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O'Donnell Z01B Assembly Instructions Manual

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ASSEMBLY INSTRUCTIONS
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Summary of Contents for O'Donnell Z01B

  • Page 1 ASSEMBLY INSTRUCTIONS ®...

  • Page 2: Warranty

    • O’Donnell ® guarantees this kit to be free from defects in both To return your Z01B for repairs covered under warranty you should material and workmanship at the date of purchase. O’Donnell will send your buggy to: warranty this kit for 90 days after the purchase date. O’Donnell will repair or replace, at no charge, the incorrectly made part.

  • Page 3: Safety Precautions

    • Model engine fuel is fl ammable and when ignited has a fl ame that is diffi cult to see. Avoid sparks, fl ames, smoking, or any • Do not operate the Z01B near people. Spectators should be other ignition source when fuel is near.

  • Page 4: Required Accessories

    REQUIRED ACCESSORIES Servo High Torque Steering Servo Receiver Transmitter 5-Cell Receiver Hump Pack Engine Tires Header & Pipe Tire Inserts...
  • Page 5 REQUIRED TOOLS & TRACK EQUIPMENT Fuel Diff, Shock & Air Filter Oils Threadlock CA Tire Glue Bottle Glow Plug (and spares) Clutch Tool Flywheel Wrench Hobby Knife Fuel 1.5mm Hex 2.0mm Hex 2.5mm Hex Wrench Wrench Wrench 4-Way Wrench Body Scissors Glow Plug Ignitor...
  • Page 6 DIFF HOUSING HARDWARE Front/Rear (x2) Make sure the bearing is fully seated on the diff housing. (x3) Apply a small amount of included 8x16mm Bearing grease to the O-ring before installing. Center (x1) This will help prevent damage to the O-ring when installing the drive joint.
  • Page 7 SPUR/DIFF GEARS HARDWARE Apply a small amount of the included grease to the O-ring before installing. This will help prevent damage to the O-ring when installing the drive joint. (x3) 8x16mm Bearing Make sure the bearing is fully seated on the gear. Center (x3) Diff Outdrive O-Ring...
  • Page 8 CENTER DIFF MOUNTS IMPORTANT! IMPORTANT! The grooves for the diff HARDWARE bearings face inward. (x2) 3x6mm FH Screw Make sure the brake disc guides are interlocked with the diff (x4) mounts before installing. 4x12mm FH Screw MOUNT THE CENTER DIFF HARDWARE (x4) Large...
  • Page 9 BRAKE ACTUATOR & FUEL FILTER MOUNT HARDWARE (x4) 3x35mm BH IMPORTANT! IMPORTANT! Screw Mount the fuel fi lter mount to the center upper brace before installing the center upper brace to the center diff mounts. (x2) 5x8mm Flanged Bearing (x2) 3x4mm Set Screw The angled side of the brake...
  • Page 10 REAR DIFF JOINT HARDWARE (x2) 4x14mm FH Screw (x2) 8x16mm Bearing (x1) Make sure the bearings are 5x5mm Set fully seated in the case. Screw (x2) Pinion Shaft Shim (x2) 3x14mm FH Screw REAR DIFF HOUSING HARDWARE Use the included shims to space gears properly in the diff case.

  • Page 11: Rear Shock Tower

    REAR SHOCK TOWER HARDWARE (x2) 4x14mm FH Screw (x2) 3x12mm FH Screw (x2) 4x4mm Set Screw (x2) 4x8mm Set Screw Right Refer to the setup sheets for droop settings. (x2) 4mm Lock Nut (x2) 3x14mm BH Screw Left REAR OUTDRIVES HARDWARE (x2) Wheel Hub Pin...
  • Page 12 REAR UPPER LINK Notched link end goes on the HARDWARE hub for wheel clearance. (x2) 3x25mm BH Screw (x2) 3x6mm BH Screw (x2) 3mm Washer (x2) 3x18mm SH Screw (x4) Secure the hinge pin in place 3mm Lock Nut with the 3x6mm BH screw. (x2) Outer Lower Rear Hinge Pin...
  • Page 13 REAR SWAYBAR HARDWARE (x4) 2.5x8mm SH Screw IMPORTANT! IMPORTANT! There are three sizes of swaybars and swaybar bushings. Be sure to use the correct bushing with its corresponding swaybar. Rear Swaybar Bushing Soft .093" OD ........Small Medium .100" OD ...... Medium Firm .105"...

