Novak Brushless Conversion Kit (55-5010-1) - Manual (Page 2)

3. LOCATE & DRILL BATTERY BOX MOUNTING HOLES
a drill completely through the two mounting screw holes in the
battery box with a 3.6mm (or 9/64”) drill.
b. Position the battery box in the buggy. The front of battery box and
the battery wires must clear the steering servo and its linkages.
The back of the battery box must go inward as far as possible
so that it will clear the body. Box must be at least 4mm (or 5/32”)
away from the spur gear. Refer to Figure 14 (on vehicle specifics
sheet) for correct location.
STEP 3 INSTALL BATTERY BOX (Continued)
5. INSTALL BATTERY BOX HOLD DOWN STRAP
a. With a 2.5mm Hex Wrench, screw one end of the battery strap
into battery box with a M4x20 BH screw — refer to Figure 7.
b At the other end, screw in an M4 post and use a body clip to
fasten the battery strap.
c. The size of the batteries will determine which direction you place
the strap on the box. For thin batteries, attach one of the included
plastic spacers with an M3x8 BH screw on each 3mm spacer
hole — refer to Figure 8. Tighten using a 2.0mm Hex Wrench.
Note: The M4 post should be placed on whichever end of the battery
box that has body clearance for it, which is usually the back.
For optimal side-to-side balance and vehicle performance,
Novak recommends installing one battery box. Novak’s battery
box can accommodate two, 2S Li-Po packs, which provides excellent
power and runtime.
For Dual Battery Box Setups: Refer to Figure 15 on the backside
of the vehicle-specific sheet for dual battery box instructions for the
oFNa 9.5 (#5015) and Kyosho inferno (#5013) series buggies. The
other buggies require major modifications to mount a second battery
box, and we don’t recommend it.
STEP 3 - InSTALL BATTEry BoX STEP 1 - REMOvE NITRO COMPONENTS
XRAY XB8 Buggy Shown
1. REMOVE NITRO COMPONENTS
Remove the following items from your buggy (see Figure 2).
• Nitro Engine
• Muffler
• Fuel Tank
• Radio Box (keep for Losi 8ight)
• Throttle Servo
• Steering Servo and Mount
(keep for all conversions)
• Mechanical brake assembly
parts
• other parts specific to the fuel
engine (keep mounting screws)
2. CLEAN BUGGY
If you are starting with an old buggy that is full of greasy dirt, we
highly recommend that you thoroughly clean your buggy.
figurE 2:
Buggy with Components Removed
* BH is for M4x16 button head screw; FH is for M4x20 flat head screw.
(continued)
for STEPS 2-5: Refer to the vehicle-specific sheet that
is located in the bag with the motor adapter plate.
c. With the battery box in the correct location (refer to Figure 14
on specifics sheet and double check this location), spot drill the
first hole (front or back) with a 3.6mm (or 9/64”) drill bit, going
down through the hole in the battery box — Refer to Figure 6.
d. From one of the Battery Box Hardware Bags, gather the needed
screws and washers — see table & Figure 5. A button head (BH)
screw mounts the battery box to the plastic stone guard, and the
flat head (FH) screw mounts battery box to the metal chassis.
e. After you have marked the hole, remove box and drill a 4mm hole
in this location. Using a 2.5mm Hex Wrench, mount box with the
proper screw (see table) and correct number of washers. Snug up
screw. This allows you to more accurately locate second hole.
f. Repeat steps c through e for the second battery box hole — see
Figure 7 for completed battery box.
Note: If hole is in the metal chassis, the hole must be countersunk
on the bottom of the chassis.
4. MOUNT BATTERY BOX
Remount the battery box with the proper screws, washers and
rubber foot (if needed).
• Screw from the bottom of the chassis.
• If a rubber foot is used, it will go under the inside rear corner of
the battery box for more rigidity, except Losi 8ight — see Figure
14 (on vehicle specifics sheet) for correct location.
Note: In some installations, some of the stone guard screw posts
may interfere with the ribs on the bottom of the battery box. Simply
remove that portion of the rib until you have proper clearance.
When you are done, you should have a stable battery box with
little rocking motion.
M4x16 BH Screw (2)
M4x20 FH Screw (2)
M4x20 BH Screw (2)
M3x8 BH Screw (2)
M4x9 Washer (6)
M4 Post (1)
Body Clip (1)
Rubber Foot (1)
Plastic Spacer (2)
figurE 5: Battery Box Hardware Bag Contents (#65-5010-1)
Note: There are two bags included — one for each battery box.
The following instructions are for a single battery box installation.
1. LOCATE POSITION FOR BATTERY BOX
For the best side-to-side balance, we recommend installing the
battery box on the right side of vehicle (left side for Losi 8ight).
2. SELECT PROPER BATTERY BOX & HARDWARE
On the bottom of the battery box, there is a LEFT and RIGHT
notation. Follow the list below to know which box and what hardware
is used to correctly mount the battery box in your vehicle.
Model Number Battery
Box(es)
Screw
Front*
Screw
Rear*
Front/Rear
#Washers
Rubber
Foot
#5010 Associated RC8 (Horiz) Left BH FH 0 / 6 1
#5010 Associated RC8 (Vert) Left FH FH 6 / 6 1
#5011 CEN Matrix Right FH FH 6 / 6 0
#5012 Hot Bodies Lightning Left BH FH 2 / 6 1
#5013 Kyosho Inferno Left BH FH 3 / 6 1
#5013 Kyosho Inferno (Dual) Both BH (2) BH (2) 0 / 0 0
#5014 Mugen MBX5 Right BH FH 2 / 4 1
#5015 OFNA 9.5 / Ultra Right FH FH 6 / 6 1
#5015 OFNA 9.5/Ultra (Dual) Both BH (2) BH (2) 0 / 0 0
#5016 OFNA Hyper 8 Left BH FH 0 / 5 1
#5017 OFNA Hyper 7 Left BH FH 0 / 5 1
#5018 XRAY XB8 Left BH FH 0 / 8 1
#5019 Losi 8ight Left FH BH 5 / 4 1
(continued)
M3x16 BH Screw (2)
M3x8 FH Screw (4)
M4x10 FH Screw (4)
M4 Nylon Insert Lock Nut (4)
figurE 9: Motor Hardware Bag Contents (#65-5010-2)
(continued on back)
figurE 8: Battery Box with Thin Batteries
figurE 6:
Sample Location
of Drilled Mounting
Holes for Battery
Box.
XRAY XB8 buggy
shown. Refer also to
Figure 14 on insert.
Hole in plastic
stone guard*
Hole in metal
chassis*
*hole location for typical battery
box location.
Battery
Box
spacers
M3x8 BH
Screw
P2 P3
a. M4x20 BH
SCREw
b. SPACER
HOLES
c. ROUTE
BATTERY
wIRES IN
CUT-OUT
d. M4 POST &
BODY CLIP
e. 2S LI-PO
BATTERY
PACKS (2)
(not shown)
fig. 7:
Completed
Battery Box
a
e
c
d
b
figurE 10:
Motor
Heat Sink
Installation
Clamping holes in
heat sink face toward
outside of buggy.
Apply thin coat of thermal
paste to stator.
Slide heat sink
on to motor
figurE 4:
Modified Servo Tray*
Be sure to smooth
sharp corners and keep
mounting holes intact.
*OFNA Hyper 7 Servo Tray shown
For Losi 8ight Vehicle: refer to Figure 16 (on specifics sheet).
1. REMOVE & MODIFY SERVO TRAY
Cut off the part of the servo tray that holds the throttle servo. This is
best done with a dremel Tool with a carbide cutting wheel. Round
off the sharp corners where necessary — see Figures 3 & 4.
Make sure that the three or four (depending on kit) servo tray
mounting post holes remain intact.
2. RE-INSTALL STEERING SERVO ASSEMBLY
Install steering servo assembly to chassis and hook up steering
linkage. Refer to Figure 14 on specifics sheet (or Figure 15 for
dual battery set-ups if applicable).
• For Associated RC-8: You can either mount the steering
servo upright (vertical) or on its side (horizontal).
figurE 3:
Servo Tray*
Cut servo
tray along
line with a
Dremel Tool
Hardware Bag contents in Figures
5, 9 & 13 are actual size and can be
used for comparison.
STEP 4 - InSTALL BruSHLESS MoTor
A Novak 550-size brushless motor is required for this
conversion kit. If the motor does not have a 5mm output shaft,
the motor needs to be upgraded (Novak Kit #5924) . This step uses
parts from the Motor Hardware Bag — see Figure 9.
STEP 2 - INSTALL STEERING SERvO
1. INSTALL MOTOR HEAT SINK
a. Remove front endbell (end with output shaft) and sleeve of Novak
550-size brushless motor by removing the three 4-40 cap head
screws, using a 3/32” Hex Wrench and sliding off the endbell
— being careful not to lose any shim washers.
b. Using the included cotton swab, apply a thin coat of thermal
paste to outside of the motor’s stator and to the inside of the
heat sink sleeve.
c. Slide heat sink onto motor, being sure that the two clamping
screw holes in the heat sink face the outside of buggy — see
Figure 10. Refer to Figure 14 (or Fig. 15 for applicable dual
setups) on the specifics sheet for direction of motor solder tabs.
d. Replace front endbell and tighten the three motor screws.
e. Slightly re-loosen the three motor screws (one turn each) and,
using a 2.0mm Hex Wrench, tighten the M3x16 BH heat sink
clamping screws.
f. Re-tighten the three 4-40 cap head screws
on the motor’s front endbell.