1/6 GAS-POWERED 2WD BUGGY

Size: px

Start display at page:

Download "1/6 GAS-POWERED 2WD BUGGY"

Natalie Banks
5 years ago
Views:

1 1/6 GAS-POWERED 2WD BUGGY ASSEMBLY AND OPERATING INSTRUCTIONS Features of Your New XTM Racing 1/6 Gas-Powered 2WD Buggy: Incredible 1/6 Scale Size! Includes 23cc Gasoline Engine with Pull-Starter Steel Differential Full Ball Bearings Huge Front Bumper Factory-Trimmed Body Double Epoxy Brake Discs Strong 7mm Thick Dogbones Heavy-Duty Side Dust Guards Factory-Glued Tires with Inserts Internal Roll Cage for Protection Massive Servo Saver for Steering Fully Threaded, Oil-Filled Aluminum Shocks Dust Cover to Protect the Pinion and Spur Gears Adjustable Camber, Castor and Toe-In Front and Rear 4mm Aluminum Chassis with Curved Edges for More Strength Uses Regular Unleaded Gasoline with 2-Stroke Oil Added Water-Resistant Receiver and Battery Boxes Large Fuel Tank with Ventilation Lines Large Pull-Starter for Easy Starting Thank you for purchasing the XTM Racing 1/6 Gas-Powered 2WD Buggy. These Assembly and Operating Instructions are provided to help you enjoy your new 1/6 Gas-Powered 2WD Buggy without any of the hassles you might expect. Please read through all of the literature that is provided in the box. IMPORTANT Before operating your new 1/6 Gas-Powered 2WD Buggy, please read and understand the warnings listed on the next page. Failure to do so could lead to bodily harm and/or injury. The XTM Racing 1/6 Gas-Powered 2WD Buggy is not intended for persons under 12 years of age, unless closely supervised by an adult. The XTM Racing 1/6 Gas-Powered 2WD Buggy is distributed exclusively in the U.S.A.by Global Hobby Distributors Bandilier Circle Fountain Valley, CA All contents copyright 2004, Global Hobby Distributors Version V1.0 July 2004 Kit Product #

2 FOR YOUR SAFETY - PLEASE READ THESE WARNINGS FIRST! ENGINE WARNINGS Never use any fuel in your engine other than regular unleaded gasoline with 2-stroke oil added. Use of any other types of fuel, such as glow fuels for nitro-powered engines and diesel fuel should never be used. Never operate your model on any public streets. This could cause traffic accidents, personal injury or property damage. Gas engines emit exhaust vapors that are poisonous and can be dangerous to your health. It is important that you operate your engine in a very well-ventilated area, preferably outdoors. Before starting your engine, make sure that the throttle trim is set to the idle position. Starting your engine at any setting above idle can cause the model to lurch out of your hands. When your engine is running, there are certain parts that rotate at high speeds. Be careful not to touch the drive shafts, gears, clutch assembly or any other moving parts. Otherwise, serious injury could result. It is normal for your engine and muffler to get very hot during operation. Never touch these parts while they are hot or you might be burned. Model car engines produce vibration when they are running. It is important to periodically check the engine mounting screws and other assemblies to ensure they are tight. Running your engine with the engine mounting screws loose can lead to severe engine and/or chassis damage. FUEL WARNINGS The gasoline used in your 1/6 Gas-Powered 2WD Buggy is poisonous. Follow all safety precautions and keep gasoline in a tightly sealed container specifically for this purpose. Keep fuel out of the reach of children. Gasoline and its vapors are extremely flammable. Keep away from high heat, sparks and flame. GENERAL WARNINGS Under no circumstances should you operate your model in crowds of people. Serious injury could result. Never operate your model on busy streets or if there are cars around. Do not use your model to chase pets or other animals. The receiver and battery boxes are not waterproof; therefore, do not drive through water, wet grass, mud or snow. Because your model is operated by radio control, it is important to make sure you always are using fresh and/or fully charged batteries. Never allow the batteries to run low or you could lose control of the model. If your model becomes stuck, allow the engine to idle, then retrieve your model by hand. To prevent excessive r.p.m.'s from damaging your engine and/or drivetrain components, we suggest reducing throttle while in the air during jumps. CUSTOMER INFORMATION If you should have trouble with any of the steps listed in these Assembly and Operating Instructions, or if you find a missing or damaged part in your kit, please contact us at the address below: Global Services Bandilier Circle Fountain Valley, CA Check out our website for more information on this and other exciting XTM Racing products! Phone: (714) Fax: (714) service@globalhobby.net CHECK IT OUT! We urge you to come check out our website at There you will find public message boards frequented by other XTM Racing product owners and the XTM Racing support staff. This is a great place to learn about new XTM Racing products, get help and suggestions for your current XTM Racing products or just simply hang out and chat with people that share your same interests. To allow us to serve your needs better, please include your address with any correspondence you send to us. Your address will be added to our Customer Service Database so you will automatically receive free updates and tech notices for your particular product. You will also receive repair status updates (if applicable) and other important information about your product as it becomes available. IMPORTANT INFORMATION ABOUT YOUR ADDRESS Global Hobby Distributors will not disclose the information it collects to outside parties. Global Hobby Distributors does not sell, trade, or rent your personal information to others. Your privacy is important to us. 2