  • Page 14: Rear Suspension

    REAR SUSPENSION HARDWARE (x4) 4x12mm FH Screw Make sure the tabs on the bottom of the gearbox key into the chassis. Position the gasket between the gearbox Install a 2mm dogbone and chassis. spacer inside the drive cup. Make sure the rear bumper is installed before installing these screws.
  • Page 15 FRONT DIFF HOUSING HARDWARE HARDWARE (x1) 5x5mm Set Screw (x2) (x2) IMPORTANT! IMPORTANT! 4x4mm Set Screw Diff Shim Apply a 1/4" strip of the included grease to three locations on the ring gear. (x2) 4x16mm BH Screw (x2) Pinion Shaft Shim Make sure the bearings are fully seated in the diff housing.

  • Page 16: Front Shock Tower

    FRONT SHOCK TOWER HARDWARE (x4) 4x14mm FH Screw (x2) 3x14mm BH Screw LEFT & RIGHT FRONT STEERING BLOCKS HARDWARE (x4) 8x16mm Bearing Note: The front universals are longer than the rear. (x4) 4x10mm BH Screw (x2) Make sure the bearings are fully Wheel Hub Pin seated in the steering blocks.

  • Page 17: Front Suspension

    FRONT SUSPENSION HARDWARE 10° Caster Block (x2) 4mm Lock Nut (x2) 4x4mm Set Screw (x2) 3x6mm BH Screw (x2) Outer Lower Front Hinge Pin FRONT UPPER LINKS HARDWARE (x2) 3x25mm BH Screw (x1) 3x10mm BH Screw Make sure to use (x6) the correct part.

  • Page 18: Steering Assembly

    STEERING ASSEMBLY HARDWARE Actual Size (x3) 3mm Lock Nut (x1) 78mm 3x16mm FH Screw Trim this edge if (x4) there is interference 6x10mm Bearing at full steering. (x2) Note the direction 3x14mm FH Screw of the arms. Shock End Ball (x4) Standard Rod End Ball...

  • Page 19: Front End

    FRONT CHASSIS BRACE HARDWARE (x2) 3x8mm FH Screw (x2) 3x16mm BH Screw (x2) Standard Rod End Ball FRONT END HARDWARE (x2) 4x12mm FH Screw Make sure the dogbone is placed under the steering rack bar. Install a 1.5mm dogbone spacer inside drive cup. Position the gasket between the gearbox and chassis.
  • Page 20 FRONT SWAYBAR HARDWARE (x4) 2.5x8mm SH Screw The swaybar goes over the axles. IMPORTANT! IMPORTANT! There are three sizes of swaybars and swaybar Install the correct swaybar bushings. Be sure to use the correct bushing with bushings onto the swaybar. its corresponding swaybar.

  • Page 21: Front Bumper

    FRONT BUMPER HARDWARE (x2) 3x18mm BH Screw Make sure the steering link is mounted on top (x2) of the knuckle arm. 3 Lock Nut Use three 3mm washers to minimize bump steer. (x2) 4x8mm FH Screw (x6) 3mm Washer 3x18mm BH (x2) Steering Link Adjustment Washers...

