts as found inthe JRX-PRO kit. YourJuniorTwocomeswitha
molded composite challis, ratherthanalayed upgraphiteunit. Thisuniquemoldedchassisisthe
result of 18 monthsofengineering and track test•~ · It's superiorstiffnessand strengthhasbeen
achieved wtthoutcompromising weight,making thas thebestmass producedchassis everoffered.
To provehowcompetitivethiskitIs,mydad hasbeenracing Itagainstsomeofthebeststockclass
racers InSouthernCalifornia. Althoughheisgetti ng upthereinyears andracesinfrequently, he has
been extremelycompetitivehaving won as well as topqualifyingseveralevents. We believe Team Losl
hassetanewstandardwhen It comes to entrylevelracingcars. We feelsureyouwillagreewhen you
decide
to tryyourluckatyourlocaltrack.
Thankstoourracingteamforallofthetestingtheyhavedone
to Insurethesuccessofthisprojectand
yourfutureracing.
Thanksforchoosing
Team Losi,
GilLosiJr.
1. INTRODUCTION
The Junior2kitiscomposed ofdifferentbags
marked
Bag Athrough Bag G. Each bag con-
tainsalloftheparts necessary
to completea
certainsection ofthecar. ItIsessentialthat
youopenonly
bag atati me andfollowtheright
sequence,otherwiseyouwillfacedifficultiesin
findingtherightpart. ItIshelpful
to read theen-
tireinstructionsforthe bag prior to starting as-
sembly. Keynumbers (In circles)have been
a11lgned to each partandremainthesameIn
theillustrationandthroughoutthe instruc-
tions. Foryourconvenience,anactualsize
hardwareidentificationguideisIncludedin
eachstep.
To checkapart,hold it againstthe
silhouetteuntil it isIdentified. Insomecases
extra hardwarehasbeensupplied to replace
easilylostparts. When assemblingshaftsto
plasticparts,differentfitse.g ., press,net ,
loosehave beendesignedIntotheparts. To
ensurethatpartsarenotlostduringconstruc-
tion,itissuggestedthatyouworkoveratowel
or mattopreventthepartsfromrolling away.
IMPORTANT SAFETY NOTES
1. Selectan area forassemblythat is awayfrom
rttach of smallchildren. Thepartsaresmalland can be
swallowedbychildrencausingchokingand poatble
Internalinjuries.
2. Theshockfluidsuppliedshouldbe kepC out of
children'sreach. ltis nottoxic butIt was no Unlended
forhumanconsumption.
3. Exercise care whenusinganyhandtoola,ahatp
instrumentsand powertoolsduringconstruction.
4. Carefully read a// manufacturerswamtngs and
cautionsforanygluesorpaints that ma ybeusedfor
assemblypurposes.