3 TOOLS NEEDED FOR ASSEMBLY PHILLIPS HEAD SCREWDRIVERS (# 1 AND # 2 SIZES) MODELING KNIFE WIRE CUTTERS 1.5MM, 2MM AND 2.5MM HEX WRENCHES NEEDLE NOSE PLIERS C/A GLUE YOU WILL ALSO NEED HIGH-QUALITY 2-STROKE ENGINE OIL TO MIX WITH THE REGULAR UNLEADED GASOLINE USED IN THE ENGINE. THE OIL SHOULD BE MIXED AT A RATIO OF 32:1 (i.e. 32 PARTS GASOLINE TO 1 PART 2-STROKE OIL). RADIO CONTROL SYSTEM REQUIRED PLEASE READ AND UNDERSTAND THE INSTRUCTIONS PROVIDED WITH YOUR RADIO CONTROL SYSTEM BEFORE INSTALLING IT INTO YOUR 1/6 GAS-POWERED 2WD BUGGY. Although an AM radio control system can be used, we recommend using an FM radio control system. RECEIVER We suggest using a Sub-C size 6 volt battery pack with a minimum capacity of 2000mAH. Before installing the servos, the servo output shafts must be centered. To set the center position, turn on the transmitter and receiver. Set the trim levers on the transmitter to the center position and turn off the receiver, then the transmitter. At this point, the servo output shafts will be in the centered position and are ready for installation. For the steering servo, we strongly recommend using a 1/4 scale servo that has a minimum of 200 oz./in. torque at 6 volts. SUB-C 6V RECEIVER BATTERY PACK STEERING SERVO SWITCH HARNESS For the throttle/brake servo, we suggest using a high-quality standard servo with a minimum of 60 oz./in. torque at 6 volts. THROTTLE/BRAKE SERVO 3

4 Certain servos may require the use of the included spacers to mount properly. This will be dependent on brand and type, and may not be required for all servos. When installing the servos, both servos' output shafts should be toward the REAR of the chassis. 4

5 5

6 6

7 7

8 8

9 9

10 10

Spark plug gap should be set to 0.7mm - 0.8mm OEM replacement spark plug part # 32730 Your engine comes equipped with a standard air filter that includes a foam filter element.

11 Spark plug gap should be set to 0.7mm - 0.8mm OEM replacement spark plug part # Your engine comes equipped with a standard air filter that includes a foam filter element. As a precaution, we recommend that you change or clean the air filter element on a regular basis. To ensure the long life of your engine, we strongly suggest "wetting" the air filter element with Air Filter Oil after you clean or replace the air filter element. The high and low speed mixture screws come preset from the factory for initial starting and running. Do not adjust them at this time. Use only Regular Unleaded gasoline with an Octane rating of 89 to 91 in your engine. It's very important to add a high-quality 2-stroke engine oil to the gasoline at a ratio of 32:1 (i.e. 32 parts gasoline to 1 part 2-stroke oil). When it's time to replace the spark plug, we strongly suggest using only the OEM brand spark plug designed specifically for the engine. Use of any other type of spark plug may result in engine damage and/or poor engine performance. Starting a Cold Engine: Set the carburetor throttle lever to the idle position, then choke the engine by closing the choke lever. Press the primer pump until it is filled with fuel. Slowly pull out the pull-start cord until you begin to feel resistance, then pull strongly on the pull-start cord until you hear the engine ignite. Normally, the engine will immediately stop after this first ignition. Now, open the choke lever and pull the pull-start cord firmly until the engine starts. To stop the engine, press and hold the ignition switch until the engine stops. Hold the model firmly with your free hand when pulling on the pull-start cord. 11

