Team Losi Double-XT CR Graphite Plus User manual

--
OWNER•s
MANUAL
~ Carefully read through all instructions to familiarize yourself wilh the parts, constr uc tion
techniques, and tuning tips outlined in this manual. Being able to grasp the overall de~ign of
your Double-XT 'CR' GraphitePlus racing truck before ~ginning the construction process will
ensure a smooth assembly.
,. ~ Take your time and pay close attention to detail. Keep th is manual for future reference.
.·
Team Losl, Inc ., 13848 Magnolia Ave ., Chino , CA 91710
phone: [phone] • fax: [phone]
h tt p; /l www.Teamlosi.com • [e-mail]
sc an courtesy of Vintagelosi.com
MADE IN THE UNITED STATES OF AMERICA PI NSOG-0105

_......
Welcome Double-XT ·cR· Graphite Plus Owner ~
Thank y ou for choo sing T ea m Lo si an d the value-packed Do ubl e-X T ' CR ' Graph ite Plu s ki t. As you probabl y kn ow,
'Jearn Los i has be en the pion ee r in offering feature - pa ck ed, ra ce-re ad y, rac e-w inn i ng RIC car and t ru ck kits. Th e
D ouble -XT 'CR' Graphit e Plus is pe rh aps the bes t examp le of this. Titan ium ; carbon fiber /g ra phi te; precision - ma c hin ed,
li ghtwe ight al uminum; and space-age coated part s cr eate a Lru ly sta te- of - the - art ra ce t ru ck. Now yo u can build a truck
like the ones used by T ea m L os i drivers to dominat e ra cing thr ougho ut the coun tr y- winn ing e very Modifi ed Nati ona l
Championship for the p ast two years!
As always, please ta ke a mom e nt to r ead through the instructions befo re star ting the act ual asse mbl y. Also ch ec k out
• the tech ti ps for tuning idea s.
Good luck, and thank you for ch oosi ng Team Losi.
1. INTRODUCTION
DOUBLE-XT 'CR' GRAPHITEPLUS COMPLETED KIT DIMENSIONS
Lengt h: 15.5"
Wheelbase: 11 .4 " Front Width: 12.5" Rear Widt
h: 12.6" Heigh t: 5.5"
All dimensions at ride height. Weight will vary depending on accessories.
NOTES & SYMBOLS USED
ljt. !i!ijl
This is a common figure number found at the beg in ning
of eac.: h new illu stration throughout the manual.
0 Step I. - Each Slep throughout the entire manu al has a
check
box to the le ft of i i. As yn u wm plete each step, mark the
box with a check. Ifyou need to take a break and return to build-
ing at a later time you will be ab le to locate the exacr step where
yo u left off.
"N OTE:Trusisa common n ote.lt is used to call attention to
spec ifi c deta il s ofa certain step in the assemb ly .
& IM PORTANT NOTE: Even if you are familiar wi lh
T ea m Losi kits, be sure and pa y attention to these notes. They
point out very importantdetails during the assembly process. Do
not ignore these not es!
,......, This wrench de signatesa p erf onnance tip. These tips
are not necess ar y, but can improve the pe rformance of your
Graphite Plus 'CR' truck.
In illustrations where it is important to note which
direc ti on parts ar c pointing,a helmet li ke this one will be incl ud ed
in the
illu st ration. Th e helmetw ill alwa ys face the front of the car.
Any reference to the right or left s id e w ill relate to the direc ti on of
the helme L.
KIT/MANUAL ORGANIZATION
The kit is composed of different bags marked A through G. Each
ba g conrains all of the parts necessary to complete a particular
sec ti on of the Graphite Plu s'CR'. Some of these bags have s ub as-
sembly bags within them. It is essential that you open only one
bag at a
tim e and follo w the corre ct assembly sequence, other i
wise you may face diffi cu lti es in finding the correctpart. It is helpf ul
to read through the instructions for an entire bag prior to b f.'!-'111
ningasse mb ly. Ke y nu mb ers ( in parenthesis) have been a ss i ~ p wd
to each partand remain the same throughout themanual. In soml
illustra ti on s, parts which havealready been installed ar e not sho'' n
so that the current steps can
be illustrated more cl ea rl y.
For your conven ie nce, an actual -s iz e hardware id entifica
tion guide is included with each ste p. To check a part, hold it
against the silhouette until the correct p:m is identified. In som t'
cases extra hardware has been s up p li ed for parts that may b l'
easy to lose.
Th e molded parts in the Grapltit e Plus 'CR' arc manufac·
lured to demanding tolerance s. When screws are tightened to lhe
point of being snug, thP p art..., art> held firmly in plac e. For th is
reason it is very im portant that sc rews not be overtightened in
any ofthe plastic parts.
To insure that parts are not lost dur ing construction, it is
recommended that you work overa towel or marto pr event pan s
from rolling away.
IMPORTANT SAFETY NOTES
l. Select an area for assembly thatis awa y from the reach of
small children. Th e pa r is in th ekit are small and can be swallowed by
clzildretz, c ausing choking and po ss ib le inl ema l injury .
2. The shock fluid a nd greases supplied should be kept out
of c hi ldren's reach. Th ey are not intended for human consumption.'
3. &ercirecarewhen using any hand tools, sharp instrument s,
or power tools during construction.
4. Ca refull y read all manufacturer's w arnin gs and c autions for
any glues, chemicals, or paints that may be used for assembly and
operating purposes.