INTRODUCTION (Cont.)
TOOLS REQUIRED
Team Loalhassuppliedallallenwrenchesandaspe-
cialwrenchthatisneededforassemblyandadjust-
ments. Aplasticset
up toolIsalsoprovided to
determinelengthsofcamberandtirerodsandride
heights. Thefollowingcommontoolswillalso
be re-
quired:
#2 Phillipsscrewdriver,smallflatbladescrew
driver,needlenosepliers,regularpliers,scissors
or
otherbodycutting/trimmingtool. 3/16'', 1/4",and 3/8''
nutdriversareoptional.
RADIO/ELECTRICAL
Allradioand electricalequipmentvaries. It is forthis
reasonthat
we havenotIncludedspecificinstructions
onradioand electricalequipmentinstallation.
We have
leftthissubject
to the personalpreference of the
owner/racer. AsuggestedlayoutIsprovidedInthia
manual(Page 26). If youhaveanyfurtherquestions,
yourhighperformanceR/Ccenterwill be able to
answerany of yourquestions.
HARDWARE IDENTIFICATION
When Inquestion,usethehardwareIdentification
guideineachstep. Forscrews,theprefixnumber
designatesthescrewsizeand numberthreadsperInch
e.g., 4-40 Ia a #4screw with 40 threadsperInch. The
fractionfollowingdesignateslengthofttvead
or overall
Hflatheadtype. Bearingsandbushingaarereferenced
byinsidediameterXoutsidediameter. Shaftsandpins
arediameterXlength. Washersaredescribed
by Inside
diameter. E-cllpsaresized by theshaftdiameter of at-
tachment.
TABLE OF CONTENTS
1. INTRODUCTION
Important safety notes
Tools Required . ••. . ••• •. . . . . . . . . . •. •• •••. ••• II
Hardware •••••.•••...•..•..• •.•• .•.•.••... •• i
Radio IElectrical . •• . . . . . . • . . . •• •• ••. . ••• •••••• ii
2. BAGA
Front End Main Components •••••• ••• .•••••••••• 1-3
Battery Box . . . • . . . . . •• . . . . . •. . . . . . . . . . . . •. . . . 3-4
Rear End Main Components . •••• . . . •••• ••••• •••. 4-5
3. BAG B
Front Suspension and Steering Assembly ••. • .•••••. 6-8
4. BAG C
Gear Box Assembly • . ••. • •••••••• • •••• •• 9-15
5. BAG D
II
Rear Suspension Assembly ••• ••. ••••••• ••• 16-19
6.BAG E
Shock Absorber Assembly ••••••••••••.•.• 20-22
Shock Absorber Attachment . • •••• ••••• ••• • 23
7.BAG F
Wheel and Tire Assembly . . •• •. ••• •••• • ••• 24
8.BAGG
Gear Cover Attachment ••• ••••• •••• • •••• • 25
Antenna Mounting ••• •. ••• . •. •••• •• . • •••• 25
Body
Painting and Trimming . • •• ••• ••. • •• •. 26
Wing Assembly . •••••••• •••. • •••• ••• ••. 27
9.Toe In I Toe Out and Camber ....... 2a
10.TIPS ............................. 29-30
11.SPARES ...... .. .. ..... .. .. •.... 31-33

BAGA
BagAconsistsofthemainchassisparts. Thisincludesthefrontandrearbulkheads, frontand rearshocktowera,
bumper,batteryboxandfrontA-arms.Careshould be taken whenscrewtngInaluminum8-32screws to avoidstripping
theheads.
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1. Threadtwo 4-40 x1"socketheadscrews(122) to top
offrontshocktower(2) fromtherearasshown. Fig 1.
2. Thread two3/8"studded balls (22) Intolowerholein
frontshocktower(2) and securewith
4-40 nylonnuts
(75) as shown. Fig. 1.
I
3. Securefrontshocktower(2)tofront bulkhead (4) as
shownusingtwo
4-40 x5/8"sockethead screws.(103)
Fig. 2.
* NOTE : Trim flash from bottom of front shock tower
well.
Page 1
FIG. ·1
FIG .2

. BAG A (Cont...)
c
(f)
4. AssemblefrontA-arms(5) to frontbulkhead(4)
using1/ ff 'x 1.650hinge pins (8) and secure the pins (8)
with four 1/8" E-cllps(7). Fig. 3.
5. Securesteeringposts (11 ) to chassis(9) as shown
usingtwo4-40x3 /8"flatheadscrews(12). Fig. 4
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FIG.4

BAG A (Cont. .. )
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6. Secure front bulkhead(4) assembly and front
bumper (8) to front of chassis (9) using four 8-32x 1/2'
aluminum flatheadscrews(10) as shown . Fig. 5.
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7. Peel off backingfrom batteryboxfoam (13) and
apply to recessIn bottom of battery box lid (14). Fig. 6.
8. Securebattery box lid (14) to battery box (15) usinga
4-40x 1/Z' sockethead screw (16)asshown. Fig.6.
* NOTE: Thread screw {16) in through chamfered end
of hole in battery box li d (1 4).
9. Securelid (14) with body clip (17). Fig.6.
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! ® FIG.S
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FIG.6

