Team Losi BK2 User manual

Take your time and pay close attention to detail. Keep this manual for future reference.
Team Losi, A Division of Horizon Hobby inc.,
4710 East Guasti R ., Ontario CA 91761
Phone: [phone] / Fax: [phone]
(web) www.TeamLosi.com / (email) [e-mail]
BK2 OWNER'S MANUAL
1/10 Scale 2wd Electric Off-Road Racing Buggy
P/N - 800-0214
J.A. . - M.D.B.
11/01/2003
MADE IN THE UNITED STATES OF AMERICA
Carefully read through all instructions to familiarize yourself with the parts, construction
technique, and tuning tips outlined in this manual. Being able to grasp the overall design of
your new XXX-BK2 racing buggy before begining the construction process will ensure a
smooth assembly.

When all else fails, read the
instructions.
For the latest setup tips and information on your
new XXX-BK2, visit Team Losi on the Internet at:
www.TeamLosi.com

i
Welcome Team Losi XXX-BK2 Owner!
Thank you for choosing the Team Losi XXX-BK2. I have been fortunate to work and race for Team Losi through the years. I owe
a great deal of my success to their cutting edge designs and attention to detail. The Team Losi XXX-BK2 kit includes a large
selection of the more important specialty parts I used to win many ROAR Modified Wheel Drive National Championships.
Before you start building your new XXX-BK2, I suggest you read through the instructions first. Be sure to check out the perfor-
mance tips as you build and the tuning tips at the back of this manual as well. I hope you enjoy your XXX-BK as much as I do
mine.
Good luck, and thank you for choosing Team Losi.
1. INTRODUCTION
T IPLE-X KINWALD, EDITION 2, COMPLETED KIT DIMENSIONS
Length: 14.875" Front Width: 9.8 " Rear Width: 9.84" Height: 5.1 5"
Wheelbase: 10.6" All dimensions at ride height. Weight will vary depending on accessories.
NOTES & SYMBOLS USED
Step A-1
This is a common step sequence foun at the beginning of
each new illustration throughout the manual.
q1. Each step throughout the entire manual has a check box to
the left of it. As you complete each step, mark the box with a check. If
you nee to take a break an return to buil ing at a later time, you will
be able to locate the exact step where you left off.
*NOTE: This is a common note. It is use to call attention to
specific etails of a certain step in the assembly.
IMPORTANT NOTE: Even if you are familiar with Team
Losi kits, be sure an pay attention to these notes. They point out
very important etails uring the assembly process. Do not ignore
these notes!
The Team Losi icon esignates a performance tip. These tips
are not necessary, but can improve the performance of your
XXX-BK2 car.
In illustrations where it is important to note which irection
parts are facing, a helmet like this one will be inclu e in the illustra-
tion. The helmet will always face with a river's perspective. Any ref-
erence to the right or left si e will relate to the irection of the helmet.
KIT/MANUAL O GANIZATION
The kit is compose of ifferent bags marke A through G. Each bag
contains all of the parts necessary to complete a particular section of
the kit. Some of these bags have subassembly bags within them. It is
essential that you open only one bag at a time an follow the correct
assembly sequence, otherwise you may face ifficulties in fin ing the
correct part. It is helpful to rea through the instructions for an entire
bag prior to beginning assembly. Key numbers (in parentheses) have
been assigne to each part an remain the same throughout the manual.
In some illustrations, parts which have alrea y been installe are not
shown so that the current steps can be illustrate more clearly.
For your convenience, an actual-size har ware i entification
gui e is inclu e with each step. To check a part, hol it against the
silhouette until the correct part is i entifie . In some cases extra har -
ware has been supplie for parts that may be easy to lose.
The mol e parts in the kit are manufacture to eman ing tol-
erances. When screws are tightene to the point of being snug, the
parts are hel firmly in place. For this reason it is very important that
screws not be overtightene in any of the plastic parts.
To ensure that parts are not lost uring construction, it is rec-
ommen e that you work over a towel or mat to prevent parts from
rolling away.
IMPO TANT SAFETY NOTES
1. Select an area for assembly that is away from the reach of
small chil ren. Some parts in this kit are small and can be swallowed
by children causing choking and possible internal injury.
2. The shock flui an greases supplie shoul be kept out of
chil ren's reach. They are not intended for human consumption!
3. Exercise care when using any han tools, sharp instruments,
or power tools uring construction.
4. Carefully read all manufacturers' warnings and cautions for
any glues, chemicals, or paints that may be use for assembly an
operating purposes.

