Team Losi XXX4 User manual

MADEINTHEUNITEDSTATESOFAMERICA
P/N 800-0186
4710GaustiRd.,OntarioCA91761
phone:[phone]/Fax:[phone]
www.TeamLosi.com / [e-mail] RWW
OWNER'S
MANUAL
Team losi, Division of Horizon Hobby inc.,
Carefullyreadthroughallinstructionstofamiliarizeyourselfwiththeparts,constructiontechniques,and
tuningtips outlined inthismanual. Being abletograsp the overalldesignof your newXXX-4Buggy
before beginning the construction process will ensure a smooth assembly.
Take yourtime andpay close attention to detail. Keep this manual forfuturereference.
8/29/2002

Welcome Team Losi XXX-4 Owner!
ThankyouforselectingTeamLosiandtheXXX-4asyournewracing Buggy. Asyouwillsee,wehavemadeeveryeffort
to design and produce a kit that is not only the most competitve, but easy to build and maintain. The simple bag-by-bag
assemblysequenceandunmatchedeasilyfollowedinstructions,combinedwithTeamLosi'sworldfamousquality-fittingparts,
shouldmakebuildingyour newXXX-4amost enjoyableproject.
Beforeyouopen thefirstbagorstart anyassembly,pleasetakea fewmomentstoreadcompletely throughthefollowing
instructions.This willfamiliarizeyou withthevarious partsaswell asthetools youwillneed.Takinganextra momentbefore
startingcansaveyouagooddeal of time and assureproperassembly.
Onceagain,thank youforchoosingTeamLosi.
Goodluckandgoodracing!
1. INTRODUCTION
XXX-4 COMPLETED KIT DIMENSIONS
OverallLength:15-3/8" FrontWidth: 9-3/4" RearWidth: 9-5/8" Height: 5-3/8"
Wheelbase: 10-3/4" All dimensions at ride height. Weight will vary depending on accessories.
Step A-1
i
NOTES& SYMBOLS USED
This is a common Step sequence found at the beginning of each
new illustration throughout the manual.
!1. Each step throughout the entire manual has a check box to the
leftof it.As you completeeachstep, mark thebox with a check.If you
need to take a break and return to building at a later time you will be
able to locate the exact step where you left off.
This is a common note. It is used to call attention to specific
details of a certain step in the assembly.
IMPORTANTNOTE:Evenif you are familiar withTeam
Losi kits, be sure and pay attention to these notes. They point out
very important details during the assembly process. Do not ignore
these notes!
In illustrations where it is important to note which
directionparts are facing,a helmet likethisone will beincluded in the
illustration. The helmet will always face the front of the car. Any
reference to the right of left side will relate to the direction of the
helmet.
The kit is composed of different bags markedAthrough H. Each
bag contains all of the parts necessary to complete a particular sec-
tion of the XXX-4. Some of these bags have subassembly bags within
them. It is essential that you open only one bag at a time and follow
the correct assembly sequence, otherwise you may face difficulties
in finding the correct part. It is helpful to read through the instruc-
tions for an entire bag prior to beginning assembly. Key numbers (in
parenthesis) have been assigned to each part and remain the same
thoughout the manual. In some illustrations, parts which have al-
ready been installed are not shown so that the current steps can be
illustratedmore clearly.
For your convenience, an actual-size hardware identification
guide is included with each step. To check a part, hold it against the
silhouette until the correct part is identified. In some cases extra
hardware has been supplied for parts that may be easy to lose.
The molded parts in the XXX-4 are manufactured so that they
interlock. Whenscrews aretightened to thepoint ofbeingsnug, the
partsare heldfirmlyin place.For this reason it is very important that
screws not be overtightened in any of the plastic parts.
To ensure that parts are not lost during construction, it is recom-
mended that you work over a towel or mat to prevent parts from
rollingaway.
1.Select an areafor assemblythatis away fromthe reachofsmall
children. Some parts in this kit are small and can be swallowed by
children, causing choking and possible internal injury.
2. The shock fluid and greases supplied should be kept out of
childrens' reach. They are not intended for human consumption!
3. Exercise care when using any hand tools, sharp instruments,
or power tools during construction.
4. Carefullyread allmanufacturers'warnings and cautionsfor
any glues, chemicals, or paints that may be used for assembly and
operatingpurposes. When you areusing glues,chemicals, andpaints
you should always wear eye protection and a mask.
KIT/MANUALORGANIZATION
IMPORTANTSAFETYNOTES