BAG A (Cont...)
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1 o. Attachbattery box {15) to chassis {9) us i ng four 8·
32x 1/2" flatheadaluminumscrews (10). Fig. 7.
11. Affixantenna
mount cap {18) onto antenna mount
(19) and secure anten na mount (19) to chassis(9) as
shown using one ~40 x3/8"flathead screw {12). Fig. 7.
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12. Insertwing tubes (20) Into rearbulkhead {21 )as
shown. Fig. 8.
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* NOTE: They ar e a tight fit.
13. Install3/8" studded balls (22) into rear bul khead
(21)
as shown . Fig. 8.
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! A
FIG .7
FIG.S

BAG A {Cont...)
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14. Secure shock mounts (23) to rear shock tower (24)
as shown using two 4-40x 7/ PI ' socket head screws (1).
Fig. 9.
15. Attach rear shock tower (24) to rear bulkhead (21)
as shown using four 4-40x5/ P/' socket head screws
(103). Fig. 9.
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16 . Attach rear bulkhead (21) to chassis (9) as shown
using two 8-32x1/2'flathead aluminum screws (1 O) in
the rear and two 4-40x 3/8"flathead screws (12) In the
front. Fig. 10.
17. Secure top of chassis (9) to rear bulkhead (21)
using two 4-40x3/ P/ ' socket head screws (101) and studded
ball washers (28) Fig. 10.
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21
FIG.9
21
9
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FIG.10

BAGB
Bag B consists of all oft he parts for the front suspension and steering. For the steering set up, the key is freedom of
movement. Make sure there are no binds or tight spots in the front end when assembled. You'll find some pins are tight
during assembly, but this is by design. To set the proper lengths of camber links and the rods, use the plastic set-up tool
provided. When mounting the servo, align the servo with the score marks on the chassis as shown.
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1. Thread3/8" studded balls (22) into servosaver (25)
as shown. Fig 11.
2. Slide idler arm (26) and servosaver (25) onto steer-
ing posts (11) and secure them with 3/16" E-clips (43).
Fig. 11.
3. Thread two 1/8" studded balls (3) into both sides of
steering sector arm (27) using studded ball washers
(28).Fig. 11.
4. Secure steering sector arm (27) to idler arm (26) and
servo saver (25) as shown using 4-40x 1/8" socket
head shoulder screws (117). Fig. 11.
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5. Slide front axle (29) into spindle (30) (121)asshown
so that holes are aligned. This is now called the spindle
assembly. Fig.12.
* NOTE : Spindle arms are markedtor lett (L) ( 121 ) an d
right
(R) ( 30) .
6. Place spindle assembly into splndle carrier (31) so
letter on spindle (30) (121) arm faces up and insert 1/8"
x.690
hinge pin (32) through spindle carrier (31) and
spindle assembly and secure with two 1/8" E-clips (7).
Fig.12.
7. Thread one 3/8" studded ball (22) into top hole in
spindle carrier (31) from the rear and one 3/8" studded
ball (22) into spindle (30) (121) armfromthetop. This is
now called the spindle carrier assembly. Fig ..12.
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FIG.12

BAG B (Cont •.. )
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8. AttachaplnctlecarrleraaaemblytoA-arms(5) us i ng
1/8"x.960hingepin(33)secured by two 1/ P/ 'E-clipa(7).
Fig. 13.
* NOTE: Besurespindle carrieris onproperside.
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9. Thread an adjustable rod end (34) onto eachaideof a
11/ Z' threadedrod (35). This is assemblyA. Flg.14.
These are front camber rod~ .
1 o. Thread an adjustable rod end (34) onto both sides
ofa 17/ 8"threaded rod (36). ThiaisaaaemblyB. Flg.14.
These are front tie rods
* NOT E: Use set-up t ool provided to adjustthe lengths
of adjustable /Inks. To use the set-up tool lay the
threaded
rod against the desired arrow on the tool.
Screw the
rod ends (34) equally closer t og ether or
furtherapartuntilthe arrowonthe tool fits between the
rod ends {3 4).
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FIG.13
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FIG .14