ii
TOOLS EQUI ED
Team Losi has supplie all necessary Allen wrenches an a special wrench that is nee e for assembly an a justments. The following common
tools will also be require : Nee le nose pliers, regular pliers, hobby knife, scissors or other bo y cutting/trimming tools, an a sol ering iron
may be necessary for ra io installation. 3/16", 1/4", 11/32", an 3/8" nut rivers are optional.
ADIO/ELECT ICAL
A suggeste ra io layout is provi e in this manual. Your high performance R/C center shoul be consulte regar ing specific questions
pertaining to ra io/electrical equipment.
HA DWA E IDENTIFICATION
When in question, use the har ware i entification gui e in each step. For screws, the prefix number esignates the screw size an number of
threa s per inch (i.e., 4-40 is #4 screw with 40 threa s per inch). The secon number or fraction esignates the length of the screw. For Cap Hea
an Button Hea Screws, this number refers to the length of the threa e portion of the screw. For Flat Hea Screws, this number refers to the
overall length of the screw. Bearings an bushings are reference by the insi e iameter x outsi e iameter. Shafts an pins are referre to by
iameter x length. Washers are escribe by insi e iameter or the screw size that will pass through the insi e iameter. E-clips are size by the
shaft iameter that they attach to.
MOTO S AND GEA ING
The XXX-BK2 inclu es an 78-tooth, 48-pitch Kevlar spur gear. The overall internal rive ratio of the transmission is 2.56:1. The pinion gear that
is use will etermine the final rive ratio. To calculate the final rive ratio, first ivi e the spur gear size by the pinion gear size. For example,
if you are using a 21-tooth pinion gear, you woul ivi e 78 (spur gear size) by 21 (pinion gear size) 78/21=3.71. This tells you that 3.71 is the
external rive ratio. Next, multiply the internal rive ratio (2.56) by the external rive ratio (in this case 3.71). 2.56 x 3.71 = 9.50. This means that
by using a 21-tooth pinion gear with a 78-tooth spur gear, the final rive ratio is 9.50:1.
Consult your high-performance shop for recommen ations to suit your racing style an class. The chart below lists some of the more
common motor types an a recommen e initial gearing for that motor. Ratios can be a juste epen ing on various track layouts, tire sizes,
an battery types.
RECOMMENDED INITIAL GEARING FOR COMMON MOTORS
TYPE OF MOTOR PINION SPUR
24o Stock 20-22 78
10-Turn Mo ifie 19 78
11-Turn Mo ifie 20 78
12-Turn Mo ifie 21 78
13-Turn Mo ifie 22 78
14-Turn Mo ifie 23 78
15-Turn Mo ifie 24 78
16-Turn Mo ifie 25 78
Team Losi is continually changing and improving designs; therefore, the actual part may appear slightly different than the illustrated part. Illustrations of parts and
assemblies may be slightly distorted to enhance pertinent details.
TABLE OF CO TE TS
1. INTRODUCTION .................................................................... i
Complete Kit Dimensions .................................................... i
Notes & Symbols .................................................................. i
Kit Manual Organization ....................................................... i
Important Safety Notes ......................................................... i
Tools Require ..................................................................... ii
Ra io/Electrical .................................................................... ii
Har ware I entification ........................................................ ii
Recommen e Gearing ......................................................... ii
2. BAG A .................................................................................. 1-2
3. BAG B .................................................................................. 3-7
4. BAG C ................................................................................ 8-11
5. BAG D ............................................................................. 12-1
6. BAG E ............................................................................. 20-23
7. BAG F ................................................................................... 24
8. BAG G ............................................................................. 25-30
. Checklist Before Your First Run ......................................... 31
10. Tips From the Team ........................................................ 31-33
11. Spare Parts List ............................................................. 34-36

12
11
1
8
7
1
8
11
3
2
1
3
4
5
6
BAG A
1
Step A-1
Step A-2
q 1. Place the Servo Saver Bottom (1) over the Servo Saver Post (2)
and slide the Servo Saver Bottom all the way against the hex at the
opposite end. Be sure that the hex on the Servo Saver Post is inserted
into the hex in the Servo Saver Bottom.
q 2. Slide the Servo Saver Top (3) down over the Servo Saver Post
so that the V area of the Servo Saver Top rests in the V area of the
Servo Saver Bottom. The arm on the Servo Saver Top and the arm on
the Servo Saver Bottom should now point in opposite directions as
shown in Figure 1.
q 3. Slide the Servo Saver Spring (4) over the Servo Saver Post and
push it into the recessed area of the Servo Saver Top. Install the
Servo Saver Spring Cap (5) and thread the 6-40 Locknut (6) onto the
end of the Servo Saver Post.
q 4. Tighten the 6-40 Locknut all the way down and then loosen it
two full turns (e.g. 360o x 2). This is a good starting point for the
adjustment. Once assembly is complete, if you wish, the servo saver
can be adjusted tighter or looser.
q 1. Insert a 4-40 Mini-Locknut (7) into the outer hex area in the
Servo Saver Bottom (1) and steering Idler Arm (8) as shown in Figure
2. Thread a 3/16" Ball Stud (11) through the outside hole in each arm,
into the Nuts, and tighten. Insert a 4-40 Mini-Locknut into the hex
area in the Servo Saver Top (3). Thread a 3/16" Ball Stud through the
hole in the Arm, into the Nut, and tighten.
q 2. Insert a 4-40 Mini-Locknut into the hex areas in the rear holes
of the Servo Saver Bottom and the steering Idler Arm as shown in
Figure 2. Thread a 3/16" Ball Stud through the Arms, into each Nut,
and tighten.
Once assembly of your new XXX-BK2 is complete, you may
notice that the tires toe-in slightly as the suspension compresses.
We have found this setting to yield the best performance. Should
you prefer to change this so that the tires do not toe in, you can add
one Ball Stud Washer under the Ball Studs on the outside of the
Servo Saver assembly and steering Idler Arm. To accomplish this,
you will want to replace the 3/16" Ball Studs with 1/4" Ball Studs.
Step A-3
q 1. Snap one end of the steering Draglink (12) to the rear Ball Stud
(11) on the Servo Saver Bottom (1). Snap the other end to the Rear
Ball Stud on the steering Idler Arm (8).
*NOTE: Be sure to snap the rod onto the correct ball studs as shown!
Figure 1
Figure 2
7
11
Servo Saver Assembly:
Ball Stud Install:
Servo Link:
Figure 3
6