TOOLS REQUIRED
Team Losi has supplied all necessary Allen wrenches and a special wrenches that are needed for assembly and adjustments.
followi ng common tools will also be r eq uired: Need le-nose p li ers, regularpliers, hobby knife, scissors or other body cutting /t ri m
tools,
and a so ldering ir on may be necessary for radio installation. 3/ 16", 1/4", and 3/8" nut drivers are optional.
RADIO/ELECTRICAL
A suggested radio l ayout is provided in this manual. Your high-perfotmance RIC center sh ould be consulted regarding spec ifio oo
radio/electrical equipment.
HARDWARE IDENTIFICATION
When in question, use the hardware identification guide in each step. For screws, the prefix number designates the sere" in.> .v>d
numbe r of threads per inch (i.e., 4- 40 is #4 screw with 40 threads per inch). The second number or fraction designates the length
the screw. For cap- head screws, this number refers to the length of the threaded portion of the screw. For flat-head screws. tht numbr.r
refers to the overall length of the screw. Bearings and bushings are referenced by the i ns ide diameter x outside diam et er !wits and
pins are diame ter x length. Washers arc described by ins id e diameter or the screw size that will pass through the ms1de d....une<n
E-clips are sized by the shaft diameter tha t they attach to.
MOTORS AND GEARING
T he D oub l e· XT 'CR' Graphit e Plus includes an 88 -tooth, 48 -pitch spur gear . The overall internal drive ratio of the Graphite Pl us 'C R'
is 2.61: I. The pinion gear thatis used will det e rmine lhe final dr i ve rat io.To calculate the final drive ratio, fir st di, ·ide the spur gear size
by the pinion gear size. For examp le, ifyou are using a 20 -tooth pinion gear, you would divide 88 ( spur gear s iLe b: 10 (pinion gear
size).
88 /2 0 =4.4. This tells you that 4.4is the external drive ratio. Next, multiply the internal drive ratio ( 2.Ci I by the external drive
ratio (in this case
4..4) . 2.67 x 4.4 = 77.484. Th is means that by using a 20 -tooth pinion gear with the standard 88-tooth sp ur gea r, the
final
dt;ve ratio is 11.481 1: l.
Consult your high-performance shop for recommendations to suit your racing style and class. Th e chan below lists some of t he
more common motor types and a recommended initial gearing for that motor. Ratios can be adjusted depending on various track
layouts, tire sizes,
and bat t ery types.
RECOMMENDED INITI AL GEARING FOR COMMON MOTORS
TYPE OF MOTOR PINION SPUR
24° Stock 22 88
36° Stock
21
88
1 1· Turn Modified 16 88
12 ·Turn Modified 17 88
13-Turn Modified 18 88
14 -Turn Modified 19 88
15-Turn Modified 20 88
16 -Turn Modified
21 88
17-Turn Modified 22 88
TABLE OF CONTENTS
1.INTRODUCTION ................................... .. ................ .. .....i 2. BAG A .........................
.. ....... .. . .. . .. ..................... .. ...... 1 ·4
Completed Kit Dimensions .......................................i
3. BAG B ............................. .. ........................ .. ...... .... .. 5-10
Notes & Symbols .......................................................i 4.BAG C ..........
.. ... .. . .. .. .... ...... .... ........ ...... ......... .. . .. . 1H4
Kit Manual Organization............................:::....... .. ....i 5. BAG D ........................... .. ...................................... 15·22
Important Safety Notes .............. .. ........................... .. i 6. BAG E .......................... .. ...................... .... ........... .. 23·26
Tools Required... ... ....... ... ...... .. .... .. ............... ...... ....... ii
?.BAG F............................ .. ..................... .. .....................27
Radio/Electrical ...... ........................ .... .... .. ............... .. ii 8. BAG G ....
.. ............................................ .... ............. 28-30
HardwareIdentification ....... .. ...... .. ......................... .. ii 9. Checklist
Be foreYour First Run ................................... 31
Recommended Gearing .. ... ............... .... ................... ii 10.Tips From the Team .............................................
.. 31 ·33
11 .Spare Parts List ...................................... .. .... .... ..... 34·36
Team Losi is co nHmulll y c han g ing and improvin g d es ig1~1; th e refor e, th e acwal part may appear slightly different than the illustrated pa r t. Jllustmti ons of parts and assemblies may be
slight/)' distorted to enhanc e pertinent details .
ii
scan courtesy of Vintagelosi.com