i
TOOLSREQUIRED
Team Losi has supplied all necessary allen wrenches and two special assembly wrenches that are needed for slipper adjustment, assembly and
turnbuckle adjustments. The following common tools will also be required: Needle-nose pliers, regular pliers, medium grit sandpapper, hobby
knife, scissors, and body cutting/trimming tools.Asoldering iron may be necessary for electrical installation. 3/16", 1/4", and 11/32" nut drivers
are optional. RADIO/ELECTRICAL
A suggested radio layout is provided in this manual. Your high-performance R/C center should be consulted regarding specific questions
pertaining to radio/electrical equipment. HARDWAREIDENTIFICATION
When in question, use the hardware identification guide in each step. For screws, the prefix number designates the screw size and number of
threads per inch (i.e. 4-40 is #4 screw with 40 threads per inch). The second number or fraction designates the length of the screw. For cap head
and button head screws, this number refers to the length of the threaded portion of the screw. For flat head screws, this number refers to the
overall length of the screw. Bearings and bushings are referenced by the inside diameter xoutside diameter. Shafts and pins are referred to by
diameter xlength. Washers are described by inside diameter or the screw size that will pass through the inside diameter. E-clips are sized by the
shaft diameter that they attach to. MOTORSAND GEARING
The XXX-4 includes an 92-tooth, 48-pitch spur gear. The internal drive ratio of the XXX-4 is 2.10. The pinion gear that is used will determine
thefinal drive ratio.To calculate thefinaldrive ratio, first dividethespur gear size bythepiniongear size. Forexample, if youareusing a 20-tooth
pinion gear, you would divide 92 (spur gear size) by 20 (pinion gear size). 92/20 = 4.60. This tells you that 4.60 is the external drive ratio. Next,
multiplytheinternal drive ratio (2.10)by the externaldrive ratio (inthis case 4.60).2.10 x4.60 = 9.66:1.This means thatby using a 20-toothpinion
gear with the standard 92-tooth spur gear, the final drive ratio is 9.66:1.
Consult you high-performance shop for recommendations to suit your racing style and class. The chart below lists some of the more
common motor types and recommended initial gearing for that motor. Ratios can be adjusted depending on the various track layouts, tire sizes,
and battery types.
RECOMMENDEDINITIALGEARINGFORCOMMONMOTORS
TYPEOFMOTOR PINION SPUR
24º Stock 25 92
8-Turn Modified 16 92
9-Turn Modified 17 92
10-Turn Modified 18 92
11-TurnModified 19 92
12-TurnModified 20 92
13-TurnModified 21 92
14-TurnModified 22 92
15-TurnModified 23 92
TABLEOFCONTENTS
1.INTRODUCTION................................................................................i
CompletedKitDimensions.............................................................. i
Notes&Symbols .............................................................................. i
KitManualOrganization .................................................................. i
ImportantSafetyNotes....................................................................i
Tools Required ................................................................................. ii
Radio/Electrical................................................................................ii
HardwareIdentification..................................................................ii
RecommendedGearing................................................................... ii
2.BAGA...............................................................................................1-7
3.BAGB...............................................................................................8-11
4.BAGC..........................................................................................12-15
5.BAGD........................................................................................16-20
6.BAGE.........................................................................................21-25
7.BAGF.........................................................................................26-28
8.BAGG................................................................................................29
9.BAGH........................................................................................30-34
10.ChecklistBeforeYourFirst Run ................................................35
11.TipsFromtheTeam..................................................................35-37
12.SparePartsList ........................................................................38-41
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. i

!1. Locate the 1/16" Allen wrench (125) supplied with the kit.
Place the diff nut carrier (27), nut side first, over the Allen wrench
towards the "L-end."
Figure 1
!1.Insert a 4-40mini locknut(183) into the hexareaof the diffnut
carrier (27). The thread-locking portion (plastic) of the nut should
face the outside.
!2.Stackthe six 1/8" Bellevillewashers (154)over thewrench and
up against the diff nut carrier. The washers should all point the same
direction and open away from the diff nut carrier as shown in Figure
2A.
Figure 2B
Figure 2A
Figure 3
!1. Insert all of the parts that are stacked on the wrench (125) into
theplastic male outdrive/diffhalf (19) (the onewiththe post). Lineup
the tabs on the diff nut carrier (27) with the slots in the male outdrive.
Press the parts all the way into the male outdrive.
!1.Apply a small amount of clear diff grease (172) to the outside
ring of the plastic male outdrive (19).Attach a diff drive ring (108) to
the male outdrive by lining up the flat section of the ring with the flat
section on the outdrive.
*NOTE: Only a small amount of grease is needed. It is only used
to hold the drive ring in place.
Figure 4
IMPORTANT NOTE: Do not glue the drive rings to the
outdrive/ diff halves. Doing so may not allow the washers to mount
flat.
STOP!Therearetwo,completedifferentialassemblies in theXXX-4kit.TheFront-plasticdifferential,showninstepsA-1thru
A-9andThe Rear- steeldifferential,shown instepsA-10 thruA-19.TheXXX-4 kitwas designedusingthe stock42Tdrive
pulleysinthe front andrearofthe car.Thereisanoptional 41Tpulleyincluded in BagHofthis kit,Thisfeaturecanbeusedto
applyunder-driveorover-driveinthevehicle.Seeset-uptipsattheendof this manual.
BAG A
11
11
1
Step A-1
Step A-2
Step A-3
Step A-4
Diff Nut Carrier:
Diff Nut w/Belleville washers:
Diff Nut to Male Outdrive:
Diff Drive Ring to Male Outdrive
183
27
183
154
125
27
125
19
154
19
108
CLEAR DIFF
GREASE (172)

BAG A (Continued)
22
22
2
Step A-5
Step A-6
Figure 5
!1.Inserta5mmx8mmBearing(117)intothecenterofthe42Tdiff
pulley(42).
!2.Press a 3/32" diffball (82)into eachofthetwelve small holes in
the diff pulley as indicated in Figure 5.
117
82
!1. Apply a heavy coat of clear diff grease (172) to the exposed
side of the diff ring (108) that is already attached to the outdrive (19).
!2.Carefullyplacethe diff pulley (42) overthe post onthe outdrive
so that the diff balls (82) and diff pulley rest against the greased drive
ring. Leave the assembly with the 1/16"Allen wrench (125) standing
as shown in Figure 6.
Diff Pulley
Diff Pulley to Male Outdrive
82
42
117
(BAG H)
(
43
)
41T PULLEY
"w/o FLANGE"
42T PULLEY
"w/ FLANGE"
(42)
108
42
82
CLEAR DIFF
GREASE (172)
19
Figure 6

Step A-7
Step A-9
Step A-8
33
33
3
BAG A (Continued)
!1. Press a 5mm x 8mm bearing (117) into the center area of the
female plastic outdrive/ diff half (20) as indicated. The edge of the
bearing should be flush with the front of the outdrive.
!2.Apply a smallamount ofcleardiffgrease(172) to the outerring
of the outdrive. Install the second drive ring(108), again aligning the
flat sections of the outdrive and the drive ring. Figure 7
117
91
149
95
!1. Place the foam thrust bearing seal (186) over the shoulder of
the diff adjusting screw (91).
!2. Place one of the 1/8" x 5/16" thrust bearing washers (149) over
the diff screw.
!3. Using the MIP RED grease (157), apply a fairly heavy coat of
grease to the thrust washer and position the eight 5/64" thrust balls
(95) in a circular pattern around the diff screw.Apply another coat of
RED MIP grease over the thrust balls and place the second thrust
bearing washer over the diff screw and up against the thrust balls.
*NOTE: The thrust bearing washers are packaged in a small bag
along with the eight 5/64" thrust bearing balls.
!4. Insert the diff screw into the female outdrive (20). Pull the
threaded end of the diff screw until the thrust assembly rests against
the inside of the outdrive.
Figure 8
Figure 9
!1. Carefully replace theAllen wrench (125) with a pen or pencil
fromthemaleoutdrive(19) and place it in the slot of thefemaleoutdrive
(20) containing the diff screw (91). The pen will be used to hold the
diff nut carrier (27) assembly in the bottom side.
!2. Apply a good amount of clear grease (enouth to cover the
balls completely) (172) to the exposed side of the balls in the diff
pulley (42) on the male outdrive.
!3. While holding the female outdrive withAllen wrench inserted,
carefully assemble it to the male outdrive.
!4.Make sure thatthe slot inthediff screw islined up withtheslot
inthe female halfand then whileholdingthe male halfslowly turn the
female outdrive until the threads of the diff screw engage on the
threads of the 4-40 mini nut (183). Remove the pencil from the male
half and thread the two outdrives together until the screw just starts
to snug up.
!5. Tighten the diff until the pulley (42) cannot be turned while
bothoftheoutdrives are being held firmly. Final diffadjustmentshould
be made after completion of the XXX-4.
When tightening the diff, tighten the screw a little and then
"work" the diff a little. Then tighten the screw a little more and
"work" the diff again. Continue this until the diff doesn't slip. This
ensures that the parts in the diff are properly seated. Refer to tech
tips for final adjustment. "Working" the diff is done by rotating the
outdrives in opposite directions.
Bearing to Female Outdrive
Female
Outdrive Assembly
Male to Female Outdrive Assembly
186
157
149
157
MIP RED
GREASE
91
95
20
PENCIL
108
125
27 19
42
20
91
CLEAR DIF
F
GREASE
(172)
186
117
108
20