13
14
15
16
17
14
17
19
BAG A (Continued)
2
Step A-4
q 1. Insert a 3/32" x 3/16" Ball Bearing (13) into the two large, angled
holes in the bottom of the front Kickplate (14). Insert the other two
Bearings into the two outer holes in the Steering Brace (15).
q 2. Insert a 3/32" x .930" Hinge Pin (16) through the hole in the
steering Idler Arm (8) and center the Hinge Pin in the Idler Arm. Place
the Servo Saver assembly and the steering Idler Arm into the Bear-
ings in the Kickplate so that the installed Draglink is to the front as
shown in Figure 4.
q 3. Place the Steering Brace on top of the Servo Saver assembly
and steering Idler Arm ensuring that the Ball Bearings slide over the
Pins.
There is a short Thread-Cutting Screw included in the Wrench
bag. This Screw can be used to tap threads in the holes in the Kickplate.
Pre-tapping these holes makes it easier to install the Screws during
assembly.
q 4. Secure the Steering Brace to the Kickplate using two 4-40 x 3/8"
Cap Head Screws (17).
q 1. Install a Threaded Insert (18) into the top of each of the two
forward holes in the main Chassis (19). The inserts should be in-
stalled with the hex-side up as shown in Figure 5. Press the Threaded
Inserts all the way into the holes in the Chassis, lining up the hex on
the inserts with the hex in the holes.
Step A-6
There is a short Thread-Cutting Screw included in the wrench
bag. This Screw can be used to tap threads into the back two holes in
the front part of the main Chassis. Pre-tapping these holes makes it
easier to install the Screws during assembly.
IMPORTANT NOTE: Ensure that the hex of the Threaded
Insert remains seated in the hex area on top of the Chassis.
q 1. Attach the front Kickplate (14) to the bottom of the main Chas-
sis (19). Align the four holes in the Kickplate with the four holes in
the main Chassis. Secure the Kickplate to the Chassis by threading
two 4-40 x 3/8" Cap Head Screws (17) through the forward holes and
into the Threaded Inserts (18). Thread two more 4-40 x 3/8" Cap Head
Screws through the two rear holes of the Kickplate and into the Chas-
sis. Figure 6
Figure 4
Figure 5
Step A-5
13
17
18
17
Steering Install:
Threaded Insert Install:
Kickplate Install:
18
19
16

24
20
21
9
26
24
25
89
20
14
54
19
21
BAG B
3
Step B-2
There is a short Thread-Cutting Screw included in the Wrench
bag. This Screw can be used to tap threads into the middle bottom
hole in the front Bulkhead. Pre-tapping this hole makes it easier to
install the Screw during assembly.
q 1. Position the front Bulkhead 20) on top of the front Kickplate
14) and main Chassis 19) as shown in Figure 7. Secure the front
Bulkhead to the Chassis by threading two 4-40 x 3/8" Button Head
Screws 21) through the hole in the top of the Bulkhead and into the
Threaded Inserts in the Chassis.
q 2. Secure the front Kickplate to the front Bulkhead by threading a
4-40 x 3/8" Flat Head Screw 54) through the center hole in the front of
the Kickplate and into the Bulkhead.
q 1. Insert two 4-40 x 3/4" Cap Head Screws 89), one on each side
through center holes in the top of the Front Shock Tower 24). Secure
the Screws to the Shock Tower by threading a 4-40 Nut 25) over each
Screw and tightening.
Figure 7
Figure 8
Step B-1
21
54
25
Front Bulkhead Install:
Front Shock Tower Assembly:
9
26
Front Shock Tower Install:
21
IMPORTANT NOTE: The Screws in the top of the Shock Tower
must be pointing forward as shown in Figure 9.
q 1. Attach the front Shock Tower 24) to the front Bulkhead 20)
with four 4-40 x 3/8" Button Head Screws 21). The Screws thread into
the top-most and bottom-most holes in the Bulkhead, corresponding
with the appropriate holes in the front Shock Tower. The center holes
are not used.
q 2. Place one Ball Stud Washer 9) over each of the two 3/8" Ball
Studs 26). Thread a 3/8" Ball Stud into the outside of the three cam-
ber position holes, on each side of the front Bulkhead. Figure 9
Step B-3
89

