User manual NOVAK BRUSHLESS CONVERSION KIT INSTRUCTIONS

[. . . ] INSTALL RECEIVER AND ANTENNA MOUNT M3x8 FH screws (4) 3. INSTALL MOTOR PINION GEAR Install a Mod 1 pinion gear to the output shaft. A hardened steel, high-strength pinion gear is recommended with a 5mm bore. Novak offers these pinion gears in 11T-16T (Novak #5100-#5105). [. . . ] Stick type or pre-assembled NiMH sport packs are NOT RECOMMENDED. Novak recommends using high quality (20C minimum) li-Poly battery packs for better balance, lower vehicle weight and longer run times. INCLUdEd ITEMS figurE 1: Included Items There are four Hardware Bags included and are detailed in the relevant instruction sections. a c b a. INSTALL BRUSHLESS MOTOR ASSEMBLY MuST BE 18 YEArS Or OLDEr NOVAK 550-SiZE MOTOrS ONLY MAY VOiD VEHiCLE'S WArrANTY GEARING SETUP Refer to Vehicle Specifics Sheet for Novak's recommended gearing Starting Points. fOLLOW ESC & MOTOr PrECAuTiONS HigH QuALiTY BATTEriES ONLY! f e d f. Y-HARNESS THERMAL PASTE, MOUNTING TAPE & ZIP TIES* *not shown figurE 12: Motor Adapter Plate Installation (slotted plate shown) Note: Motor and Heat Sink removed to show screw detail For slotted plates, use four, M4x10 FH screws and four M4 lock nuts. Motor operating temperature is the ONLY way to set vehicle gearing The Motor and Speed Control should not exceed 160-170°f MAX at end of the run! BE SurE TO CrEATE SuffiCiENT VENTiLATiON ACCESSORIES MOD 1 PINION GEARS FOR 5MM SHAFT [Novak #5100-5105] HV BRUSHLESS MOTOR 5MM UPGRADE KIT [Novak #5924] SUPER-FLEX SILICONE 14G WIRE [Novak kits #5500 & 5508] LEAD-FREE 3% SILVER SOLDER [Novak kit #5830] noVAK HV BruSHLESS SySTEM rEQuIrEd This kit requires a Novak HV Brushless ESC and a 550-size HV Brushless Motor for completion. Compatible Novak HV Brushless Motors: · HV4. 5*, HV5. 5, HV6. 5, or HV7. 5 High-Voltage Brushless Motor with 5mm shaft (#3524-3527) · HV4. 5* & HV6. 5 High-Voltage Brushless Motors (#3424 & #3426) and HV4400 (original). These motors have a 1/8" shaft and need to be updated with a 5mm rotor with Novak #5924 Upgrade Kit. Change the gearing to avoid overheating! Note: For non-slotted plates, use the hardware that was included with your Nitro engine. Do not use M4x10 FH screws of M4 lock nuts. Free-running your brushless motor in a no-load condition can cause rotor failure & ESC transistor damage and will void the product's warranty. DO NOT frEE-rEV MOTOr! TOOLS NEEdEd · RoToRy/DREMEl Tool WITH CUT-OFF WHEEL ANd SANdINg dRUM PoWER HaND DRill 3. 6mm oR 9/64" DRill BiT 4mm oR 5/32" DRill BiT 3/32" HEX WRENCH · · · · · · 3. 0mm HEX WRENCH 2. 5mm HEX WRENCH 2. 0mm HEX WRENCH PHilliPS SCREWDRiVER 90O COUNTER SINK TOOL THREaD-loCKiNg agENT *HV4. 5 is for high-speed runs only 5. INSTALL MOTOR FAN ON HEAT SINK For optimal performance, place the included 40x40mm fan square and flush on top of heat sink (refer to label on fan for direction). Quality Racing Electronics since 1978 ·Using a 3/32" Hex Wrench, screw four 4-40x1/2" socket cap screws (in Add'l Hardware Bag) through fan into heat sink -- see Figure 11 & Figure 14 (on specifics sheet). ·Use included Y-harness (see Figure 1) to plug the motor fan and ESC fan into the Novak HV High-Voltage Brushless ESC. · P4 Monday-Friday: 8:00am-5:00pm (PST) · (949) 833-8873 · FAX (949) 833-1631 E-MAIL: cs@teamnovak. com · WEB: www. teamnovak. com NOvAK ELECTRONICS, INC. · · · This product is guaranteed to be free from defects in materials or workmanship for a period of 120 days from the original date of purchase (verified by dated, itemized sales receipt). Warranty does not cover incorrect installation, components worn by use, or any damage caused by a crash, flooding or natural disaster. Because Novak has no control over the installation of this conversion kit, no liability may be assumed nor will be accepted for any damage resulting from the use of this product. By the act of installing the components of this conversion kit, user accepts all resulting liability. In no case shall our liability exceed the product's original cost. We reserve the right to modify warranty provisions without notice. ProducT WArrAnTy P1 ©2008 Novak Electronics, inc. · all Rights Reserved · No part of these instructions may be reproduced without the written permission of Novak Electronics, Inc. STEP 1 - REMOvE NITRO COMPONENTS 1. REMOVE NITRO COMPONENTS · Nitro Engine · Muffler · Fuel Tank · Radio Box (keep for Losi 8ight) · Throttle Servo STEP 3 - InSTALL BATTEry BoX 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 (Continued) 3. LOCATE & DRILL BATTERY BOX MOUNTING HOLES battery box with a 3. 6mm (or 9/64") drill. 5. INSTALL BATTERY BOX HOLD DOWN STRAP a. [. . . ] 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. (continued) Clamping holes in heat sink face toward outside of buggy. 2. RE-INSTALL STEERING SERVO ASSEMBLY Install steering servo assembly to chassis and hook up steering linkage. [. . . ]