  • Page 22: On/Off Switch

    THROTTLE SERVO HARDWARE (x4) 3x16mm FH Screw Note orientation of the servo. (x4) (Servo included with radio system.) 3mm Countersunk Washer Spacer Servo Type Spline Adapter Spacer Airtronics/Sanwa ....23T ..... 2mm* Futaba/Duratrax ....25T ..... 2mm* Hitec/Hobbico ....24T ..... 0* KO Propo ......23T ..... 1mm* JP Propo ......23T .....
  • Page 23 SERVO TRAY POSTS HARDWARE (x6) 3x8mm FH Screw SERVO TRAY HARDWARE (x2) 3x8mm FH Screw (x2) 3x10mm FH Screw...
  • Page 24 SERVO LINKAGES HARDWARE THROTTLE LINKAGE BRAKE LINKAGES (x1) Pivot A Threadlock on 3x14mm BH Screw all set screws. (x1) Shock Ball End 37.5mm Pivot B 19.25mm (x1) 3mm Lock Nut (x1) 3x16mm BH Screw 3x10mm BH 3x16mm BH (x1) Lightly tighten both screws. 3x10mm BH Screw Pivot A Make sure the pivots can...
  • Page 25 RECEIVER HARDWARE (x1) 3x6mm BH Screw Secure the antenna tube to the radio box using a 3x6mm BH screw. Do not overtighten. FUEL TANK HARDWARE IMPORTANT! IMPORTANT! Make sure you do not overtighten (x2) the 3x18mm FH fuel tank screw. 3mm Countersunk Washer Note the direction of...

  • Page 26: Side Guards

    SIDE GUARDS HARDWARE (x6) 3x10mm FH Screw TUNED PIPE MOUNT HARDWARE (x1) 4x4mm Set Screw (x1) 4x12mm FH Screw Depending on which pipe and header used, you may need to cut the end of the pipe mount wire to fi t.

  • Page 27: Engine Mount

    ENGINE MOUNT HARDWARE (x4) 4x12mm FH Screw (x4) 4x10mm SH Washer Screw (x4) 4mm Lock Nut IMPORTANT! IMPORTANT! Use threadlock on all four 4x10mm SH washer screws. FLYWHEEL ENGINE SOLD SEPARATELY! ENGINE SOLD SEPARATELY!
  • Page 28 CLUTCH HARDWARE (x2) 5x10mm Bearing (x4) Clutch Shim (x1) 3mm SH Screw with Washer Shim the clutch bell to allow minimal end play. HEADER & PIPE HEADER AND PIPE ASSEMBLY HEADER AND PIPE ASSEMBLY SOLD SEPARATELY! SOLD SEPARATELY!

  • Page 29: Engine Installation

    ENGINE INSTALLATION HARDWARE (x4) 3x14mm SH Screw Place a strip of paper between the spur and clutch bell to help properly set the gear mesh. Once the gear mesh is set, remove the paper. THROTTLE LINKAGE Snap the throttle linkage ball end onto the carb arm.
  • Page 30 SHOCK SHAFT Do not overtighten the nut. HARDWARE (x4) Note: The notch in the 3mm 3mm Lock Nut silver washer does not affect shock performance and can be positioned in any direction. (x4) 3mm Washer (Silver) IMPORTANT! IMPORTANT! Make sure the snap ring is securely seated in the groove.

  • Page 31: Shock Oil

    SHOCK OIL Fill the shock body with shock oil (with shock shaft fully extended, oil level should be just below the top of the shock body). Gently work the shaft up and down in the shock body to allow the air bubbles to work out of the oil.

  • Page 32: Front Shock Installation

    SHOCK BOOT AND SPRING Install the shock boot over the shock end and secure it in place on the shock body. Gently work the shock end out the bottom of the shock boot. The bottom of the shock boot should be fi...

  • Page 33: Rear Shock Installation

    REAR SHOCK INSTALLATION The washer side of the shock bushing HARDWARE faces toward the shock tower. (x2) 3x20mm BH Screw (x2) 3mm Lock Nut (x2) 3mm Lock Nut FUEL TUBING Install fuel tubing as shown, making sure it is not close to any moving parts or kinked.

  • Page 34: Air Filter

    AIR FILTER HARDWARE Secure the air fi lter assembly to the air fi lter (x1) boot with one of the included tie straps. 3x8mm BH Screw Secure the air fi lter to IMPORTANT! IMPORTANT! the carb with one of Place the inner element into a small plastic the included tie straps.
  • Page 35 TIRE AND WHEEL INSTALLATION HARDWARE Tires and inserts sold separately. (x4) Wheel Nut BODY Trim body as shown.
  • Page 36 Copyright © 2008 ODOZ1000 for ODOC0100...

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