4
BAG B (Continued)
Step B-4
Step B-5
Figure 11
*NOTE: If the 3/16" x 3/8" Bearing only has one Teflon seal
(colore , woven-looking) in it, position the bearing so that the seal
faces the outsi e of the Spin le.
q 1. Insert a 3/16" x 3/8" sealed Bearing 27) into each side of both
front Spindles [left 28), right 29)].
q 2. Insert a front Stub Axle 30) from the outside of both Spindles as
shown in Figure 10.
q 3. Place a front Axle Spacer 31) over each of the two front Stub
Axles as shown in Figure 10. Thread a 4-40 x 1" Button Head Screw
32) into each of the Stub Axles from the back side. The front Axle
Spacer should be positioned on the Stub Axle between the head of
the Screw and the inner sealed Bearing. Tighten the Screws while
holding the Stub Axle with a 3/8" socket wrench or pliers.
Be sure that the front Axle Screws are TIGHT! The thread-lock
compound that is on the Screws takes 24 hours to cure.
q 1. Attach the left Spindle 28) to the left Spindle Carrier 33) by
aligning the holes in each part and inserting a 3/32" x 1.050" Hinge Pin
35) from the bottom. Do not insert the Pin all the way through both
parts yet.
q 2. Insert a front Spindle Spacer 36) between the top of the Spindle
and the Spindle Carrier as shown in Figure 11. Once the Spacer is in
place, insert the Hinge Pin through the Spacer and the top of the
Spindle Carrier. Center the Hinge Pin in the Spindle Carrier.
IMPORTANT NOTE: There are two different sizes of E-clips in
this assembly bag. Be sure to use the smallest E-clips on the 3/32"
Hinge Pins. Refer to Figure 11 and make sure that the Spindles are
installed correctly.
q 3. Secure the Hinge Pin with two 3/32" E-clips 37), one on each
end.
q 4. Repeat Steps 1-3 for the right Spindle 29) and right Spindle
Carrier 34).
Figure 10
27
31
32
36
37
Front Spindle Assembly:
Front Spindle to Spindle Carrier:
33
35
28
36
37
32
31
28
30
27
35

33
38
39
42
41
37
166
10
41
40
10
33
7
10
28
BAG B (Continued)
5
Figure 13
Step B-7
IMPORTANT NOTE: There are two sizes of E-clips in this as-
sembly bag. Be sure to use the small E-clips on the 3/32" Pins.
q 1. Place the left Spindle and Carrier assembly Figure 12) into a
front suspension Arm 38) as shown in Figure 13. Note that the Spindle
Arm faces the side of the suspension Arm with the Shock mount
holes rear) and the Ball Stud 10) in the Spindle Carrier is pointing
forward. Line up the two sets of holes in the Spindle Carrier 33) with
the holes in the front Arm, insert a 3/32 x .930" Hinge Pin 166) in the
inside of the outer two holes of the Arm and Spindle Carrier then
attach a 3/32 E-clip 37) to both sides of the Hinge Pin.
q 2. Install a 1/8" E-clip 41) on one end of each inner 1/8" x 1.42"
Hinge Pin 40).
q 3. Attach the Arm to the left side of the front Pivot Block 39) by
inserting Hinge Pin from the back side, through the inside hole in the
front Arm, and Pivot Block as shown in Figure 13.
q 4. Repeat Steps 1-3 for the right Spindle and Carrier assembly and
remaining front suspension Arm.
q 5. Slide the front Hinge Pin Brace 42) over both front inner Hinge
Pins. The E-clip grooves in both Hinge Pins should be exposed in
front of the Brace. Secure the Brace by installing a 1/8" E-clip to the
front of each Hinge Pin.
The XXX-BK2 has been designed with Varaible Length Arms
VLA). For a more detailed description of the VLA system, please
read the VLA section in the back of this manual.
IMPORTANT NOTE: Make sure that the Hinge Pin is installed
into both of the inner-most holes on the VLA Arms and Spindle Car-
riers.
Step B-6
Figure 12
q 1. Insert a 4-40 Mini Locknut 7) into the hex area on the back side
of each Spindle Carrier 33), 34) as shown in Figure 12. Insert a 1/4"
Ball Stud 10) into the outside hole closest to the installed Hinge Pin)
and tighten.
q 2. Insert a 4-40 Mini Locknut into the hex area in the top side of
each Spindle 28), 29). Thread a 1/4" Ball Stud into the Nut from the
bottom of the Spindle and tighten.
IMPORTANT NOTE: Do not overtighten the Ball Studs! This
can strip out the hex area in the Spindles and cause the Spindle Car-
rier to crack/break.
7
10
41
Ball Stud To Front Spindle:
Front Suspension Arm Assembly:
37
166
40