'
BAGA
'i[.!!ii¥1
0 Step J. Attach the f ront bu lkhead (I) to the main chass is (2)
by aligning lhe bottom hinge holes on the bulkhead (I) and the
main chassis (2}.
Onc e the holes are aligned, carefu ll y tap the
118" lower bulkhead hinge pin (3}through the bulkh ead (I}and
the ch assis ( ~ ) until the hinge pin {3) is centered in the chassis (2).
*NOT E: Use the 7/8 "hinge pin with the lar ge groove in th e cen ter .
The lo wer hinge pin fit is VERY TIGHT! Be sure that th e hol es ar e
aligned before tapping th epin th roug h the p arts.
0 Step2. Secure the pin (3) by threadinga 2- .56 x 51 16" button-
head screw (· ~ ) into the sma JI ho le Oocated at the rear) in the top
of the front bulkhead (I). Thr ea d the screw (4) all the way in.
0 Step 3. Attach the front chassis stiffener (5) to the fT ont bulk-
head (I) b) aligni ng the holes in the sti!Jener (5) with the holes in
the tO p hinge of the bulkhead (1). Secure the two parts by inseit-
ing the II H" upper bulkhead hinge pin (6}lhrough both the bul k-
head (I) and stiffener ( .5 ).
'NOTE: Use the shortest 718 " !ting e pin witlwut a groove in th e
c
enter . The hinge pinfit is tight! Lightly tap th e hinge pin through both
parts untilit is centered.
0 Step 4. Center the hinge pin (6) and attach an l/8" £- cl ip (7)
to each end of the hinge pin (6).
~ When removing the front l>u lkh ea d for any reason,
the 2-56 x 5/ 16" button-head screw
mu st be co mp lelely removed
before removing the lower hinge pin.
1
it.li!i¥1
0 11 111111: lllllil, llll tUII'IIIIII
[:D
® @
0 Step 5. Insert a 1/4" ball stud (8) into each of the inside holes
on the bottom
of the shock tower (9). Mount the ball studs ( ~ )
from th e rear as s how n.
0 Step 6. Insert a 4-40 x 718" cap-h ead screw ( 10 ) from the
rear, through the inside hole in on the top
of the shock to we r (9 )
on each side.
Threa d a top shock mount bushing ( 11 ) onto each
of the two screws ( 10 ) and tighten.
,6 IMPORTANT NOTE: Remove all flashing from the
bottom
of the front shock tower. This wi ll ensure prop er fit of the
fro nt shock t ower to the front bulkhead.
1
D
®
5
(fum m
@
\ \
Figure 1
p
~
Figur e 2
til
®
scan courtesy ofVintagelosi.com
@"?)
cv

BAG A (Continued)
'i'·!i"i'
@
0 Step 7. Attach th e front shock tower (9) to the front s id e of
the front bulkhead (I) with f our 4·40x 3/8"cap-headscrews ( 12 ).
0 Step 8. Attach the front body mount ( 13 ) to t he front side of
the front shock tower (9) with two 4-40 x 3/l:!" cap -head screws
(12 ) as shown.
@
0 Step 9. Insert a fr ont axle ( 14 ) into each of the front sp indles
[left (1 5), ri ght (1 6) ) as shown. Th e hole in the ax le (14) should
line
up with the hole in the spindle ( 15 ), (1 6).
0 Step 10. Place four ball stud washers ( 18 ) over the end of a
kingpin/ball stud (
1 9) .Slide the washers ( 18 ) all the way against
the base
of the ball stud on the kingpin/ball stud ( 19 ).
0 Step 11. Attach the right sp indle ( 16 ) to one of the spindle
carriers ( 17 ) by a li gning the holes in each and inserting a
the kingpin/ba
ll stud (1 9), with washers attached, through the
spindle carrier (
17 ), spindl t: (16 ), and axle ( 14 ). Secure the kin g-
pin /ha ll stud (19) with a 3/ 32" E·clip (20) at the bottom of the
shaft.
& IMPOR TANT NOTE: Th ere are two siz;s of'E' clips
in this assembly bag. Be sure to usc the small E-clips on the
3/ 32" pins.
0 Step 1 2. Check to see that the spindle (16) rotates easily in
the spindle carrier (17
). If the spindle doesn't rotate easily, mo ve
the kingpin
/ba ll stud up slightly so that there is a small s pa ce
between the washers (
18 ) and the spindle carrier ( 17 ). Once the
spindle (1 6) rotates easily, thr ea d a 5-40 setscrew (21) into the
back side of
th e axle (14) and tighen.
0 Step 13. R epea t Steps J0-12 for the left spi ndle ( IS ) and the
second spindle carr
ie r ( 17 ).
Figure 3
16
Figure 4
14
2
19

..
BAG A (Continued)
@ @
CJ Step 14. Insert a 4-tJO mini locknut (22) into the hex area in
the bottom
of ea ch spindle (15), ( 16 ). Thr ea d a 3/16" ball stud
(23) in from the top and tighten.
& IMP ORTANT NOTE : Do not overtighten the ball
studs!
iij!ijil#j
10
Figure 5
Dl
CJ Step I S. Attach the right spindle and carr ier assembly to the right front suspension arm ( 25) as shown. Line up the hol es in the
sp indle carrier ( 17 ) with the holes in the front arm (25 ), inse rt a 3/32" x 1. 050" hinge pin (26) and attach a 3/32" E-clip (2 0) to both
sides
of the hinge pin (26).
& IM PORT ANT NO TE: There are two sizes of £-clips in this a~sembly bag . Be sure to use the small E-clips on the
3/32" pins.
CJ Step 16. Attach the arm (25) to the right side of the front bulkhead (I) by inserting the 1/ 8" inner front hinge pin (27), from the
front, through the arm (25) and bulkhead (1).
CJ Step 17. Inserr a 1/ 8" £-clip (7) in lhe r ea r groove. of the hinge pin ( 27 ).
CJ Step IR. R epea t Steps 15 - 17 for the left spindle and carrier assembly and left suspension arm (24).
CJ Step 19. Slide the front hinge pin bra ce (28) over the front of bo th hinge pins (27 ). Be su re that the brace (2 8) is installed correctly
so that
theE -clipgrooves in both hing e pins (27) are exposed. Secure the brace by attachinga L/8" £-clip (7) to the front ofeach hinge
pin (27).
27
25
I
Figure 6
3