Starting a Warm Engine: Set the carburetor throttle lever to the idle position, but leave the choke lever open. Press the primer pump until it is filled with fuel.

12 Starting a Warm Engine: Set the carburetor throttle lever to the idle position, but leave the choke lever open. Press the primer pump until it is filled with fuel. Pull the pull-start cord firmly until the engine starts. To stop the engine, press and hold the ignition switch until the engine stops. Hold the model firmly with your free hand when pulling on the pull-start cord. Adjusting the Carburetor (Low Speed): The carburetor adjustment screws are preset from the factory for initial running. Depending on many factors, such as local weather conditions, air filter and muffler, the carburetor settings may need to be changed. Drive the car at medium RPM until the engine has reached normal operating temperature. If after the engine is warmed up the engine decelerates a little during acceleration, the engine is too lean. In this case, turn the Low Speed Mixture Screw counterclockwise (richen). If the engine stutters and lots of smoke comes from the exhaust during acceleration, the engine is too rich. In this case, turn the Low Speed Mixture Screw clockwise (lean). When set properly, the engine should accelerate without hesitation from idle to full power. Adjusting the Carburetor (High Speed): To adjust the engine for maximum RPM, carefully lift the car so that the rear wheels are off the ground. With the engine warmed up to normal operating temperature, hold the throttle wide open for a short time. If the engine is running rich, turn the High Speed Mixture Screw clockwise (lean) until full power is achieved. If the engine is running lean, turn the High Speed Mixture Screw counterclockwise (richen) until full power is achieved. After adjusting the High Speed Mixture Screw, it may be necessary to readjust the Low Speed Mixture Screw, since they interact with each other. WARNING Don't keep the engine running at full power for any longer than necessary with the rear wheels off the ground. Running the engine for too long without a load can cause severe engine damage. Resetting the Mixture Screws to the Factory Settings: To reset the mixture screws to the factory settings, first close both mixture screws by turning them clockwise GENTLY. To reset the Low Speed Mixture Screw, turn the screw counterclockwise from the fully closed position 1.25 turns. To reset the High Speed Mixture Screw, turn the screw counterclockwise from the fully closed position 1.5 turns. WARNING For the first two tanks of fuel, you should avoid running the engine at full RPM for any length of time. This will keep the engine from getting too hot during the short break-in period. You should also range check your radio system while the engine is running to ensure there is no interference caused by the ignition system and/or vibration. 12