BAG B (Cont...)
11. Snap one end of auembly A onto studdedball(22)
in front shock tower (2). Fig. 15.
12. Snap
the freeend of assemblyA onto studdedball
(22) intopofsplndlecarrler(31). Fig. 15.
13. Snapone
end of assemblyB onto studdedball joint
(3) Insteering uctorarm (27). Fig.15.
14. Snap
the freeend of auembly B onto studdedball
(22) Inspindle(30) (121)arm. Fig. 15.
15. Repeatsteps5-14 for other side.
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16. Attachsteeringservo using servotape(37) to front
of chassis(9) as shown. Fig. 16.
tt NOTE: Be sure servo arm Is parallel and In line with
the scribe marks on the chassis (9) as shown and a
studdedball (22) is
in steering servo arm. Fig . 16
17. Thread an adjustable rod end {34) onto both sides
of 11/2"threadedrod (35).
18. Thread
one3/16 "studdedball (123) into steering
nrvo arm and securewith4-40 nut (124).
19. Attach
one end of 1 1/2!'rod (35} onto studdedball
(22) in servosaver(25) and other end onto studdedball
(123)1
in steeringservo arm .
20. Secure front stiffener(38) to chassis (9)using four
8-32x 1/2!'steelflathead screws(39). Fig. 16.
* NOTE: Be sure servo arm can travel freely.
Screws are silver.
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FIG.15
FIG.16

BAGC
BagC contains the gearbox. Extracareandpatienceneeds to.,. applied to this bag. Read through BagCInstructions
thoroughly beforestarting. All partsshould be carefully trimmed and organized. Be sure to avoid gettinggrease on
gearteeth. Read through tips about how to properlyadjust your differentialbeforerunning yourcar.
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1. Insert 1 /1 6' 'x7/ 16' 'solld pin (40)throughtopgearbo x
shaft(41). Fig. 17.
2. Slideinternal
pinion gear (42) down shaft(41) so pin
Interlocks with groove in gear(42). Fig.17.
3. Secure gear (42) onto shaft(41) using3/16"E- clip
(43) and attach two 3/16' '" E" clips (43) in the other
groovesshownonshaft(41). Fig.17. Thlsisnowas-
semblyC. Set aside until step- 29.
* NO TE : Make sure ge ar cannotslide between E-clip
and pin. If
it does, remove gear and place between
other
pin andgroove setin shaft.
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4. Insert two 8mm x 14mmbearings(44) Into both sides
of lowerbearingseatIn right half of gearbox(45). Fig.
18.
Page9
FIG.17
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FIG .18

BAG C (Cont...)
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5. Install output gear (46) Into lower bearings in right
half of gearbox(45). Fig.19.
6. Slideoutdrlve
spacer (47) onto U-jolnt outdrlve (48)
with
the largesidefirst. Fig. 19.
7. InstallU-jointoutdrive(48)
into lower bearings in
right half of gearbox(45) and rotateU-jolntoutdrlve(48)
untilinterlocked
with output gear (46). Fig. 19.
8. Secure
the two together w it h a4-40x 1/Z'soeket
head screw {16) threaded in through the U-jolntout-
drive(48) I nto the output gear (46).Setasideuntilstep
27. Fig.19.
* NOT E: Do notovertighten.
9. Repeat steps 4-8 for left half (63) of gearbox.
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1o.Locate grease container (49) and open. Grease
only items that areindlcatied. Keepgreaseaway from
teeth of transmission assembly .
11. Locate centerdifferential
gear (SO )fromsmallbag. Fig.20.
12. Insert3/ 3Z 'differential gear balls (51) Into holes in
centerdifferential
gear (50). Fig.20.
13. Usinga tooth pick, carefully dab a small
amount of grease onto eachside of each3/ 3Z 'ball(51).
Fig. 20.
14. Insert1I4"x 3/8" bush i ng (52) into female half of dif-
ferential(53). Fig. 20.
15. Insert5-40 lock nut (54) into opposite side of female
half of differential(53). Fig. 20.
16. Placeonehex thrust washer (~5) onto male half of
differential(56)
and other he x thrust washer(55) onto
female half of differential(53). Fig. 20.
17. Assemblediferential by placingcenterdifferential
gear (50) onto male half of differential (56}followed by
female half of differential(53). This now becomes as-
semblyD.
18. Setaside assembly Df or now with female half of dif-
ferential up until step 26
Page 10
••
FIG.19
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FIG.20

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BAG C (Cont ..• )
19. Using5-40x7/8" button head ahoulder screw (57)
88semblethrultaaaemblyinthefollowlng order. Fig.
21.
20. Slide three opposing belleville cone washers(58)
down the 5-40x7/fr' button head ahoulder screw (57)
with the tip ofthe cone of the firlt waaher(58)against
the head ofthe screw (57). Fig.21.
* NOTE: The bellevillewashers areblack. The washers
(5 8) should be oppo si ng (ie; the tops of the co nes
should meet
and the bottoms of the cones should
meet).
21 . Slide one wellgreased thrust washer(59) down
screw(57) shaft as shown. Fig. 21.
* NOTE: The thrust washer should only touch the big
edge of the last belleville (58). Grease thrust bearing
side
of washeronlyas indicated by arrows
22.Slidewellgreased
bronze bearingcage(60) down
screw(57) shaft. Fig. 21 .
23 . Insert eight 1/16" thrust balls(61) Into the cage (60).
Fig.21.
24. Slide
the secondwellgreased· thrust washer(59)
down screw (57) shaft . Fig.21.
* NOTE: Grease thrust bearing side of thrust washer
only.
25.
This a88embly will be referred to as assembly E.
26. Complete the differential by Insertinga88emblyE
Into male side of assembly D and screw the 5-40x7/fr'
screw(57) Into 5-40 locknut (54) In oppoaite side of o.
Fig.22.Set aside until step 30.
* NOTE: See ''Adjusting the Ditr'in tuning tips inappendix.
Page 11
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FIG. 21
FIG.22

BAG C (Cont. .. )
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27 . Insert3/ 16 "x 3/8"bearings (62) into upperbearing
seatsin bothsides
of gearbox [Right (45),Left (63)].
Fig 23 .
28 . Press5/ 16 "x1/2"bearings(64) onto middlebearing
seats
of both side of gearbox (45)(63). Fig. 23 .
29.Placedifferential onto centerbearing (64) in right
half of gearboxso that the head of the 5-40x7/8"
shoulder screw (57) is exposed. Fig. 24 .
30 . Slide long side of assembly C through upper bear-
ing in right half of gearbox (45). Fig. 24.
Page 12
62
FIG.23
FIG.24

BAG C (Cont...)
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31. Place the two halvesofthegearbox (45) (63)
together and secure them to the motor plate(65) using
three4-40x 13/8" socket head shoulder screws(66).
Fig.25 .
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32. Insert3/ 32x 1/Z' spirol pin (67) into universal pivot
joint (68) so that Itextends out evenly on both sides.
Fig.
26
Page 13 FIG.26

BAG C (Cont. .. )
33. Wedge one end of 3/32" x 1/Z' spirol pin (67) in
universal pivot joint (68) into female drive shaft (69)
Fig.
27A ..
34. Using
rounded end of TEAMLOSI wrench supplied
with kit, pry opposite end of3 / 32x 1/Z' spirol pin (67)
into other side of female drive shaft (69) Fig. 27 A.
35 . Usingremaining pins in universalpi vot joint (68)
repeat
steps 33 and 34 to secure the sameuniversal
pi
vot joint (68) to U- jo i nt outdrive (48). Fig. 27 B.
36 . Repeat steps 32 - 35 fo r other side of car .
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37. Insert1/ 16 "x 7/16" solid pin (40) into top gearbo x
shaft . Fig. 28 .
38. Slide
spur gear (71) o ver shaft so that the slot in
gear lines up with pin (40) and secure spur gear (71)
with3/
16 "E- clip (43). Fig. 28 .
B
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A
FIG.27
FIG.28

BAG C (Cont...)
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39. While holding rear pivot support (72) in place under
rear of gearbox, slide gearbox into place in rear
bulkhead (21). Fig. 29.
40. Secure gearbo x and rear pivot support (72) to chas-
sis (9) using four 8-32x 1/Z' steelflatheadscrews(39).
Fig. 29
* NOT£: Screws are silver.
41. Securegearbox to rearbulkhead (21) using a4-40x
13/4"
socket head screw (73) with a #4 washer(74)
under
the head . Fig. 29.
42. Attach
motorplate (65) to chassis (9) usinga4-40x
1/4"flathead screw (78). Fig. 29.
43. Push
dust cover (1 18) over differential adjustment
hole in left half of gearbox(63). Fig. 29.
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FIG.29

BAGD
BagD contains therearsuspension. Just asinBag B,the most importantthing about Bag Dis freed()m of movement.
Besurethereare
no binds or "st icky "spots intheH-arm'stravel,thedriveshafthalvesmovewell and that the camber
links don 't bind. Refer to thetuning tips to understand whatadjustmentscanbe made to the rearsuspensionand how
theywillaffectthe car 's performance.
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1. Thread one3/8"studded ball (22) from the front into
centerinsideholein hub carrier(79). Fig. 30.
* NOTE : Hubs are nondlrectional, assign a hub to one
s/de andbuild It to suitthat side.
2. Presstwo 3/ 16 "x3/8"bushings (80) intobothsides
of hubcarrier(79). Fig. 30.
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3. Place hub carrier (79) in -betweenouterrails of H-arm
[Right (81), Left(82)] asshown. Fig. 31 .
* NOTE: Be sure to have studdedball {22) In hub carrier
{79) pointing the same direction as arrow on bottom of
H-arm {81 ) { 82) .
4. Insert1/8"x 1.420 hinge pin (83) through H-arm ( 81 )
(82) and
through upper hole in hub carrier(79). Fig. 31 .
5. Clip on snap clips (84) into groovesin pin (83). Fig.
31 . l
* NOTE: Its easiest if one groove in the pin (83}Js given
excess room for clip (84), then push ht:J9.. ccy:rler (79)
upagainstItandsnap In secofldclip (84} .
6. Repeat steps 1-5 for other side of car.
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FIG.30
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FIG.31

BAG D (Cont...)
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7. Alignfreeend of H-arm(81) (82) betweenrearpivot
support(72)andrearbulkhead
(21 ). Fig. 32.
* NOTE: Be s ure t he arrow on the bottom ofthe H -arm
(81) (82) points to the front of the car
a. Insert1/8"x 1. 785hingepin(85)throughrearpivot
support(72) H-arm (81)
{82) andIntorearbulkhead
(21). Fig.
32.
9. SecureH-arm(81) {82) wl1h two 1/W'E-clipa (7) in
grooves
In 1/8"x 1. 785 hingepin(85).Fig. 32.
* NOTE: It's easiest if one groove in pin (85) is given
excess room to put on clip (7), then push it into rear
bulkhead (21)
and clip in second 1/8" e-clip (7).
1 o. Threadanadjustablerodend (34) ontoeachend of
a11/Z'threadedrod (35). Use thesetuptooltoadjust
thelengths.Fig.
33 . Setasideuntilstep17.
These are rear camberrods
* NOTE: Th is will be referred to as assemblyF.
Page 17
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72
FIG.32
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FIG.33