BAG A (Continued)
Ut.!i!l¥
1
0 Step 20. Thr ead a plastic rod end (29) onto each end of a 2-3/4" turnbuckle (3 0). Tighten both rod ends (29) equally until the rod
is Lhe same length as the rod in figure 7 A. Make two of these camber link assemblies.
30
.. ~
Figure 7
cr=== ~~ CI==~u~== ~r- ~-~d~~
Figure 7A
0 Step 21. Place a "foam thing" { 31 ) over the ball on each of the kingpin/ball st1. 1d s ( 19 ) in th e spindle carriers (1 7} and the ball studs
(8) in the shock tower{9}. Next, attach one side of a camber link assembly to the ba ll stud (8) on the right side of the shock tower (9).
Attach the other side of the camber link assembly to the kingpin/ball stud in the spindle carrier (1 7).
0 Step 22. Attach the second camber link assembly to the left si de of the truck.
~ Try to m'ount all of the camber links so that the threads adjust the same dir ection. This makes it much easier to make
adjustments later. I
31
Figure 8
4

"
BAG B
'U · !i"¥'
~
llllllmJ10
~
@
® @ @
0 tep l. Place theservo saver bottom (3 2)overthe servo saver
po st ( :-13 ) and slide the servo saver bottom aU the way down. Be
sure that the hex
in the servo saver po st (33) is inserted into the
hex in the servo saver bottom (32).
0 Step 2. Slide lht! servo saver top (34) down over the servo
saver post (
33 )so that itrests against the servosaver bottom (32).
The arm on the servo saver top (34} and the arm on the servo
saver bottom
(32) should point in opposite directions.
0 Step 3. Slide the servo saver spring (35) over the servo saver
post (33)
and push it into the recessed area of the servo saver top
{
34 ). Install the servo saver spring cap (36) and thread the 6--W
locknut (3 7) onto the threads of the servo saver post (33).
0 Step 4. Tighten the 6- 40 locknut (37) a ll the way down and
then loosen
it two full turns (e.g. 360 ox 2).This is a good starting
point for the adjustment. Once assembly
is complete, ifyou wish,
the servo saver can be adjusted tighter
or looser.
® @
0 Step 5. Insert a 4- 40 mini locknut (22) into the outside hex
area
in the servo saver bottom (32) and steering idlerarm (38) as
show
n. Pl ace two ball stud washers (1 8)over each of the two 114"
baJI studs (8). Th read a 1/4" baJI stud (8) through the outside hole
in each arm,
int o the nuts (22), and tighten. Insert a -1- - 40 mini
locknut(22) into the hex area in the servo saver top ( 34 ).Thread
a
3/ 1 6" ba ll stud (23 ) through the hole in the arm, into the nut
(22), a
nd tighten.
0 Step 6. I nsert a 4- 40 mini locknut (22) into the hex
areas in the rear of the servo saver bottom (32) and the steering
idler
arm (38) as shown. Thr ead a 3/16" ba ll stud (23) through
the arms, into each nut (22), and lighten.
1
it.l'lli
11
I Bnlll
0
[IIIII"'"
1111111111111~1111 bt: mJlJJlJDl!JID
0 Step 7. Thr ead a plastic rod end ( 2!:1 ) onto each e nd of a
2-3/8" turnbuc
kl e ( 39 ). Tighten both rod ends (29) equally until
the completed lie rod assembly is the same length as the one in
Figure II
A. Make two of these li e rod assemblies.
0 Step 8. Thread a short plastic rod end ( 40 ) onto each end of
the 1- 118 '' turnbuc kl e ( 41 ). Tighten both rod ends ( 40 ) equally
un ti l the comp leted drag link is the same length as the one in
Figure Il
A.
5
@
@
~~
34· "® 35
32
Figure 9
Figure 10
~
~
Figure11 ~~
@ @
Figure 77A

BAG B (Continued)
1
i' · !l
11
ifJ
D Step 9. Snap one end of t he short drag link to the rear ball
stud (23)
on the servo saver bottom (3 2). Snap the other end to
the rear ball stud ( 23 ) on the steering idler arm ( 38 ).
"NOTE: Be sure to snap the rod onto the correct ball studs as shown!
I a[.!!' ii fl
10 01
@
0 Step 10. Inserta 3/32" x 3/ 16" bearing ( 42 )into the two large
holes
in the bottom of the steering brace ( 43 ). Insert t he other
two bearings {42) into the two holes in the ma in chassis (2).
0 Step ll. Inser t a 3/32" x .930" hinge pin ( 44 ) through the
hole in the steering idler arm (3 8) and position it as shown in
Figure 13A. Place the servo saver assembly
and the steeringidler
arm (38) into the bearings ( 42 ) in the chassis (2) so that the
installed
drag link is in th e front.
0 Step 12. Place the steering brace (4 3) on top of the servo
saver assembly and steering idler arm (38) being sure that th e
bearings (42) slide
over the pins.
0 Step 13. Attach the stee ring brace to the chassis (2) usingtwo
4- 40 x 3/8" cap-head screws ( 12 ).
& IMPOR TANT NOTE: Tighten the two 4-40 screws
all the way
and then back them off 1 /8 of a rurn. This vvi ll keep
the posts
on the chassis from "taking a ser" ifthey should twist at
all.
Figure 72
Figure 73A
6
32
Figure 73