13 ENGINE TROUBLESHOOTING GUIDE This troubleshooting guide has been provided to help you diagnose and solve most problems that you may encounter with the engine in your 1/6 Gas-Powered 2WD Buggy. Most problems encountered can be solved by carefully following the problem-cause-solution sections. If you cannot solve the problem using this troubleshooting guide, please feel free to contact us at the address, phone number or address shown on the second page of these Assembly and Operating Instructions. ENGINE DOES NOT START PROBLEM CAUSE SOLUTION 1) Spark plug A) Spark plug electrode wet A) Remove spark plug and dry electrode B) Carbon deposits on electrode B) Remove spark plug and clean electrode C) Spark plug insulator damaged C) Replace spark plug D) Incorrect gap setting D) Reset gap to 0.7mm - 0.8mm E) Spark plug electrode damaged E) Replace spark plug 2) Magneto A) Ignition coil failure A) Replace ignition coil B) Damaged spark plug cable B) Replace spark plug cable C) Loose or disconnected spark plug cable C) Push spark plug cable firmly onto spark plug 3) Switch A) Switch is off A) Turn switch on B) Switch has failed B) Replace switch C) Wiring damaged C) Repair wiring ENGINE DOES NOT RUN PROBLEM CAUSE SOLUTION 1) Engine not drawing fuel A) Clogged breather air hole A) Clean breather air hole B) Clogged carburetor B) Clean carburetor C) Clogged fuel filter C) Clean and/or replace fuel filter 2) Poor compression A) Worn cylinder, piston and/or piston ring A) Check and replace as needed B) Leak between cylinder head and crankcase B) Replace cylinder head gasket 3) Engine will not run A) Engine is flooded A) Purge excess fuel from crankcase B) Carburetor settings too rich B) Readjust carburetor settings C) Clogged air cleaner C) Clean air cleaner filter element D) Old and/or contaminated fuel D) Use new fresh fuel ENGINE RUNS POORLY AND/OR HAS LACK OF POWER PROBLEM CAUSE SOLUTION 1) Engine Overheats A) Carburetor adjustments too lean A) Readjust carburetor B) Incorrect fuel/oil mixture B) Mix fuel and oil at a ratio of 32:1 C) Spark plug faulty or failed C) Replace spark plug D) Cylinder head cooling fins blocked D) Clean debris from between cooling fins E) Inadequate airflow over engine E) Increase airflow over engine 2) Engine has lack of power A) Air leak in engine and/or fuel system A) Tighten all engine bolts and fuel system joints B) Old and/or contaminated fuel B) Use new fresh fuel C) Piston begins to seize C) Replace piston, cylinder and ring D) Muffler has accumulated carbon deposits D) Clean muffler E) Carburetor settings out of adjustment E) Readjust carburetor F) Clogged air cleaner F) Clean air cleaner filter element G) Engine is overloaded G) Reduce engine load 13

14 SPARE PARTS LIST XTM Racing stocks a complete line of replacement parts for your 1/6 Gas-Powered 2WD Buggy and 23cc Gasoline Engine. Listed on the next few pages are the replacement parts that are available along with their respective part numbers for easy ordering convenience. We suggest ordering directly from your local XTM Racing dealer. If your local dealer does not stock XTM Racing or Global products, you can order directly from us at the phone number or address shown on page # 2. 14

15 SPARE PARTS LIST, CONTINUED Cylinder Head Cylinder Head Gasket Cylinder Head Screw Set M5x Carburetor Mounting Insulator Carburetor Mounting Insulator Gasket Carburetor Gasket Carburetor Mounting Screw Set M5x Muffler Assembly Muffler Mounting Screw Set Muffler Gasket Screw M4x Crankcase Alignment Pin Crankcase Gasket Ball Bearing Rear Shaft Seal Front Shaft Seal E-Ring Crankcase Screw Set M5x Piston Piston Ring Wrist Pin Wrist Pin Retaining Ring Wrist Pin Bearing Wrist Pin Washer Crankshaft Crankshaft Nut Woodruff Key Crankshaft Shim Clutch Shoes Clutch Spring Clutch Retaining Screw M6x Clutch Washer-Rear Clutch Washer-Front Clutch Housing Clutch Housing Screw M5x Clutch Driver Washer Head Screw M6x Rotor Ignition Coil Spark Plug Cap Spark Plug Cap Spring Rubber Socket Ignition Coil Mounting Spacer Ignition Coil Mounting Screw M4x Pull-Start Assembly Recoil Spring Cord Spool Ratchet Spring Screw Retainer Washer Pull-Start Cord Pull-Start Handle Pull-Start Mounting Screw Set M4x Carburetor Assembly Screen Lower Cover Lower Cover Mounting Screw Lower Gasket Diaphragm-Lower Upper Gasket Diaphragm-Upper Carburetor Body-Upper Carburetor Upper Cover Bulb Pump Spring Valve Inlet Plug Lever Screw Pin Screw Spring Throttle Shaft Spring Screw Throttle Valve Screw Throttle Lever Ring Choke Shaft Choke Lever Spring Ball Screw Spring Idle Needle Spring High Speed Needle Small Screen Ring Plug Choke Lever Spacer Screw M5x Air Filter A Housing Cover Filter Sleeve Fan Cover Screw M5x Cylinder Head Cover Screw M4x Screw TP4.5x18L Switch A Fuel Pipe Fuel Filter Clip Socket Case Screw M5x Pull-Starter Label Puller (Option) Piston Stop (Option) Spark Plug (Option) Spring (Option) Spark Plug 15

