Traxxas 4801, Assembly Manual, Tuning Manual

Page 1: ...ASSEMBLY MANUAL TUNING GUIDE MODEL 4801 ...

Page 2: ...way when you want to take a break from the assembly Allow yourself plenty of time to build this kit The assembly time is going to vary with each individual Experienced builders may only need 4 5 hours to assem ble this kit while others may spend an entire weekend on it You should feel comfortable with taking as much time as you need to properly build and set up your model The race after all is on ...

Page 3: ...nd head and countersunk screws A ruler is provided at the bottom of each page to measure the length of the screws in millimeters CENTERING THE SERVOS The kit version does not include the radio system The photos in this manual do show the installation of a typical radio system Before installing the radio system find the center neutral position of the steering and throttle servos Connect the radio s...

Page 4: ...y intend ed for flat out running on large unobstructed paved areas Organized 1 10 scale nitro touring car racing is typically done on smaller closed courses For this type of racing use a lower higher numerical gear ratio such as the stock gear ratio The following chart gives the four pos sible gear ratios sets The ratios are arranged from highest lowest numerical to lowest highest numerical A brie...

Page 5: ...t gear or too far out locked in second gear If the car has quick acceleration and does not appear to shift the transmission is never reaching the shift point The shift point needs to be lowered by turning the adjustment screw counter clockwise If the car has poor acceleration but very high top speed the transmission is shifting into second gear almost instantly The shift point needs to be raised b...

Page 6: ...toming of the chassis Also in order not to disturb cornering balance front and rear tire height diameters should be equal Replace excessively worn tires NOTE At no time should the body of the car strike the ground or interfere with the suspension or tires Either situation will cause extremely unpredictable handling SPRING SPECIFICATIONS Front and rear black springs included Coils 6 0 Wire Diameter...

Page 7: ...aluminum shock body A 3 Take a blue O ring and push it into the bottom of the shock body A 4 Find one of the white 3x6x2 5mm white PTFE spacers and carefully remove any mold flashing with a hobby knife Insert the spacer into the bottom of the shock body and press firmly so that it compresses the blue O ring Insert a blue O ring and press it against the white PTFE spacer A 5 Locate one of the 3x7 5...

Page 8: ...ear pro tective eyewear when working with the C clips STEP A 7 Locate one of the 32mm shock shafts and snap a small E clip into the bottom groove on each STEP A 8 Find one of the two hole piston heads and place it onto the shaft The picture shows two holes and two molding indentations The holes are all the way through the piston head STEP A 9 Secure the piston head with a small E clip STEP A 10 Lo...

Page 9: ...ward Use a small tool to press the edges of the diaphragm flat in the shock cap STEP A 15 Place a drop of oil into the shock cap to lubricate the edges of the rubber diaphragm This will prevent damage to the diaphragm when it it is tight ened against the shock body STEP A 13 Locate one of the 4 short nylon rod ends Grip the shock shaft with needlenose pliers just above the threads Do not grip the ...

Page 10: ...STEP A 19 Slide a spring over the shock and secure it with the nylon lower spring retainer STEP A 20 Use needlenose pliers to snap a hollow ball connector into the short rod end Repeat steps A 1 through A 20 for the 3 remaining shocks STEP A 16 Pull on the shock rod so that the piston head travels to the bottom of the shock body Fill the shock with 60WT oil until it is about 3 4 full Slowly move t...

Page 11: ... ball differential are coated with a rust and corro sion prohibitor Use solvent to remove the protective coating before assembly STEP B 4 Locate the diff shaft and the 4 belleville spring washers Note that one face of each spring washer is dished Place the washers on the shaft in the sequence shown in the drawing STEP B 5 Locate the grooved thrust washers and the thrust bearing Smooth a thin layer...

Page 12: ...ust washer retainer so that the so that the side with the rounded edge faces you Align the notch with the pin STEP B 9 Press a 5x8mm ball bearing into the center of the shaft STEP B 10 Insert the retainer diff shaft assembly through either side of the main pulley assembly until the diff ring contacts the diff balls Rounded edge on face STEP B 6 Locate a 26mm diff ring Note that one face of the rin...

Page 13: ...alled in the model you will turn the wheel connected to to the right output shaft to change the adjustment It takes only a very small turn of the wheel right output shaft to change the adjustment BAG C Assemble the Turnbuckles and Upper control Arms The dimensions specified will give rough alignment Final alignment should be done with camber and toe gauges STEP C 1 Locate the 4 24mm titanium turnb...

Page 14: ... Snap in the metal hollow ball connectors The center to center distance should be 50mm STEP C 6 Steering arm Quantity 1 Locate the 20mm threaded rod and 2 short rod ends for the steering arm Assemble as shown Note that the rod ends are turned 90 degrees from each other Snap in the metal hollow ball connectors The center to center distance should be 30 5mm STEP C 7 Locate the upper control arms 2 2...

Page 15: ...s into like groups STEP D 2 Find 1 stub axle 1 metal u joint ball spider and one internal splined drive shaft female STEP D 3 Begin assembly by inserting one pin of the metal U joint ball into one ear of the drive shaft joint STEP D 4 Use the u joint assembly tool to snap the remaining pin into the opposite ear Apply pressure down while pushing so that both ears will spread and reduce the possibil...

Page 16: ...ential output yoke 1 metal u joint ball spider and one external splined drive shaft male STEP D 8 Assemble the 4 differential output yokes male drive shafts and metal U joint balls using the same procedure outlines in steps D 4 to D 6 STEP D 9 All of the drive shafts need to be shortened to allow full suspension trav el Use a hobby knife to cut 2mm from the ends of the male and female drive shafts...

Page 17: ...n used The recessed side of the ball joint should face down After the car is assembled you will be able to adjust the action of the sway bars by simply loosening the screws and sliding the sway bar link to the next position E 3 Attach the remaining sway bar links to the rear suspension arms with 2 3x5mm roundhead machine screws Again note the orientation and hole location used Set the front and re...

Page 18: ...lt around the differential pulley and insert the Ball differential with bearings into the front differential housing Note the orientation of the ball differential The main drive pulley is offset to the left F 6 Fit the front differential housing cover onto the front differential housing as shown F 2 Insert a 3x25mm Buttonhead machine screw through the ears on the front differential housing cover S...

Page 19: ...hock tower 2 3x20mm buttonhead machine screws and 2 3mm flange nuts F 10 Insert the 3x20mm screws through the lower holes in the shock tower ear Secure them with 3mm flange nuts The lower countersunk holes visible in step F 9 should face the rear F 11 Use an M3x 05 tap to cut screw threads into the rear shock tower for the body mount holes Set the rear shock tower assembly aside 3mm tap and handle...

Page 20: ...t this assembly aside F 14 Rear Side Plates Locate the right rear side plate 1 belt tension cam 1 5x11x4mm ball bearing and 1 10x15mm ball bearing F 15 Press the 5x11x4mm ball bearing into the pulley shaft hole in the right side plate F 16 Press the 10x15x4mm ball bearing into the belt tension cam F 12 Locate the graphite rear brace and the plastic bushing Belt tension cam ...

Page 21: ...mm caphead shoulder screws the metal brake cam and a 5mm E clip F 19 Press the 5x11x4mm ball bearing into the right stiffener Slide a 5x8x 05 plastic washer over the end of the two speed shaft F 20 Insert the two speed shaft through the 5x11mm ball bearing in the stiff ener The plastic washer should be against the ball bearing arrow F 21 Insert the 2mm pin into the hole in the two speed shaft Slid...

Page 22: ...hite brake disk F 25 Insert one of the metal brake pads between the brake cam and the brake disk The brake pad will fit into the flat cut into the brake cam shaft F 26 Slide one of the 3x15mm caphead shoulder screws through the top hole in the remaining brake pad and then through the top hole of the first brake pad Install the screw into the hole in the stiffener and tighten until it stops F 22 Sl...

Page 23: ...ly 7 5mm of exposed screw shoulder between the pads F 29 Rear Side Plate Assembly Find the right rear side plate assembly from step F 17 a 5x8x2 5mm plastic spacer a 15 groove pulley and flange an axle pin and a large E clip 5mm F 30 Insert the end of the two speed shaft right stiffener assembly through the 5x11mm ball bearing in the right rear side plate F 31 Slide the 5x8x2 5 plastic spacer onto...

Page 24: ...n cam F 35 Insert the bearing into the belt tension cam F 36 Insert the belt tension cam with bearing into the left side plate F 32 Slide on the 15 groove pulley so that the slot in the pulley engages the axle pin in the shaft Slide on the pulley flange with the beveled side of the flange facing the pulley flat side faces out ...

Page 25: ...he belt around the differential pulley F 39 Fit the belt around the 15 groove pulley and then insert the differential output shaft into the 10x15x4mm ball bearing in the right side plate F 40 Install the left side plate as shown by sliding the 10x15x4mm ball bear ing onto the remaining ball differential output shaft F 41 Fasten the rear side plates together by installing the rear graphite shock to...

Page 26: ...ngs Note that the stub axle housings are labeled L for left and R for right Press a ball bearing into the front and back of each stub axle housing F 45 Locate the 38mm hinge pins the 25 5mm hinge pins 8 small E clips and the rear camber links 38mm center to center distance Also find the rear drive shaft assemblies from step D 9 F 46 Snap a small E clip into one groove of each of the four hinge pin...

Page 27: ... small E clip F 49 Locate the male drive shaft assemblies with the differential output yokes Slide the differential output yokes onto the differential output shafts Note that the flats on the shaft must align with the flats molded inside the differential output yokes F 50 Use a 1 5mm allen wrench to tighten the 3x3mm grub screws against the differential output shafts Do not overtighten these screw...

Page 28: ...way bar from step E 1 The rear sway bar is larger than the front Insert the ends of the sway bar through the holes in the sway bar links on the lower rear suspension arms Note the photo shows the sway bar link in the wrong slot Use the instructions from E 1 F 56 Secure the rear sway bar with two 3x8mm buttonhead machine screws F 52 Find the 2 rear camber links 38mm center to center 2 3x15mm counte...

Page 29: ...e hub with the snap ring Use snap ring pliers G 4 Locate the inner gear hub and and the 10x19x5mm ball bearing Also find a socket or some other round object which matches the diameter of the outside race of the ball bearing 19mm diameter G 5 Use the socket and a mallet to gently tap the bearing into position The socket should be sized to only touch the outside race of the bearing If you try to pre...

Page 30: ...e set screw with the flat on the two speed shaft and then tighten the set screw Note the adjustment is to the back G 9 Slide the two speed gear and hub assembly onto the two speed shaft G 10 Locate a 20 groove pulley pulley flange 1 axle pin and a large E clip 5mm G 6 Locate the 41 tooth spur gear and another snap ring Slide the spur gear onto the hub so that the pins in the hub engage the holes i...

Page 31: ...ey G 13 Secure the 20 groove pulley with a large 5mm E clip BAG H Upper Chassis and Bellcrank Assembly H 1 Locate the graphite upper chassis plate battery plate bearing block 2 3x6x8 9 bearing block spacers blue anodized 2 3x6x10 75 bearing block spacers blue anodized 2 3x20mm buttonhead machine screws two 3x20mm countersunk machine screws 4 3mm locknuts and 2 5x11mm ball bearings H 2 Insert the 5...

Page 32: ...ssembly with the photo to ensure correct assembly H 7 Locate the graphite top plate Position 2 3x6x10 75 bearing block spacers tapered end up on the top plate as shown Study the photo to make sure that the topside of the top plate is facing you note tab H 3 Turn the bearing block over with the smooth edge facing you arrow1 The bearing block spacers have a slight taper cone shape on one end Insert ...

Page 33: ...gh the remaining bearing block holes H 10 Secure the 3x20mm screws with 3mm locknuts H 11 Steering Stops Locate 2 3x6x1 5mm aluminum spacers 2 3x6x2 5mm aluminum spacers 2 3x10mm buttonhead machine screws and 2 3mm nylon locknuts H 12 Slide a 3x6x2 5mm spacer over each of the 3x10mm buttonhead machine screws Insert the screws through the holes in the graphite top plate as shown ...

Page 34: ...ider one around the main seam of the tank H 16 Install the secondary isolator just above the main isolator H 17 Locate the graphite receiver plate the antenna mount and 1 3x8mm buttonhead machine screw H 13 Slide a 3x6x1 5mm aluminum spacer over the end of each screw and secure them with 3mm locknuts ...

Page 35: ...r each screw H 21 The top isolator should fit uni formly in the gap between the tank and the top plate see photo at right Sandwich the fuel tank assembly main rubber isolator between the left stiffener and the graphite top plate H 22 Secure the top plate by fastening the radio tray to the left stiffener as shown with the 3x20mm buttonhead screws Slide the remaining 3x6x8mm aluminum spacer over the...

Page 36: ...facing the pul ley Secure the pulley with a large E clip H 26 Insert the pulley shaft assembly through the bearing block as shown Insert an axle pin into the remaining hole in the pulley shaft Slide the 20 tooth pulley onto the pulley shaft until the axle pin engages the slot in the pulley H 27 Wrap the 120 tooth drive belt around the rear 20 tooth pulley and then over the front 20 tooth pulley H ...

Page 37: ...y flange onto the shaft with the beveled edge facing the pulley Secure the pulley with a large E clip BAG I Bellcrank Assembly I 1 Bellcrank Assembly Locate the left and right bellcranks and 4 5x8mm ball bearings I 2 Insert two 5x8mm ball bearings into each bellcrank I 3 Locate the 2 bellcrank posts 2 bellcrank spacers 1 3x8mm and 1 3x10mm buttonhead machine screw The bellcrank posts and spacer ar...

Page 38: ...to ensure that you have the left and right bellcrank placement correct I 7 Front Suspension Locate the lower front suspension arms the lower front suspension arm mount the graphite tie bar 4 small e clips and the 45 5mm hinge pins I 8 Snap a small E clip into one groove of each of the hinge pins I 9 Attach the lower front suspension arms to the front suspension arm mount by inserting 45 5mm hinge ...

Page 39: ...shown It may be nec essary to use a 1 8 125 drill bit to open up the holes in the tie bar Secure the opposite end of each hinge pin with a small E clip I 11 Locate the front sway bar I 12 Insert the ends of the sway bar through the links in the front suspension arms I 13 Locate the front bumper Use a sharp hobby knife to trim off the corner as shown ...

Page 40: ...of the differential housing should engage the slots in the lower mount I 18 Locate your throttle servo not included with the kit Install the throttle servo into the right stiffener with the output shaft positioned as shown Secure the servo with 4 3x8mm buttonhead machine screws Route the servo lead through the slot in the bottom of the right stiffener under the fuel tank and then over to the recei...

Page 41: ... and the bellcrank arrow I 24 Locate the upper control arm mount 2 33 5mm hinge pins 4 small e clips 3mm 2 3x12mm buttonhead machine screws 2 3x15mm but tonhead machine screws and the upper control arms from step C 8 I 21 Locate the drag link from step C 5 50mm center to center 2 3x10mm caphead machine screws and 2 3x6x 5mm flat metal washers I 20 Turn the assembly over and fasten the lower chassi...

Page 42: ... spacers Insert 1 thick spacer in the front location and 1 thin spacer in the rear location on each upper control arm I 29 Locate the front left and right stub axle housings 4 threaded metal inserts 4 5x11x4mm ball bearings and 4 3x8mm caphead machine screws I 26 Attach the upper front control arms to the upper control arm mount by inserting 33 5mm hinge pins through the pivot points Secure the op...

Page 43: ...alfshaft assembly I 32 Locate the male front drive shaft assemblies with the differential output yokes Slide the differential output yokes onto the differential output shafts Note that the flats on the shaft must align with the flats molded inside the differential output yokes I 30 Insert the threaded metal inserts into the front axle housings If necessary use a drop of CA glue Super Glue on each ...

Page 44: ...aluminum spacers I 35 Insert the metal stub axle through the ball bearings in the front axle housing Note that the stub axle housings are labeled L and R for left and right Apply a drop of threadlocking compound to the threads of a 3x8mm caphead machine screw Fasten the front axle housing to the upper control arm with the 3x8mm caphead machine screw Repeat for the other side Make sure the bosses a...

Page 45: ...4 Attach the bottom of each shock to the lower suspension arms with the 3x15mm countersunk machine screws I 41 The shock mounting procedure is the same for all four shocks Begin by sliding a nylon shock mounting bushing over the long screws in the front and rear shock towers I 40 Shock Installation Locate the front and rear shocks 4 nylon shock mounting bushings with washers 4 3mm nylon locknuts a...

Page 46: ... these screws The engine mount needs to be loose for adjustment J 4 Clutch Assembly Locate the 19 tooth and 15 tooth clutch bell gears the clutch bell and 2 5x10mm ball bearings I 45 By now your Nitro 4 Tec Pro should look fairly complete Now it s time to install the engine and radio gear BAG J Engine Mount Radio system installation J 1 Locate the engine mount 1 3x20mm countersunk machine screw 1 ...

Page 47: ... Some engines with wide recoil starters may not fit because of the starter O S and clones These engines will require a backplate and an electric starter box Also locate the split beveled cone the flywheel the clutch shoes the clutch spring and the clutch adapter nut J 10 Slide the split beveled cone onto the end of the crankshaft J 11 Slide the flywheel onto the crankshaft so that the tapered side...

Page 48: ...ng edges of the clutch shoes are positioned correctly J 15 Locate the clutchbell a chrome 3x10mm caphead machine screw with metal washers attached and a 5x8x 05 plastic washer Slide the washer over the end of the 3x10mm caphead machine screw J 16 Place the clutch bell over the clutch shoes and secure it with the chrome 3x10mm caphead machine screw and plastic washer J 14 Close the ends of the clut...

Page 49: ...acklash by running a thin strip of note paper through the gear mesh Slide the engine back so that clutch bell gears and spur gears are meshed tightly with the paper J 20 Remove the 3x20 button head screw and spacer J 16 Install the engine into the chassis The engine assem bly is a tight fit In order to install it you will need the move the brake disk towards the center of the car and fit the engin...

Page 50: ... your manufactures instruc tions Install fresh batteries Turn on the transmitter and receiver Set the throttle and steering trims to their neutral positions Now turn off the receiver followed by the transmitter Be careful not to turn any of the servo output shafts during installation K 1 Locate the servo saver the steering link from step C 6 1 3x15mm countersunk machine screw and 1 3mm locknut K 1...

Page 51: ...he receiver plate K 6 Mount the on off switch in the receiver plate as shown K 2 Attach one end of the steering link to the servo saver with the 3x15mm countersunk machine screw and the 3mm nylon locknut K 2 K 3 Attach the remaining end of the link to the inside hole in the left bell crank with a 3x12mm countersunk machine screw Note If your radio system does not have steering end point adjustment...

Page 52: ... one end of the receiver K 11 Stretch a rubber balloon over the receiver to protect it from fuel contami nation Secure the receiver to the receiver tray with a zip tie Neatly bun dle the servo leads with small zip ties the wiring should be clear of the steering mechanism and the exhaust system Note picture not shown with balloon K 8 Attach the steering servo to the steering servo mounts with the 4...

Page 53: ...dard servos without an adapter Sanwa and Airtronics servos may require an adapter K 16 Install the servo saver with adapter if necessary onto the steering servo in the 12 00 position straight up Secure the servo saver with the screw included in your radio system K 12 Insert the antenna wire through the plastic antenna tube K 13 Insert the plastic antenna tube into the antenna mount on the receiver...

Page 54: ...he throttle brake servo horn 2 rod guides and 2 3mm lock nuts Note the servo is compatible with Traxxas and Futaba standard servos If you are using another brand of servo use one of the universal servo horns included with your radio system K 17 Turn on the radio system and test the steering setup Notice that the drag link s 3x10 Caphead screws strike the inboard steering stops at full steering thr...

Page 55: ...d guide K 23 Insert the end of the throttle rod through the top hole on the carburetor throttle arm Attach the servo horn to the servo as shown with the screw included in your radio system K 24 Locate the brake cam lever and a 3mm grub screw K 25 Slide a 3x6mm flat metal washer over the end of the brake rod followed by the 20mm piece of fuel tubing Secure the assembly with a screw col lar and 3mm ...

Page 56: ... the pipe Tighten the grub screw in the end of the pipe against the wire arrow K 30 Attach the the coupler to the end of the pipe Fit the other end of the coupler over the end of the header K 28 Locate your tuned pipe not included in kit the pipe coupler the exhaust hanger wire 3x10mm countersunk machine screw and 3mm locknut K 27 Fasten a screw collar to one end of the brake rod with a 3mm grub s...

Page 57: ...tire point to the front of the car L 4 Glue the tires to the rims with thin CA glue Pull back the tire and allow the glue to run into the tire rim bead L 5 Locate 4 axle pins 4 aluminum hex hubs blue anodized and 4 4mm flange nuts foam insert Bag L Wheels and Tires L 1 Locate 4 molded foam inserts 4 tires and 4 wheel rims Wash the tires in warm soapy water Let them dry completely before continuing...

Page 58: ...nut Repeat steps L 6 through L 8 for the remaining three tires Bag M Body Mounts M 1 Locate the front body posts the rear body posts 4 nylon clamps 4 3x12mm buttonhead machine screws and 2 3x10mm countersunk machine screws L 7 Slide the wheel hex onto the stub axle so that the slot in the hex hub engages the pin in the stub axle hex nut L 6 Insert an axle pin into the hole in the stub axle ...

Page 59: ...th the body washers and clips M 6 Connect a section of fuel line between the front fitting in the tank and the pressure fitting on the header Connect the back fitting in the fuel tank to the carburetor inlet M 7 Congratulations Your Nitro 4 Tec Pro is assembled Now refer to the alignment specifications in the front of this manual and fine tune all the wheel settings Then follow your engine manufac...