•
BAG B (Continued)
0 Step 14. Snap one end of a completed tie rod a<osembly to the ball stud (8) in th e idler arm ( 38 ). Snap the other end to the ball stud
(23}in the right spindle (16). Attach the
other tie rod assembly to the ball studs in the servo saver assembly and the l ef t spindle ( 15 ).
>-=> On ce again, assure that all turnbuc kl es ar e mou nted w it h the thr ea ds in the same dil·ection f or easi er adjustment later!
16
1
it.l'liifj
~N OTE: If you do not ha ve your servo at this time, skip to Bag C
and
con tinue assembly. It is recomm e nded that th e :;ervo be inrtalled at
th
is t ime since muc h of the front end ofthe truck is built around the servo
and minor disass e mbl y willbe requ ir ed to install it later.
& IMP OR TANT NO TE : If the se rvo mo unting
instructions are not fo ll owed carefully, your servo may be d am -
aged!
0 Step I S. Using a flle or a Dr emel tool, trim the two lower
e
ar s o ff of yo ur servo (not included) as shown in Figure 15. Be
very
e<tr eful to Lrim th e conect ears! Ifthe wrong ea rs arc trimmed,
your servo will not be able to be mounted unless the servo case is
replaced.
6 IMP ORTANT NO TE: It is not reco mmended thatyou
use cutters
or a h obby knife to re mov e t he servo ears. Some cases
are made
of very brittle mat er ial and dama ge to your servo case
ma y resul t.
F igure 74
Figure 75
7

BAG B (Continued)
m'l'i¥'1
@ @
0 Step 16. UsingTablt! 17B, determine which servo arm (45) is
required
for your servo. If yoLLr servo is not listed, try using the
arm recommended for another servo made by the same
manufacturer, or us e one supp li ed with your servo that is the
same length as either the
23L or the 25L arm.
0 Step 17. Insert a 4-40 mini locknut (22} into the hex area of
the servo arm (45). Thread a 3/16" ball stud (23) through the
hole in the
arm (45), into the locknut ( 22 ), and tighten.
0 Step 18. Plug the servo into the radio system's receiver (not
included) ..\1ake sure that there is power to the receiver, and tum
the transll)jtter on followed by the receiver. Be sure thatthe trim
settings for the steering on yo
ur transmitt er are set to the center.
With the radjo system still turned on, attach the servo arm (45)so
that it points straight up , away from the ears that were trimmed
off of the servo case. Secure the
arm (45) with the servo arm
screw supplied with the servo.
1
it.!i"IU
@ @
0 Step 19. Use Tables 17 A and l7 B to determine how the servo
mounting posts
(46} should be attached.
,._, Trim any flashing from the pins on the mountingposts
so that they
will seat aJI the way into the holes in the chassis
brace and chassis.
0 Step 20. Place a #4 washer (47) over eac h of the two
4-40 x 3/8" cap-head screws (1 2) and attach the servo pos ts (46)
to the servo
by threadinga screw ( 12 ) through the cent er hole in
each post (46}.
Do not tighten the screws ( 12 ) all of the way yet!
Just snug them up. The screws ( 12 ) will be tightened after the
servo
is installed so that the posts (46}have the correct spacing.
Figure 76
Figure 77
8
· ·· ~

BAG B (Continued)
•Not e: P osts are nol 10 sco. k.
Position
of pin on servomount poet
1
~on, · ard away from servo
2 forward next to servo
3 To r
ear awav from servo
4 1br
ear next to servo
Ta bl e 1 7A
& I MPORTANT NOT E: Small, light·
ening hole in thf' servo m ou nting post should
always be mount ed to the top ( the side oppostte
to wht:re the mounling ears were removed fromI.
SERVO TYPE
MOUHnNG POST
PIN LOCAnON
Airtroni cs
94 1 41 , 94145 , 94151 , 94152 , 94155 , 94156 ,
94 1 57 , 94158 , 94732 , 94734 , 94735 , 94737 ,
94738 94739 9474 1 94742 94743
3
Airtronics
1
94102 94103 94322
Fut a ba
51315, 51315H, 5148, 53001 ,53003, S5101 ,
591
01 , 59201 , S9203 , 59301 ,59303,59304,
59401 59402 S9403 59404 2
Futaba
1
S132H
JR
NES-507, NES-513, NES-517, NES-531, NES- 901 ,
NES-911, NES-2700G, NEs-4000, NES-4131,
NES-4721 NES-4735 NES-9011 NES-9021 2
KO
2
PS-702 PS-703 PS-1001 PS- 1003
KO
1
PS-901 BH , P S-902
Ta bl e 77B
@ O :niii!U!IIIIII!IIIII I
@ @)
0 Step 2 l. Place the servo, with servo mounting posts (46)
attached, into the chassis
(2). Align the pi ns in th e mounting posts
(46) with the hol es in the chassis (2).Mountt.he chassis brace (48)
on top of the servo. T he slots in the chassis brace ( 48 ) should
align with the grooves in the chassis
(2) . Make sure that the pins
in the mountingposts { 46 ) are inserted into thechassis brace ( 48 )
and the chassis (2 ). Using two 4- 40 x 112 " cap head screws ( 49 )
and two b all stud washers (18), attach the chassis br ace ( 48) as
shown.
0 Step 22. Tighten the sc rews (1 2) in the servo mo un tingposts
(46)
.6. IMPO RTANT NOTE : Don't overtighten the screws
in theservo mountingposts! The mountingears on theservo can
be
da maged if these screws are overtightened.
Figure 78
9
REQUIRED
SERVO ARM
23L
235
25L
25L
235
235
235

BAG B (Continued)
llilllllill!tillll!ll il lll ii QI
®
0 Step 23. Thr ead a s hor t plastic rod end ( 40 ) onto each end ofthe 4-40 x 518" threaded rod (50).Tighten both sides equally Lmlil
the rod is the same length as the one shown in Figure 19B . Attach one end ofthe rod to the ballstud (23) in the servo arm (45) and the
other to the ball stud (23) in the servo saver
as shown in Figure 19.
Figure 79A
50
T
.• ~
(
23
Figure 79
lj[.jiiif{·*
@ @
0 Step 24. Rotate the front bulkhead (I ) back until the front
chassis stiffener (
5) can be indexed into the chassis brace (48).
Place a ball stud washer (
18) over each of the two 4-40 x 718"
cap-head screws ( 10 }. Inserta screw { 10 ) through each of the two
holes in the f
ront chassis stiffener ( 5) and tighten.
10
Figure 79B
5
48
Figure 20

•
.
...
BAGC
I if ·ljiifjl
0 Step 1. I nsert a l/8" x l/4 " washer (5 1) into the recessed ar ea
on each side of the rear pivot block (5 ~ ) .
0 Step 2. Place the right rear suspension arm {53) ove r the right
side
of the rear pivotblock (52 ).Line up the holes in the arm (53 )
wi th the holes in the pivot block ( 52 ) and attach them by insert-
ing an inner rear hinge pin (54), £-clip groove forward, all the
way
th r ough both parts. Install a 1/ 8" £-clip (7} to the fr o nt end
of the hinge pin ( 54 }.
6 I MP OR TAN T- NOT E: Th e lettering on the rear pivot
block should face up.
0 Step 3. Attach a l/4" shock mount ball (55) to th e middle
hole of the sh
oc k mou nt brac k et (56) with a 4-40 x 3/ 8" cap-head
screw ( I ~) as shown . Secure the shock mount bracket {56 ) to the
front side of the rear suspension arm ( 53 ) with two
4 40 x 3/8" cap - head screws { 12 ) as s hown .
& IMPORT ANT NOTE: Ensure that the sh oc k mount
bra cket is attached corre ctly. The outside holes should be high er
than the inside holes. The shock mount ball should be to the r ear
si de of the bracket.
0 Step 4. R epeat Steps 1-3 for th e left rear suspensi on arm { 53).
0 Step 5. At ta ch the rea r pivotblock (5 2)to th e r ear pivotpl ate
(5 7) with four 4-40 x 3/8" flat- head screws {58) .
6 IMPORTANT NOTE: Ensur e that the pivot block is
installed with the wider
end to the rear.
0 Step 6. Holding the chassis {2) upside down, install the rear
pivot plate ( 57 }so that the pi vot plate ( 57 ) is flush with the chassis
{2). Make s ure that the four holes in the chass is {2) line up with
the holes
in the pivot pl at e ( 57 ).Secure the pivotplate ( 57 ) to th e
chassis
(2) using four .+-40 x 1 12" ca p- head screws (49}.
t;t.!jilffj
OII!II!IIIIWIIIIUJIIIU I)))!il
[FD D
:r::) IIIB!!~ !I
~
@ @ @
@)
0 Step 7. Insert two 4-40 x 7/8" c ap - head screws ( 10 ) through
the third
ho le in on each side of the • ·ea r shock tower (59} as
shown.
Th rea d the to p shock mo u nt bushings (11) onto the two
screws (
10 ) an d lighten. Th e shock mount bushings { 11 ) shou ld
be
on the side of the shuck tower ( .'i9) opposite tl1e flat surface.
0 Step 8. Attach the rear shock tower { 59 ) to the rear bulkhead
( 60 }by threading four 4-40 x 1/ 2" cap- head screws ( 49 ) th rough
tlw upp er holes in the tower ( 59 }as shown. Thi s wiU mount the
tower (
59 ) in the lowest position.
0 Step 9. Thread a 3/8 " ball stud (61)into the 4f5 hole on each
side
of the rea r bulkh ea d {60) See Figure 22A. Place a "foam thing"
{31 ) over each of the two ba ll studs ( 61 ).
11
@ @
@
Figure 27
Figur e 22
Figure 22A

BAG C (Continued)
1
it.l'liif
1
@ @
0 Step 10. Place the rear bulkhead ( 60 ) into the top, forward
area of the rear pivot plate (57).Make sure that the bulkhead (60)
is nil the way down and that the mountingears are flush with the
chassis
(2) . Thread two 4-40 x 3/8" flat-head screws (58) through
the pivotplate (
57) and into the rear bulkhead (60) . Do nottighten
these screws yet.
0 Step ll. Place a ball stud washer ( 18 ) over two 4-40 x 31 8"
cap-head screws ( 12 ) and partially thread them through the two
ears in the top
of the bulkhead (60), into the chassis (2). ow
tighten all four screws starting with the flat-head screws (
58 ).
lj[.jillfJI A
0 Step 1 2. Apply a thin coal ofwhite thrust bearing/assembly
brrease ( o2) lo the outside of the CVO yoke{63). Insertthegreased
CVO yoke (63) into the large hole in the CVD rear axle ( 6-1- }so
that the hole in the
CVD yoke (6 3) can be seen through the slots
in the CV D rear axle (64).
0 Step 13. Place the CVD dogbonc (65) over the CVD rear
axle (64). Align the holes
in the CV D dogbane (65) with the hole
in the
CVD yoke (63). Secure al l three parts by inserting a J/ 16"
x 7/16" {so lid) pin (66) through the holes in the CVD do gbone
(65), the slots in the
CVD rear axle (6 tl ), and the hole in the
CVD yoke (63) .
0 Step 14 . Center the pin (66) in the CVD dogbone ( GS) and
secure it by threading a 4-40 setscrew { o7 ) into the end of th e
CVD yoke (63). Thread-lock compound (68) should be applied
to the setscrew{67}before inslalling
it.
0 Step 15. RepeatSteps 12 - 14 for the second CVD assembly.
6 IMPORTANT NOTE : Apply the enclosed thread-lock to
the setscrew before threading it into
th e CVD yoke. If thread-
lock is not used, the setscrew wi ll loosen during operation. This
wi ll cause your truck to stop running.
57
Figure 23
64
Figure 24
12

BAG C (Continued)
1
it.i
111
ffj
® @
0 Step 16. Thread a 1/ t'' ball stud (8) into the 'B ' hole in the
ri
ght re ar hub ( 70 ), from the front (the side with the letter).
& IMPORTANT NOTE: Do not overtighten the ba ll st ud s.
0 Step 17. Place a " foari1 thing" (31) over the ball stud (8).
0 St ep 18. Press a 3/ 16 " x 3/ 8" bearing (71) into the inside of
U1 e right rear hub ( 70 ). Slide a CV D rear axle (64) through the
bearing (
71 ) in the r ear hub ( 70 ).
"NOTE: If the 31 76 " x 3/8" bearing only has on e Tefl on ~ seal
{color e d, wov en looking) in it, po s ition the seal to th eoutside of th e hub.
0 Step l!J. Slide an inner rear axle spacer ( 72 ) over the CVD
rear axle (64) - from the outside -against the inside of the
bearing (71}. Place a second 3/
16 " x 3/ 8'' bearing ( 71 } over the
CVD re ar axle (64) and press the bearing( 71 )into the outside of
the rear hub ( 70 ).
W01E: If th e 31 76 "x 318" bearing only ltas on e Teflon '" se al
(co[{)red, wo v en looking) in it, po sition the seal to the outside oftlte hub.
0 Step 20. Place a outer rear axle spacer (73) over the CVD
rear axle ( 64 ), against the outside bearing ( 71 ). The small side of
the spa ce r ( 73 ) should be positioned next to the be ar ing (71).
0 St ep 2 1. Secure the cvn rt>ar axle (64) and the spacer ( 73 )
by inserting a 11 1 6" x 7/ 16" (spiro!) pin ( 74 ) llirough llie small
hole
in each of the CV D rear axle (64). Th e pin ( 74 ) shou ld be
centered in the CVD rea r axle (64).
0 Step 22. R epeat Steps 16 - 21 for the left rear hub (69).
I i[.!
1
1Jf{j
@
® @
0 Step 23. Pla ce the right rear hub (70) between the out er rails
of the right r ea r suspension arm ( 53 ). Be s ur e that the ba ll stud (8)
is towards the front. Position a rear hub spacer ( 75 ) between the
hub (70} and the suspension arm (53} on each side
of th e hub
( 70 ).
0 Step 24. Insert a 1/8" hin gt:: pin (6) into the suspension arm
(53), t
hr ough each of the two spacers ( 7.1 } and rear hub ( 70 }.
Secure the hinge pin (6}with two 1/8" E-clips (7}
0 Step 25. Repe al Steps 23 and 24 for the lefl hub ( 69 ) and left
r
ea r suspension arm (53).
13
@
Figure 25
Figure 25A

BAG C (Continued)
'iH!!iiU
( ) l
ili!WWii"l
@
0 Step 26. Thread a plas tic rod end (29) onto each end of a
2-5/8" titanium turnbuckle (
76 ). Tight en both ends (29) equally
until the rod is the same length as the one shown in Figure 27 A.
Make two of these rea r camber link assemblies.
,.._.., There is a small contain er /package of wax in cl uded
with the titanium turnbuc
kl es. It is rec ommended th at this wax
be applied to the threads
of th e turnbuckles before tryingto thr ea d
th e plastic rod ends onto the turnbuckles. The wax will help the
rod ends
to thread on much easit'r.
Figure 27
cr- ____,IIJ CI =._-=._-_- ~~B~r_- _-_- _-_JJltltnri '--=-=_= _=;0
Figure 27A
ljt.!iiifj:i
0 Step 27. Attach one end of a rear ca mber link assembly from Step 26 to the ball stud (8) in the right rear hub ( 70 )and the oU1er end
to the ba ll st ud ( 61 )in the rear bulkhead (60).
,.._.., R
emembe r to attach th e turnbuckles so that the thr ea ds are in the same direction on all of your linkages.
0 Step 28. Re pea t Step 27 for the left side of the truck.
53
rzgur e28
14
\.
. ....