16 SPARE PARTS LIST, CONTINUED (002159) Ball Bearing 8x22x7(2) (002160) Ball Bearing 10x22x (002161) Ball Bearing 12x28x (11310) Antenna Tubes (5) (11311) Antenna Caps (10) (11333) M3 Set Screws (10) (11399) Body Pins (10) (11447) M3 Lock Nuts (10) (11922) M5 Lock Nuts (5) (11923) M4 Lock Nuts (5) (32400) Spur Gear Mount-Nylon (32401) Servo Tray (32402) Roll Cage-Front (A) (32403) FR Upper Susp Arm-Left (32404) FR Lower Susp Arm-Left (32405) RR Lower Susp Arm-Left (32406) RR Upper Susp Arm-Left (32407) Rear Bulkheads for Diff (32408) Rear Axle Hubs (32409) Ball Ends "B" (8) (32410) RR Upper Turnbuckles (32411) Engine Mount-Left (32412) Front Bulkhead-Plate (32413) Rear Shock Tower (32414) Front Bulkhead-Plate (32415) Side Gear Plate (32416) Upper Steering Bellcrank (32417) FR Steering Arms (L&R) (32418) Differential Housing ( ) Side Dust Guards (L&R) (32420) Roll Cage Tubes (C) (32421) Spur Gear 46T (32422) Pinion Gear 18T-Nylon (32423) Upper Hinge Pins (32424) RR Inner Upper Hinge Pins (32425) M5 E-Rings (12) (32426) Ball Bearings 10x19x7 (5) ( ) Body Set w/decals (32428) Fuel Tank Cap Assembly (32430) M4x8 Flat Head Screws (5) 16

17 SPARE PARTS LIST, CONTINUED (32431) M4x8 R.H. Screws (5) (32432) M4x16 F.H. Screws (5) (32433) Differential - Complete (32434) M5x25 F.H. Screws (5) (32435) M5x25 Set Screws (5) (32436) Lower Shock Mounts (2) (32437) M5x4 Set Screws (5) (32438) M4x4 Set Screws (5) (32439) M5x41 C.H. Screws (5) (32440) M4x24 C.H. Screws (10) (32441) M3x23 C.H. Screws (5) (32442) M4.2x16 S.T. Screws (10) (32443) M4.2x25 S.T. Screws (5) (32444) M5x10 Set Screws (5) (32445) Diff Housing Sleeve (32446) 5x10 Ball Ends (5) (32447) 4x10 Ball Ends (4) (32448) 6.5x12x1.5 Washers (5) (32449) 8.4x117x1 Washers (5) (32450) Body Only (32451) 16T Layshaft Gear (32452) Main Diff Gear-48T (32453) Clutch Bell (32454) Diff Spider Gears w/shaft (2) (32455) Diff Bevel Gears (2) (32456) Front Square Hub (32457) Spacer Sleeves (3) (32458) Rear Wheel Axles (2) (32459) Diff Output Shafts (2) (32460) Chassis-4mm (32461) Rear Brace Plate (32462) Rear Square Hub (32463) FT Upper Turnbuckles (2) (32464) Front Axles (2) (32465) Rear Drive Shafts (2) (32466) Front Brace Plate (32467) Throttle Linkage (32468) Turnbuckles/RR Lower Arms (32469) Brake Hub (32470) Brake Rod 17

18 SPARE PARTS LIST, CONTINUED (32471) Brake Cam & Lever (32472) Brake Pads (32473) Fuel Line (32474) Engine Mount Washers (4) (32475) Rear Layshaft (32476) Spacers/Brakes (32477) Spring/Servo Saver (32478) M4 Collars (5) (32479) M2 Collars (5) (32480) Bearing Spacers (8) (32481) Rear Chassis Guard (32482) Wheels (1 PR) (32483) Tires w/inserts (1 PR) (32484) Mounted Tires (1 PR) (32485) Side Body Posts (4) (32486) Roll Cage Tubes (32487) Engine Mount-Right (32488) FR Shocks w/springs (32489) Front Body Post ( ) Front Bumper ( ) Battery Cover (32492) Roll Cage Rear Section (32493) Vent Line "Y" Connector ( ) Fuel Tank Assembly (32495) Front Shock Towers (2) (32496) Rear Wing ( ) Receiver Case (32498) FR Hinge Pins (4) (32499) RR Lower Hinge Pins (2) ( ) Main Gear Cover (32522) Fuel Tank Key (32523) M6 Ball Ends (4) (32524) Servo Spacers (32525) Servo Plates (2 Pair) (35545) FR Upper Susp. Arm-Right (32546) FR Lower Susp. Arm-Right (32547) RR Lower Susp. Arm-Right (32548) RR Upper Susp. Arm-Right (32549) Shock Shafts (4) (32550) Lower Shock Mounts (4) 18