26
47
20
33
There is a small container/package of White Grease in this bag.
It is recommended that this be applied to the threads of the Turn-
buckles before trying to thread on the plastic Rod Ends.
*NOTE: The two en s of the turnbuckle are threa e opposite.
The en closest to the groove, next to the square, has stan ar
right-han threa s, the other en has left-han threa s. This allows
the length of the Tiero s, once installe , to be a juste without
removing them.
q 1.Thread a plastic Rod End 45) onto each end of a
1-5/8" Turnbuckle 46). Tighten both Rod Ends equally until the Tierod
is the same length as the Rod in Figure 15B. Make two of these
camber link assemblies.
20
14
39
43
42
150
6
BAG B (Continued)
Step B-9
Figure 15B
Step B-8
q 1. Hold the Chassis assembly upside down. Place the front Pivot
Block 39) over the front edge of the front Kick plate 14) as shown in
Figure 14. The front edge of the front Bulkhead 20) should be posi-
tioned between the front Pivot Block and the Hinge Pin Brace 42).
q 2. While holding the front suspension assembly in place, position
the front Bumper 43) on the bottom of the front Pivot Block so that
the four holes in the Bumper are aligned with the four holes in the
Pivot Block. The Bumper should be attached as shown so that the
edges curve towards the top of the Chassis. Secure the Bumper and
Pivot Block to the front Bulkhead and Kickplate by threading four 4-
40 x 5/8" Flat Head Screws 150) through the Bumper and Pivot Block
and tightening.
Figure 15A
*NOTE: Assure that the grooves on all of the front Turnbuckles
are locate on the rivers right-han si e for easier a justment
later.
q 1. Place a "Foam Thing" 47) over the Ball Studs 10) in each of the
Spindle Carriers 33), 34). Next, attach one side of a camber link as-
sembly Figure 15B) to the Ball Stud 26) on the left side of the Bulk-
head. Attach the other side of the camber link assembly to the Ball
Stud in the Spindle Carrier.
q 2. Attach the second camber Tierod to the right side of the car.
150
45
Front Suspension Arm Install:
Tierod - Camber Link Assembly:
Camber Link Install:
Step B-10
Figure 14
Figure 16
46
46
45

28 11
1
10
47
BAG B (Continued)
7
Step B-11
Step B-12
There is a small container/package of White Grease in this bag.
It is recommended that this be applied to the threads of the Turn-
buckles before trying to thread on the plastic Rod Ends.
*NOTE: The two en s of the turnbuckle are threa e opposite.
The en closest to the groove, next to the square, has stan ar
right-han threa s, the other en has left-han threa s. This allows
the length of the Tiero s, once installe , to be a juste without
removing them.
q 1. Thread a Plastic Rod End 45) onto each End of a
1-7/8" Turnbuckle 72). Tighten both Rod Ends equally until the Rod
is the same length as the Rod in Figure 17B. Make two of these Tierod
assemblies.
*NOTE: Assure that the grooves on all of the front Turnbuckles
are locate on the rivers right-han si e for easier a justment
later.
q 1. Place a "Foam thing" 47) over the Ball Studs 10) in each of the
Spindle 28), 29).Snap one end of a steering Tierod assembly Figure
17B) to the Ball Stud 11) in the steering Servo Saver Bottom 1). Snap
the other end to the Ball Stud 10) in the left Spindle 28).
q 2. Attach the second steering Tierod to the right side of the car.
Figure 17A
Figure 17B
45
Steering Tierod:
Steering Tierod Install:
Figure 18
72
72
45

60
63
62
59
61
47
69
62
27
22
66 67
27
68
7
Step C-1 CVD Dogbone Assembly:
q 1. Apply a thin coat of White Thrust Bearing/Assembly Grease
(87) to the outsi e of the CVD Coupling (60). Insert the grease Cou-
pling into the large hole in the rear Axle (62) so that the hole in the
Coupling can be seen through the slots in the Axle.
q 2. Place the CVD Dogbone (59) over the rear Axle. Align the holes
in the Dogbone with the hole in the Coupling. Secure all three parts
by inserting a 1/16" x 7/16" (soli ) Coupling Pin (61) through the
holes in the Dogbone, the slots in the rear Axle, an the hole in the
Coupling.
IMPORTANT NOTE: Apply the enclose threa -lock to the Set
Screw before threa ing it into the CVD Coupling. If Threa Lock is
not use , the Set Screw coul loosen uring operation causing your
CVD to possibly fail or be amage .
q 3. Center the Pin in the Dogbone an secure it by threa ing a 4-40
Setscrew (63) into the en of the Coupling.
q 4. Buil two of these assemblies. Figure 19
Step C-2
Figure 20
q 1.Threa a silver colore Ball Stu (22) into the insi e hole of the
left rear Hub (66), from the front (the si e without the recesse area)
an secure it with a 4-40 Mini-Nut (7) as shown in Figure 20.
IMPORTANT NOTE: Do not overtighten the Ball Stu s.
q 2. Place a "Foam Thing" (47) over the Ball Stu .
*NOTE: If the 3/16" x 3/8" Bearings only have one Teflon seal
( olored, woven-looking) in it, position the seal to the outside of
the Hub.
q 3. Press a 3/16" x 3/8" seale Bearing (27) into the insi e of the left
rear Hub. Sli e a rear Axle (62) through the seale Bearing in the rear
Hub.
q 4. Sli e an inner rear Bearing Spacer (67) over the rear Axle, from
the outsi e, against the insi e of the Bearing. Place a secon 3/16" x
3/8" Bearing over the rear Axle an press the Bearing into the outsi e
of the rear Hub.
q 5. Place a rear Axle Spacer (68) over the rear Axle, small si e first,
against the outsi e Bearing.
q 6. Secure the rear Axle an the rear Axle Spacer by inserting a
1/16" x 7/16" Spirol Pin (69) through the small hole in the rear Axle.
The Pin shoul be centere in the rear Axle.
q 7. Repeat Steps 1-6 for the right rear Hub (65).
Rear Hub Assembly:
BAG C
60
61
63
69
27
67
8
7
22
68