44
44
4
BAG A (Continued)
Step A-10
!1.Insert a 4-40mini locknut(183) into the hexareaof the diffnut
carrier (27). The thread-locking portion (plastic) of the nut should
face the outside.
Diff Nut Carrier:
Figure 10
Step A-11 Figure 11A
!1. Locate the 1/16" Allen wrench (125) supplied with the kit.
Place the diff nut carrier (27), nut side first, over the Allen wrench
towards the "L-end."
!2.Stackthe six 1/8" Bellevillewashers (154)over thewrench and
up against the diff nut carrier. The washers should all point the same
direction and open away from the diff nut carrier as shown in Figure
2A.
Step A-12
Figure 12
!1. Insert all of the parts that are stacked on the wrench (125) into
the outdrive/ diff half (87). Line up the tabs on the diff nut carrier (27)
with the slots in the outdrive. Press the parts all the way into the
outdrive, so that the diff tube (86) is seated inside the outdrive.
Diff Tube Assembly to Outdrive:
Diff Tube Assembly:
Step A-13
!1.Apply a small amount of clear diff grease (172) to the outside
ridge of the outdrive/diff half (87).Attach a diff washer (108) to the
outdrive by lining up the flat section of the diff washer with the flat
section of the outdrive.
*NOTE: Only a small amount of grease is needed. It is only
there to hold the diff washer in place.
IMPORTANT NOTE: Do not glue the diff washers to the
outdrive/diff halves. Doing so may not allow the washers to mount
flat.
Diff Drive Ring to Male Outdrive
!3.Place the difftube(86) over thewrench,large side first,sothat
it rests against the beveled washers.
86
IMPORTANTNOTE: Maleoutdrive defined as:Outdrive
containing diff tube assembly (fig 11). Female outdrive defined as:
Outdrive containing thrust assembly (fig 17).
183
27
183
27
86 154
125
86
27
87
87
108
SMALL AMOUNT
OF CLEAR DIFF
GREASE (172)
108
Figure 13
Figure 11B
154

BAG A (Continued)
Step A-14
!1.Inserta5mmx8mmBearing(117)intothecenterofthe42Tdiff
pulley(42).
!2.Pressa 3/32" diff ball(82) into eachof the smallholes inthe diff
pulley as indicated in Figure 14.
Diff Pulley
117
82
Figure 14
Step A-15
!1.Applyaheavy coat (sameas stepA-9) of cleardiffgrease (172)
to the exposed side of the diff ring (108) that is already attached to the
outdrive(87).
!2.Carefullyplacethe diff pulley (42) overthe post onthe outdrive
so that the diff balls (82) and diff pulley rest against the greased diff
ring. Leave the assembly with the 1/16"Allen wrench (125) standing
as shown in Figure 15.
55
55
5
FIGGIGUREFASDF
82
42
117
(BAG H)
(
43
)
41T PULLEY
"w/o FLANGE"
42T PULLEY
"w/ FLANGE"
(42)
Diff Pulley to Diff Tube
108
42 82
CLEAR DIFF
GREASE (172)
87
Figure 15

BAG A (Continued)
!1. Insert a 5mm x 8mm bearing (117) into the second outdrive/
diffhalf (87). Makesure that thebearingis pushed allthe way intothe
outdrive.Apencil or the handle of a hobby knife can be used to push
the bearing into place.
!2. Apply a slight amount of clear diff grease (172) to the
1/4"x 5/16"shim (153). Insert theshim into theoutdrive/diff half next
to the 5mm x 8mm bearing. Make sure that the shim is flat against the
bearing. Be extra careful not to bend this shim!
*NOTE: Only a small amount of grease is needed. It is only
needed to hold the shim in place next to the bearing.
Step A-16 Bearing Insert
!1. Locate the diff adjusting screw (91) and place the foam thrust
bearing seal (186) over the shoulder of the screw.
!2.Place one ofthe 3mmx8mm thrust bearing washers(149)over
the diff screw.
*NOTE: The thrust bearing washers are packaged in a small
bag along with the eight 5/64" thrust bearing balls.
!3. Grease the thrust washer well with MIP RED thrust bearing
grease (157) and place the eight 5/64" thrust bearing balls (95) on top
of the washer, around the diff screw.Apply more RED thrust bearing
grease to the tops of the thrust bearing balls. Place the second thrust
washer over the screw and against the thrust bearing balls.
!4. Very carefully insert the diff screw, with the thrust bearing
assembly installed, into the outdrive (87). Be very careful not to bend
orpinch the shim (153)while insertingthe diff screw. Pull the threaded
end of the diff screw until the thrust bearing assembly rests against
the shim and bearing (117) inside of the outdrive.
IMPORTANTNOTE:Ensure that all eight thrust bearing
balls remain in place between the two washers, around the diff screw.
Step A-17 Diff Adjusting Screw Assembly
66
66
6
91
186
149
95
153
117
Figure 16
Figure 17
91
95
87
186
149
157
157
MIP RED
THRUST BEARING
GREASE
87
153
117

Step A-18 BAG A (Continued)
77
77
7
!1. Locate the smallest of the Allen wrenches, 0.050 (128), and
place it through the slot in the outdrive/diff half (87) containing the
diff screw (91). Slide the wrench all the way against the screw. By
handlingthe outdrive/diff halfwith thewrenchinserted, the diffscrew
will be held in place while finishing assembly of the differential.
!2. Apply a small amount of clear diff grease (172) to the outer
ridge of the outdrive. Install the remaining diff washer (108), again
lining up the flat sections of the outdrive/diff half with the flat sec-
tions in the washer.
IMPORTANT NOTE: Do not glue the diff washers to the
outdrive/diff halves. Doing so may not allow the washers to mount
flat.
Diff Drive Ring to Female Outdrive
Step A-19
!1. Carefully replace theAllen wrench (125) with a pen or pencil
from the male outdrive (87). The pen will be used to hold the diff nut
carrier (27) assembly in the bottom side.
!2.Apply a fairly heavy coat of clear diff grease (172) to the ex-
posed side of the drive/ diff ring (108) on the female outdrive.
!3.While holdingthefemale outdrive with Allenwrenchinserted,
carefully assemble it to the male outdrive.
!4.Make sure thatthe slot inthediff screw islined up withtheslot
inthe female halfand then whileholdingthe male halfslowly turn the
female outdrive until the threads of the diff screw engage on the
threads of the 4-40 mini nut (183). Remove the pencil from the male
half and thread the two outdrives together until the screw just starts
to snug up.
!5. Tighten the diff until the pulley (42) cannot be turned while
bothoftheoutdrives are being held firmly. Final diffadjustmentshould
be made after completion of the XXX-4.
When tightening the diff, tighten the screw a little and then
"work" the diff a little. Then tighten the screw a little more and
"work" the diff again. Continue this until the diff doesn't slip. This
ensures that the parts in the diff are properly seated. Refer to tech
tips for final adjustment. "Working" the diff is done by rotating the
outdrives in opposite directions.
Outdrive Assembly
Figure 18
Figure 19
87
91
108
128
SMALL AMOUNT
OF CLEAR DIFF
GREASE (172)
PENCIL
108
27 87
42
87
CLEAR DIF
F
GREASE
91
(172)
128
108

116
110
152
44
98
146
77
29 46
Step B-2
!1. Snap a 3/16" x 3/8" bearing (116) into the right side of the idler
pulley (44). The bearing will snap past the ridge and stop.
!2. Place the idler pulley shaft (98) through the idler pulley from
the bearing side.
!3.Slidea#4 x .020 washer (152)over the 4-40x 5/16" button head
screw(146).
!4. Insert the 4-40 x 5/16" button head screw through the idler
pulley and secure it to the belt tensioner arm (110).
Figure 21
Figure 20
BAG B
88
88
8
152
116
146
98
!1. Position the chassis (46) upside-down on your work bench.
Insert the belt (77) and pull it through both ends of the chassis.
!2. Pull the belt out, just slightly, through the bottom of the chas-
sis and insert the Steering tunnel (29), tall end forward, into the slot in
the front of the chassis. Press into position as indicated in Figure 21.
The steering tunnel should now be located in between the belt,
with the belt still slightly hanging out of both ends of the car.
Step B-1
*NEVER PINCH THE BELT*
NEVER OVER TIGHTEN THE SCREWS IN THE
CHASSIS - Team Losi has designed interlocking
features into the XXX-4 chassis when screws are to the
point of being snug the parts are held firmly in place.
Tensioner Arm Assy:
Belt Installation:

BAG B (Continued)
Figure 22
99
99
9
Note: Use the plastic diff assembly for the front of the XXX-4.
The diff adjustment screw should be facing the drivers left side
of the chassis.
!1. Slide one 1/2" x 3/4" bearing (118) over each of the outdrive
cups (19),(20) with the teflon seal facing away from the diff pulley
(42).
!2.Pull the belt(77)slightly out ofthefront of thechassis(46) and
install a diff assembly into the slots as indicated in Figure 22. Pull the
slack from the belt through the rear of the chassis.
!3. Secure the diff assembly by installing the front diff cover (62)
withtwo 4-40 x1/2"cap head screws(129)through the diffcoverinto
the two counter-bored holes in the chassis.
!4. Flip the chassis over and install the two 4-40 x 3/8" flat head
screws (134) through the bottom of the chassis into the front diff
cover as indicated in Figure 22.
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 main
chassis and the bottom of the diff cover. Pre-tapping these holes
makes it easier to install the screws during assembly.
134
134
Step B-3 Front Diff
Install:
Step B-4 Rear Diff Install:
129
20
42
62
129
77
46
134
SIDE WITH
DIFF NUT
CARRIER (27)
118
19
129
118
118
129
87
69
77 42
46
134
87
118
SIDE WITH
DIFF NUT
CARRIER (27)
Figure 23
Note: Use the steel diff assembly for the rear of the XXX-4.
Once again, the diff adjustment screw should be facing the
drivers left side of the chassis.
!1. Slide one 1/2" x 3/4" bearing (118) over each of the outdrive
cups(87),(87)with the teflon seal facingaway from thediff pulley (42)
on the remaining differential.
!2. Spread the belt (77) apart and install the diff assembly into the
slots of the chassis (46) as indicated in Figure 23. Once the diff as-
sembly is in place, pull the slack up through the center of the chassis
from the top side.
!3. Secure the diff assembly by installing the rear diff cover (69)
withtwo 4-40 x 1/2"caphead screws (129) throughthe diffcover into
the counter-bored holes in the rear of the chassis.
!4. Flip the chassis over and install the two 4-40 x 3/8" flat head
screws (134) through the bottom of the chassis into the rear diff cover
as indicated in Figure 23.
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 main
chassis and the bottom of the diff cover. Pre-tapping these holes
makes it easier to install the screws during assembly.

BAG B (Continued)
Step B-6
Figure 25
Step B-5
1010
1010
10
99
96
146
151
!1. Holding the Slipper Clutch Assembly, with thumb and index
finger, pull the belt (77) up through the chassis (46) and line up the
top shaft (99) with the holes in the chassis.
!2. Place a #4 hardened washer (151) over a 4-40 x 5/16" button
head screw (146) and insert it through the left side of the chassis and
thread it into the top shaft.
You may need to slightly pinch the chassis to install the 4-40 x
5/16" button head screw.
!3. Once again, place a #4 hardened washer over a 4-40 x 5/16"
button head screw and insert it through the chassis and thread it into
the right side of the top shaft.
Leave the right side screw a bit loose until the belt tensioner is
installed.
IMPORTANTNOTE:Neverpinchthebelt as itwillresult
inashorter lifeof thebeltandcause yourvehicletostop running!
Slipper Clutch Assembly:
Slipper Clutch Insert:
119
106
77
46
96
71
146 151
Figure 24A
Figure 24B
!6. TheSlipperWrench willbe usedforthe final adjustmentof the
ClutchAssembly at a later step in this manual.
96
71
99
156
106 104
123 196
70
119
119
155
105
197
103
Tighten
!1. Press a 3/16" x 5/16" bearing (119) into the Slipper Hub (103)
from the outside/large face. Slide theTop Shaft (99) through the bear-
ing in the Slipper Hub.
!2. Place the Spur Gear (71) onto the slipper hub and place all six of
the slipper pucks (156) into the holes in the spur gear.
!3. From the "Drive Pulley" (70) side of the Slipper Clutch Assy,
slide the Slipper Bearing Spacer (106) over the Top Shaft. Place the
second 3/16" x 5/16" bearing over the Top Shaft and press the bear-
ing into the Slipper Hub.
!4. Place the flat face of the Slipper Plate (104) against the slipper
pucks in the Spur Gear. Then press the 6 pins of the Drive Pulley (70)
through the holes in the Slipper Plate continuing through the center
hole of the Spur Gear and into the 6 holes in the Slipper Hub.
!5.InsertSlipper Spring Shim(155)followed by theSlipperWave
Spring(123)intotheSlipperDrivePulleyandthreadtheSlipperFlange
(105) Counter Clockwise onto Slipper Hub until it is "finger tight".
Place one .005 shim (196) and one 0.015 shim (197) on the top shaft
nextto the bearing. Slide Bushing(96), largeside toward SlipperHub,
over Top Shaft.
Slipper Wrench (193)
196 197

46
145
61
77
70
44
BAG B (Continued)
Step B-8
Figure 26A
Step B-7
1111
1111
11
!1. With the chassis facing upside down, seal the drive train by
placing the bottom chassis cover (61) with the flat side towards the
bottom of the chassis (46). Secure the bottom chassis cover with
seven 2-56 x 3/16" flat head screws (145).
Figure 27
Figure 26B
!1. Slide the TensionerArmAssembly (110) down over the belt (77) and connect the slot in theTensionerArm with the Slipper ClutchAssy.,
Belt Tensioner Bushing (96) as indicated in Figure 26A.
!2. Slowly start rotating the TensionerArmAssy. around the Belt Tensioner Bushing in a clockwise direction as shown in Figure 26B.While
rotating the TensionerArmAssembly, slightly pull upward to keep the TensionerArm locked and rotating around the Belt Tensioner Bushing.
The belt should be positioned between the Slipper Drive Pulley (70) and the TensionerArm.
!3. Place a #4 hardened washer (151) over a 4-40 x 5/16" button head screw (146).
!4. Once you have the belt wrapped around the Slipper Drive Pulley and Belt Tensioner in position, as shown in Figure 26C, secure the
Tensioner Assembly by threading the 4-40 x 5/16" screw, with washer through the chassis (46) and into the Tensioner Arm. With the screw
about one turn loose, push down on the flat part of the tensioner and set the desired belt tension, tighten the screw.
The belt should move 1/8" (3mm) to 1/4" (7.5mm) up and down for the ideal tension.
151
146
Tensioner Arm Installation:
Bottom Cover Installation:
145
96
77
110
46
110
151
146
Figure 26C

97
31 30
32
29
46
134
80
32
30
142
81
31
33
33
100
LARGE HOLES
FORWARD
150
Step C-1
Step C-2
Using a medium grade sandpapper (i.e. 500 grit) clean the
excess material off the 5mm x 8mm bushings. This will ensure a free
working steering assembly.
"1. Thread a 3/16" ballstud (81), from the top side, into each of the
left(30) and right(31)bellcranks.
"2.Inserta 5mm x 8mmbushing (33)into thetop and bottomof the
left and right bellcranks.
"3. Insert the 2 carrier / steering bushings (100), into the bottom
side of the draglink (32) and then rest it on the top of the left and right
bellcranks.
"4. Slide the 3/8" ball stud (80) through the ball stud washer (150)
and through the Steering Bushing in the draglink and then thread
into the left bellcrank.
"5.Thread a 4-40x3/8" buttonhead screw(142) through the steer-
ing bushing and into the right bellcrank.
Figure 28
Figure 29
BAG C
12
"1.Line up thehexon the steeringpost(97) with thefronthex area
on left side of the chassis (46). Press the steering post to the bottom
of the hex. Thread a 4-40 x 3/8" flat head screw (134) through the
bottom of the chassis and into the steering post.
"2. Repeat step 1 for the right side steering post.
"3. Slide the draglink assembly from step C-1 through the steering
tunnel (29) and then slide the left bellcrank (30) over the steering post
on the left side of the chassis.
"4. Sliding the right bellcrank (31) over the right steering post will
need to be done at the same time as the left bellcrank.
The bellcrank should rotate freely.
80
81 142
Steering Bellcrank Assembly:
Steering Install:
134
150

64
30
137
BAG C (Continued)
StepC-3
Step C-4
Figure 31
Figure 30
13
"1. Thread a 4-40 x 5/8" set screw (137) into a front body mount
(64) until it hits the bottom.
"2. Thread the body mount into left bellcrank (30).
"3. Repeat steps 1 and 2 and thread into the right bellcrank (31).
The steering assembly should rotate freely. Be sure that the
screws are not too loose but, not too tight.
All standard servos should use only one silver spring and one
gold spring. All hi-torque & high-speed servos will use all three
springs.
"1. Using Table 31B (on the following page), determine which
servo saver base (36) is required for your servo. If your particular
servo is not listed, try using the arm recommended for another servo
made by the same manufacturer.
"2.Thread a 3/16"ball stud(81) intotheouterservo saver arm(39)
from the front side as indicated in Figure 31.
"3. Plug the servo into the radio system's receiver (not included).
Make sure that there is power to the receiver, and turn the transmitter
on followed by the receiver. Be sure that the trim settings for the
steering on your transmitter are set to the center. With the radio sys-
tem still turned on, attach the servo arm to the output shaft so that the
arm is vertical as shown in Figure 31.
"4. Turn off your radio, slide one of the two "silver" servo saver
springs (111) over the servo arm which is connected to the servo. Fit
the second of the "silver" springs over the first spring followed by
the "gold" spring (112). The springs should all be pressed against the
back of the servo saver base.
"5. Press the outer servo arm into the servo saver base. Insert the
servo saver washer (40) into the outer servo saver arm. Secure the
assembly to the servo with the servo arm screw supplied with the
servo.
137
64
Front Body Mount Install:
Servo Assembly:
81
SCREW
SUPPLIED WITH
SERVO
36
39
81
40
112
111

151 131
46
34
35
AIRTRONICS
ALL
FUTABA
FUTABA
S3401, S9402, S9404, S9450
HiTech
ALL
JR
JR
Z4750, Z8450
KO
PS-702, PS-703, PS-1001, PS-1003
KO
PS-901BH, PS-902
MULTIPLEX
ALL
NARROW 23
WIDE
NES-507, NES-513, NES-517, NES-901, NES-4000,
NES-4131, NES-4721, NES-4735, NES-9021, DS-
23
23
23
23WIDE
WIDE
NARROW
NARROW
SERVO TYPE OFFSET
NARROW
NARROW
NARROW
23
24
25
REQUIRED
SERVO ARM
S131, S131SH, S148, 23001, S3003, 25101, S9101,
S9201, S9304, S9401, S9403
25
BAG C (Continued)
Step C-5
Figure 32
WIDE
NARROW
Table 31A
Table 31B
14
"1. Use Figure 31A and Table 31B to determine how the servo
mounting posts (34) and (35) should be attached to the servo (not
included) in the Wide or Narrow position.
"2. Place a #4 washer (151) over each of the four 4-40 x 3/8" cap
head screws (131) and attach the servo posts to the servo by thread-
ing a screw through the servo mounting ears into the upper and lower
holes in each post. Do not tighten the screws yet! Just snug them up
so that the posts are held in place, but can still be moved from side to
side with a little resistance.
"3. As shown in Figure 32, you will use the bottom side of the
chassis to determine the exact spacing needed for your brand servo.
With the scerws still loose, push the pins on the servo mounts into
the holes in the bottom of the chassis (46). Slide the mounts until the
screws are centered on the servo, and tighten as indicated in Figure
32.
The servo should be as close to centered between the two posts
as possible.
151
131
Servo Post Assembly:

10
80
32
137
39
81
BAG C (Continued)
Figure 33
Figure 35
Figure 34B
Figure 34A
15
"1. Thread a short plastic rod end (10) onto each end of the 4-40 x
5/8" threaded rod (137). Tighten both sides equally until the rod is the
same length as the one shown in Figure 34B.
"1.Attach the rod end (10) to the ball stud (80) in the servo saver
arm(39) and theother totheball stud in thedrag link(32)as indicated
inFigure35.
Step C-6 Servo Install:
"1. Install the servo into the chassis (46). The pins from both
servo mounting posts (34), (35) should fit into the holes and sit flat
against the chassis.
"2. Secure the servo to the chassis with two 4-40 x 3/8" flat head
screws(134). 46
34
134
Step C-7
137
10
137
10
Step C-8 Servo Link Install:
134

16
Step D-1
Step D-2
!1.Install the frontleftinner pivot block(47) bythreadingtwo 4-40
x 3/8" flat head screws (134) through the bottom of the chassis (46)
into the pivot block as indicated in Figure 36. Repeat for the right
front inner pivot block (48).
The left & right inner pivots are marked with "L" & "R".
BAG D
135
134
Front Inner Pivot Install
Front Arm Install Figure 37A
46
47
134
Figure 36
194
195
135
62
53
47
49
50 101
194
195
46
!1. Slide a 1/8" inner hinge pin (101) through the larger holes of
each of the two front arms (53) also passing through the Hinge Pin
Retainer(194).
!2. Position the arm so that the shock mount hole faces the front
of the chassis (46). Place one pivot ball (49) on the rear of each hinge
pin. Insert the arm into the inner front pivot block (47) L, (48) R.
Capture the front arms by placing the front main block (50) marked
with "7.5F" onto the inner hinge pins as shown in the illustration in
Figure 37B. Secure the front main block by threading two 4-40 x 1/2"
flat head screws (135) through the main block into the holes in the
frontdiff cover (62).
!3. After securing the front main block, thread a 5-40 x 1/8 Set
Screw (195) into the Hinge Pin Retainer and tighten to secure the
hinge pin.
Figure 37B
101
ASSEMBLE MAIN BLOCK
IN THIS DIRECTION
Note: The arm should rotate freely on the
hinge pin and not in the in the front main block
or the pivot balls. If the arm does not pivot freely,
use a small file to remove a small amount of mate-
rial from the arm where the hinge pin retainer
rests against it.

BAG D (Continued)
17
Step D-3
Step D-4
!1. Insert a 4-40 x 3/4" cap head screw (130) on either side of the
shock tower (52) through the middle hole on the top of the shock
tower. Secure the screws to the tower by threading a 4-40 zinc nut
(182) over each screw and tightening.
The screws should extend away from the recessed area in the
front shock tower.
!2. Thread a short neck ball stud (107) into the inner and upper-
most of the lower five holes on either side of the shock tower.
The ball studs should face the recessed area in the front shock
tower.
182
!1.Attach the front shocktower (52) tothefront of thechassis (46)
with four 4-40 x 1/2" cap head screws (129). The screws thread into
the top-most and bottom-most holes, surrounding the posts, which
stick out of the front of the chassis. The shock tower should interlock
with the posts on the chassis.
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 main
chassis. Pre-tapping these holes makes it easier to install the screws
during assembly.
Front Shock Tower
Front Shock Tower Install
107
130
129
Figure 38
182
52
130
107
46
52
129
Figure 39