BAGD
STOP! Bag D requires that you pay close attention to the bearings involved in the assembly. Some
bearings used during the assembly of this bag are very similar
in size. It is important that you open
the bags only as they are needed.
The bearings that are of concern are packed in separate bags.
1
it.!i
11
if
1
0 Srep l. Insert a 4-40 mini locknut ( 22 ) into the hex area of
the cliff nut ca ni er ( 77 ). The thread-locking portion of the nut
(22) should be to the outside.
wt•iii'·'
@
0 Step 2. Locate the 5/64" A ll en wrench ( 78 )supplied \-\ith the
kit. Pl ac e the cliff nut carrier { 77 ), nut side first, ov er the All en
wrench {
78 ).
0 Step 3. Stack the sLx beveled washers ( 79 ) ove r the w ren ch,
next to the diffnut
ca rrier ( 77 ). The washers {79 ) sh ou ld all point
the
same direction and open away from the nut canier { 77 }.
0 Step 4. Place the cl iff tube ( 80 ) over th e wrench, bigside first,
so
that it r es ts against the beveled washers ( 79).
Ii [.(I !if II
0 Step 5. Insert all of the parts that are stacked on the wrench
into
one of the outdrive/diff halves (8 1 ). Line up the tabs on the
diff
nut carrier ( 77 ) with the slots in the outdrive ( 81 ). Make
ce rtain th at the diff tube ( 80) is pr essed all the way into the
ou tdrive/diff half (8 1 ), and that it is straight. There is a small
should
er on lhe diff tube ( 80 ) that should be flush with the outer
surface
of the outdrive ( 81 ).
1
i' ·
1111
ifJ
(Q)
@
0 Step 6. Apply a small amount of cliff gr ease (clear)( 82 )to the
ou
ts ide ring of the nutdrive/diff half { 81 ). Attach a diff washer
( 83 ) to the out drive (81)by lining up theflat sec ti on of the washer
(83) wi th the flat section of the outdrive ( 81 }.
'-'NOTE: Onl ya s11wll amount of grease is needed. It is only ther e to
hold the diff washer in place.
& IMPORTANT N OT E: Do not glue the difT washers to
the outdrive/diffhalves. D
oing so may not allow the washers to
mount nat.
15
Figur e29
f=Ff:l "'"' A
~ IIIII/ ~
Figure 30
Beve l ed washers SI")()U id face th is dir ec tion
Figure 37
77
77
Small am ount
81

BAG D (Continued)
Ia [.j I !iff I
0
0 Step 7. Insert a S mm x 8mm bearing {84) into the center of
the diffgear (
85 ).
0 Step 8. Pressa 3/3 ~ " diffball (8 6) into each of the sma ll holes
in the
cliff gear ( 85 ).
ljt . !jiif§i
0 Step 9. App ly a fairly heavy coat of clear diff grease (clear)
(R2 } to the exposed side of the cliff washer ( 83 ). Carefully place
the
cliff gear ( 8.5 }over the cl i ff tube (8 0) so that the di ff ba ll s (86)
and diff gear (
85 ) rest against the diff washer ( 83 ).
.&. IMPORTANT NOTE: It is agood ideato hold the cliff
nut carrier in place so the cliff tub e is not pu s hed through when
the gear is pushed over it.
lij[.!iiiffj
0
0 Step 10. Insert a 5 mm x 8mm b ear ing {84) into the second
outdrive/
diffhalf (81). Make sure thaltht> bearing ( 84 ) is pushed
all the way into the outdrive (81).
The hand le of a hobby knife or
a pencil can be nsed to push the bearing ( 84 ) into pl ace.
0 Step 1 1. Drop the l/4" x 5/ 16" shim ( 87 ) into the outdriv e/
cliff half (81) on top of the Smm x 8mm bearing (81}. Make sure
that the shim (87)
is flat against the b ea ring ( 84 ). Be extra carefo l
not to bend this shim.'
16
85
81
0o o
0
Figure 33
Figure 34
Figure 35
84
I
J

BAG D (Continued)
I i[.liliirj
~fL-1 __ ....J I'""'IIiii!....,I!I~....,MI
©
®
@
0
0
0 Step 12. Locate the difT adjusting screw (8 8) and place th e
foam thrust bearingseal(
89 ) over the should er of the screw (8 8).
0 Step 1 3. Place one of the 3 mm x 8mm thru st bearing
washers ( 90 ) over the diff screw ( 8H ).
0 Step 14 . Grease the thrust washer (9 0) well with white thrust
bearing/assembly grease
{6 2) and place the 3m m x 8mm thrust
bearing
(9 1) over the screw ( 88 ) and next to the washer ( 90 ).
Greasethe exposed
l. ide of the thrust bearing( 91 ) well with white
thrust bearing /as sembly grease (62) and place the second thrust
washer (90) over the screw (
88 ) and against the thrust bearing
(91) .
0 Step 15. Very carefuJly insert the diff screw (88), with the
thrustbearing assembly installed, into the outdrive (
Rl ). De very
careful
not to bend or pinch the shim (87) while insertingthe cliff
screw (
RR ). Pull the threaded end of the cliffscrew ( 88 ) until the
thrust b
ea ring assembly rests against the shim (87) and bearing
(84) inside of the outdrive ( lH ).
1
it.iiliif'
0 Step 16. Locate the sma Uesl of the Allen wrenches (78) and
place it through the slot in the outdrive/diff half(
81 ) containing
the diffscrew (88).Slide the wrench all
tl1e way against the screw
(88).
By handling the outdrive/diff half ( 81 ) with the wrench
inserted, the
cliff screw ( 88 ) will be held in place while finishing
assembly
of the differential.
0 Step 17. Apply a smaJl amount of clear cliff grease (82) to the
outer ring
of the outdrive ( 81 ). Install the second cliff washer ( 83 )
againlining up the
fl at sections uf the outdrive/diff ha lf (81) with
the flat sections
in the washer (83). Apply a fairly heavy coat of
grease ( 8~ ) to the exposed side of the cliff washer (83).
17
Figure 36
83
of grease
81
Figur e37