BAG C (Continued)
Step C-3
Rear Arm & Suspension Assembly Install:
q 1. Place the left rear Hub (66) between the outer rails of the left
rear suspension Arm (51) (Marke "L"). Be sure that the Ball Stu
(22) is pointe towar s the front of the Arm. Position a rear Hub
Spacer (70) between the Hub an the Suspension Arm on each si e
of the Hub.
q 2. Insert the outer rear Hinge Pin (71) into the insi e hole on the
Suspension Arm, through each of the two Hub Spacers an the
insi e hole in the rear Hub. Secure the Hinge Pin with two 1/8" E-
clips (41).
q 3. Repeat Steps 1 an 2 for the right rear Hub (65) assembly.
*Note: Read the VLA se tion in the ba k of this manual for
tips on when to use the outer holes on the rear Arms and Hubs..
Step C-4
Rear Hub Assembly Install:
Figure 21
Figure 22
q 1. Attach the plastic rear inner Pivot Block (49) to the rear Pivot
Plate (53) with two 4-40 x 1/2" Flat Hea Screws (44) with the Hinge
Pin holes facing rearwar . Threa the Flat Hea Screws in 3-4 turns
to hol the plastic rear Pivot in place.
q 2. Locate the small Anti-Squat Shims (165) (rea the "Anti-Squat"
section in "Tips" for when to use more or less of these). Place one
Anti-Squat Shim between the plastic rear Pivot an the rear Pivot
Plate , making sure the flat e ge is towar s the outsi e, an tighten
the two Screws.
IMPORTANT NOTE: Ensure that the Anti-Squat Shims are com-
pletely un er the plastic rear Pivot to provi e a rigi mounting sur-
face.
q 3. Attach the rear Pivot Plate to the Chassis (19) using four
4-40 x 3/8" Flat Hea Screws (54). Make sure the Pivot Plate is flush
with the Chassis, an the holes in the Pivot Plate an Chassis are
aligne .
q 4. Sli e the a rear inner Hinge Pin (52) into the left rear suspension
Arm (51) marke 'L' push the hinge pin into the left si e of the plastic
rear Pivot Block.
q 5. Repeat Step 4 for the right rear suspension Arm.
q 6. Sli e the aluminum rear Pivot (164) over the rear inner Hinge
Pins with the flat si e facing towar s the rear of the car. Threa two
4-40 x 3/8" Flat Hea Screws through the Pivot Plate into the alumi-
num rear Pivot, do not tighten them at this time!
IMPORTANT NOTE: The screws hol ing the aluminum Rear
Pivot will have to be remove later to allow for the installation of the
Motor Guar , it is important that these Screws are only snug at this
time.
70
54
165
9
51
71
41
22
70 66
44
REAR INNNER
PIVOT SCREWS
53 54
44
164
49
52
51
19
165
52
71
41

55
53
58
57
54
19
56
22
57
23
55
25
Step C-5
Step C-6
Rear Shock Tower Assembly:
Rear Shock Tower Install:
q 1. Insert two 4-40 x 7/8" Cap Hea Screws (23), one on each si e,
through the secon hole out on the top of the rear Shock Tower (55)
as shown in Figure 23. Secure the Screws to the Shock Tower by
threa ing a 4-40 Nut (25) onto each Screw an tightening.
IMPORTANT NOTE: The Screws shoul exten from the same
si e of the Shock Tower as the two tabs near the center of the Shock
Tower.
q 2.Threa a silver colore Ball Stu (22) into the center hole on
each si e of the rear Shock Tower.
IMPORTANT NOTE: The Ball Stu installe in the rear shock
tower, must be a silver colore "Short Neck" Ball Stu .
q 3. Align a rear Wing Mount (56) with the lower set of holes in the
left si e of the rear Shock Tower. Secure the Wing Mount with two 4-
40 x 1/2" Cap Hea Screws (57). Align an secure the other Wing
Mount to the right si e of the Shock Tower in the same manner.
IMPORTANT NOTE: The Wing Mounts shoul exten from
the Shock Tower in the opposite irection of the Screws in the top of
the Tower as shown in Figure 23. Figure 23
Figure 24
There is a short threa -cutting screw inclu e in the Wrench
bag. This Screw can be use to tap threa s in the holes in the Main
Chassis. Pre-tapping these holes makes it easier to install the Screws
uring assembly.
q 1. Place the rear Shock Tower (55) between the rear Suspension
Arms an behin the aluminum rear Inner Pivot (164). The Shock
Tower shoul sit flat against the rear Pivot Plate (53). Place a #4
washer (58) over two 4-40 x 1/2" Cap Hea Screws (57). Secure the
Shock Tower to the Chassis by threa ing the two 4-40 x 1/2" Cap
Hea screws, with #4 washers attache , through the tabs on the
Shock Tower an into the Chassis.
q 2. Secure the rear Shock Tower to the rear Pivot Plate by threa -
ing a 4-40 x 3/8" Flat Hea Screw (54) from the bottom si e of the
Chassis through the Pivot Plate, an into the Shock Tower.
BAG C (Continued)
23
25
57
22
54
57
58
10

Step C-7 Rear Camber Tiero Assembly:
Step C-8 Rear Camber Link Install:
Figure 25A
Figure 25B
There is a small container/package of White Grease in Bag B. It is
recommen e that this be applie to the threa s of the
Turnbuckles before trying to threa on the plastic Ro En s.
*NOTE: The two ends of the turnbu kle are threaded opposite.
The end losest to the groove, next to the square, has standard
right-hand threads, the other end has left-hand threads. This allows
the length of the Tierods, on e installed, to be adjusted without
removing them.
q 1. Threa a plastic Ro En (45) onto each en of the 1-5/8""
Turnbuckles (46). Tighten both Ro En s equally until the Ro En
is the same length as the one shown in Figure 25B. Make two of these
rear Camber Tiero assemblies.
NOTE: Assure that the grooves on all of the rear Turnbu kles
are lo ated on the drivers left-hand side for easier adjustment later.
q 1. Attach one en of a rear Camber Link assembly (Figure 25B) to
the Ball Stu (22) in the left rear Hub (66) an the other en to the Ball
Stu in the rear Shock Tower (55).
q 2. Repeat Step 1 for the right si e of the car.
Figure 26
BAG C (Continued)
45
11
66
22
55
72
45
46

BAG D
12
Step D-1
Step D-2
Step D-3
q 1. Locate the 5/64" Allen Wrench (74) supplied with the kit. Place
the iff Nut (73), over the Allen Wrench, with the ears on the iff Nut
towards the bent end of the Allen Wrench.
q 2. Place the iff Spring (76) over the Allen wrench against the iff
Nut.
q 1. Insert all of the parts that are stacked on the wrench into the
male Outdrive/ iff Half (77). Line up the tabs on the iff Nut (73) with
the slots in the Outdrive. Make certain that the iff Spring (76) is
seated all the way into the Outdrive/ iff Half, and that it is flat to the
bottom of the pocket.
Leave the Allen Wrench in place to hold the iff Nut in the
Outdrive while continuing assembly.
q1. Apply a small amount of iff Grease (clear) (78) to the outside
ridge of the Outdrive/ iff Half (77). Attach a iff Ring (79) to the
Outdrive by lining up the " shape" of the Ring with the " shape"
of the Outdrive.
*NOTE: Only a small amount of Grease is needed. It is only
used to hold the Diff Ring in place.
IMPORTANT NOTE: o not glue the iff Ring to the Outdrive/
iff Halves. oing so may not allow the Rings to mount flat on the
Outdrive.
Figure 27
Figure 28
Figure 29
Diff Nut Assembly:
Diff Nut Assembly To Outdrive:
Diff Drive Ring To Male Outdrive:
79
77
79 SMALL AMOUNT
OF GREASE
73
73
76
74
76
73
76
77

BAG D (Continued)
13
Step D-4
Step D-5
q 1. Insert a 5mm x 8mm Ball Bearing (80) into the center of the iff
Gear (81).
q 2. Press a 3/32" carbide iff Ball (82) into each of the 12 small holes
in the iff Gear. There should be a total of twelve Balls installed.
IMPORTANT NOTE: There are two sets of Balls in Bag . Be
certain to use the Balls that are packaged separatly (12 total) in Step
-4. There is a second set of eight 5/64" Balls packaged with Thrust
Washers in the bag. These Balls will be used in Step -6.
Figure 31
Diff Gear:
Diff Gear to Male Outdrive:
Figure 30
q 1. Apply a small bead of clear iff Grease (78) to the exposed side
of the iff Ring (79). Carefully place the iff Gear(81) over the bearing
boss, so the iff Balls (82) and iff Gear rest flat against the iff Ring.
IMPORTANT NOTE: It is a good idea to hold the iff Nut in
place, with the Allen Wrench, so the iff Nut is not pushed out of the
Outdrive/ iff Half.
80
82
80
82
81
GREASE BOTH
SIDES
79
81
82
GREASE

BAG D (Continued)
14
Figure 33
Step D-7 Diff Adjusting Screw Assembly:
83
84
q 1. Very carefully insert the iff Thrust Assembly, into the female
Outdrive (83). Be very careful to make sure the Thrust Balls(88) re-
main seated between the Thrust Washers (86) while inserting the iff
Screw. Pull the threaded end of the iff Screw until the Thrust Bear-
ing assembly rests against the inside of the female Outdrive.
IMPORTANT NOTE: Ensure that all eight Thrust Bearing Balls
remain in place between the two Washers, around the iff Screw.
Step D-6
Figure 32
earing Insert to Female Outdrive:
*NOTE: Be ery careful when installing the foam Thrust Bear-
ing Seals, do not o er-stretch them.
q 1. Locate the iff Adjusting Screw (84) and carefully stretch the
two blue foam Thrust Bearing Seals (85) into the groves on the head
of the iff Screw.
q 2. Place one of the Belleville Washers(75) onto the iff Adjusting
Screw with the cone pointing toward the head of the iff Screw.
*NOTE: The Thrust Bearing Washers are packaged in a small
bag along with the eight 5/64" Thrust Bearing Balls.
q 3. Place a Thrust Washer (86) on the iff Screw against the Belleville
Washer.
q 4. Grease the Thrust Washer well with White Thrust Bearing/
Assembly Grease (87) and place the eight 5/64" Thrust Bearing Balls
(88) on top of the Thrust Washer, around the iff Screw. Apply more
White Thrust Bearing/Assembly Grease to the top of the Thrust Bear-
ing Balls.
q 5. Place another Thrust Bearing Washer over the iff Screw and
against the Thrust Bearing Balls.
q 6. Place another Belleville Washer on the iff Screw with the cone
pointing away from the head of the iff Screw.
85
75
88
86
84
85
88
75
86
GREASE
84

15
Figure 35
BAG D (Continued)
Step D-9
q 1. Make sure that the slot in the iff Screw (84) is lined up with the
slot in the female Outdrive/ iff Half (83) and that the Allen Wrench is
inserted in the slot in the iff Screw.
q 2. Carefully remove the Allen Wrench from iff Nut in the male
Outdrive. Insert it through the slot of the male Outdrive (same as
what was done with the female Outdrive). This will hold the iff Nut
in place during assembly.
q 3. While holding the Female Outdrive/ iff Half with the Allen
Wrench inserted, carefully place the two Outdrive/ iff Halves to-
gether.
q 4. Hold the iff assembly so that the Outdrive/ iff Half with the
iff Nut (73) is pointing up. Slowly turn the Male iff Half clockwise
to thread the iff Screw in the iff Nut. Thread the two halves to-
gether until the Screw just starts to snug up.
When tightening the diff, tighten the screw a little and then work
the diff a little, by holding the iff Gear and Rotating the Outdrive/
iff Half. Then tighten the iff a little more and work the diff again.
Continue this until the iff is tight. This will ensure proper seating of
all the parts in the iff assembly.
q 5. Tighten the iff until the Gear (81) cannot be turned while both
of the Outdrives/ iff Halves are being held. Final iff adjustment
should be made after completion of the car.
Diff Assembly:
84
81
77
73
83
Step D-8 Diff Ring to Female Outdrive:
q 1. Insert a 5mm x 8mm Ball Bearing (80) into the center of the
female Outdrive/ iff Half (83).
q 2. Place the 1/16" Allen Wrench (92) through the slot in the Outdrive/
iff Half containing the iff Screw (84). Slide the wrench all the way
against the Screw. By handling the Outdrive/ iff Half with the Wrench
inserted, the iff Screw will be held in place while finishing assembly
of the ifferential.
q 3. Apply a small amount of Clear iff Grease (78) to the outer ridge
of the Outdrive. Install the remaining iff Ring (79), again lining up
the " shape" of the Outdrive/ iff Half with the " shape" of the iff
Ring. Apply a good size bead of grease to the exposed side of the iff
Ring.
Figure 34
83
92
84
80
SMALL AMOUN
T
OF GREASE
79
79
80

BAG D (Continued)
16
Step D-10
q 1. Insert a 3/16" x 3/8" sealed Bearing (27) into the top Bearing seat
of the left Gearbox Half (94).
q 2. Insert a 1/2" x 3/4" Bearing (95) into the lower Bearing seat of
the left Gearbox Half.
*NOTE: If the 1/2" x 3/4" Bearing only has one Teflon seal
(colored, wo en looking) in it, position the seal to the outside of the
Gearbox Half.
IMPORTANT NOTE: Never allow the Gearbox Halves to come
into direct contact with any type of motor spray/cleaner. The material
used on these parts was selected with performance in mind, and some
motor sprays/cleaners may damage the parts.
*Note: Motorplate supplied in kit may look slightly different
than pictured in Figure 37.
q 1. Place the Motor Plate (96) against the outside of the right
Gearbox Half (97) by aligning the hole in the Motor Plate with the
Top Shaft Bearing housing in the right Gearbox Half as shown in
Figure 37.
q 2. Rotate the Motor Plate so that the Screw holes in the Motor
Plate line up with the Screw holes in the Gearbox Half. Secure the
Motor Plate to the Gearbox Half by threading a 4-40 x 1/2" Cap Head
Screw (57) through the hole near the center of the Gearbox Half from
the inside into the hole in the Motor Plate and tighten.
q 3.Insert a 3/16" x 3/8"sealed Bearing (27) into the top
Bearing seat of the right Gearbox Half. Carefully push the Bearing all
the way into the Bearing seat using a pencil or the handle of a hobby
knife. Care should be taken not to damage the seals on the Bearing.
*NOTE: If the 3/16" x 3/8" Sealed Bearing only has one Teflon
seal (colored, wo en looking) in it, position the seal to the outside
of the gearbox half.
q 4. Insert a 1/2" x 3/4" sealed Bearing (95) into the lower
bearing seat of the right Gearbox Half.
q 5. Press or lightly tap the Idler Gear Shaft (98), into the hole in the
center of the right Gearbox Half.
Step D-11
Figure 37
Figure 36
earing to Left Gearbox Half:
Motor Plate to Right Gearbox Half:
97
98
95
2
7
96
57
27
95
95
98
27
57
95
95
94
94
27
27