19 SPARE PARTS LIST, CONTINUED (32551) Shock Adjusting Rings (4) (32552) Upper Shock Mounts (4) (32553) Shock Caps (4) (32554) Shock Pistons (4) (32555) Shock Cap Seals (4) (32556) Shock Spring Retainers (32557) Shock Body-Rear (2) (32558) Shock Body-Front (2) (32559) Shock Spring-Front (2) (32560) Shock Spring-Rear (2) (32561) M4.2x16 R.H. S.T. Screws (10) (32562) M4x30 C.H. Screws (5) (32563) M6x16 Hex Screws (5) (32564) M4x43 C.H. Screws (5) (32565) M5x30 F.H. Screws (5) (32566) M5x10 F.H. Screws (5) (32567) M3x12 R.H. Screws (10) (32568) M6 Lock Nuts (5) (32569) Brake Discs (2) (32570) M7 E-Rings (10) (32571) Exhaust Pipe (32572) Steering Turnbuckles (32573) Gear Bushing (32574) Rear Shocks w/springs (32576) 4.4x11x1 Washers (10) (32577) Window Net Set (32578) Servo Saver (32579) Steering Post ( ) Decal Sheet (32900) 23cc Gas Engine No Photo Available ( ) Instruction Manual 19

20 IMPORTANT WARRANTY INFORMATION - PLEASE READ! Your XTM Racing 1/6 Gas-Powered 2WD Buggy is warranted against manufacturer defects in materials and workmanship for a period of 90 days from the date of purchase. This does not cover any component parts damaged by use, misuse or modification. In no case shall XTM Racing's liability exceed the original cost of the purchased kit. Warranty service will be provided within 90 days of the date of purchase only if you are able to provide the original or a copy of the original dated sales receipt. In that XTM Racing has no control over the final assembly or material used for final assembly, no liability shall be assumed for any damage resulting from the use by the user of the final user-assembled product. By the act of using the final user-assembled product, the user accepts all resulting liability. IMPORTANT WARRANTY SERVICE INFORMATION Before returning your 1/6 Gas-Powered 2WD Buggy for warranty consideration, the status of the unit must be within the guarantee as stated above. Do not return your 1/6 Gas-Powered 2WD Buggy to the place of purchase. They are not authorized or equipped to perform warranty work on XTM Racing products. When requesting warranty service, please observe the following: Crash damage will not be covered under warranty. Do not request warranty service for a crash-damaged product. This warranty only covers the XTM Racing 1/6 Gas-Powered 2WD Buggy and the factory-installed 23cc gas engine. It does not cover after-market engines or your radio control system and other electronics. Wear items, such as spark plug, clutch shoes, tires and brake discs are not covered under warranty. Please remove radio control system from the chassis before sending the product to us. Include a note detailing the problem or service you are requesting. Service cannot be provided without this information. Include your daytime phone number, shipping address and/or address in the event we need more details pertaining to the service requested. If your vehicle is out of the warranty period you may request an estimate of services at the time you return your vehicle for service. An omission of this request implies permission for Global Services to service your vehicle at our discretion. Include a method of payment for any service charges. Send the unit to us by United Parcel Service, Federal Express or by Insured Mail. Postage is non-refundable. Send your package to: Global Services Bandilier Circle Fountain Valley CA Visit Our Website Phone: (714) Fax: (714) service@globalhobby.net 20

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS Baja Bullet ESC Features: Forward, Brake & Reverse Micro Processor Control Input Voltage: 6V - 12V Frequency: 3Khz Continuous Current: 20Amps BEC Cutoff: 5V/2Amps Temperature Cutoff: