NOVAK BALLISTIC BRUSHLESS - MOTOR INSTRUCTIONS REV D Instructions page 2

Ballistic brushless motor

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INSTALLATION INSTRUCTIONS

1. NO MOTOR CAPACITORS & SCHOTTKY NEEDED

Novak brushless motors do not need motor capacitors or external

Schottky diodes--Schottky diode usage will damage ESC.

2. CHECK MOTOR SCREW LENGTH & INSTALL MOTOR

• Insert the motor mounting screws that came with your vehicle

through the motor mounting plate. 540-size motors need no

more than 1/8" of screw extending past the vehicle's mounting

plate (2-4mm)--Too little can strip the motor's threads, too much

will cause internal motor damage & will void warranty.

• Attach motor to vehicle's motor mount using one of the sets of

threaded mounting holes--

select a mounting position that keeps the

solder tabs clear of conductive surfaces like aluminum or graphite.

3. INSTALL PINION GEAR (see GEAR SELECTION)

Install pinion on motor and test fit in vehicle to align pinion and

spur gears. Tighten pinion's set screw on the flat of motor shaft.

4. ADJUST MOTOR FOR PROPER GEAR MESH

• Adjust the motor position for proper amount of free play. You

NEED to have a small amount of play between the pinion gear

and the spur gear (about the thickness of piece of paper)--check

the free play at several positions around the spur gear to

ensure a proper mesh (just in case the gears are out of round).

MAKE SURE THE PINION/SPUR GEAR MESH IS NOT TOO TIGHT!

If gear mesh is too tight, motor shaft breakage can occur.

• Tighten motor mounting screws--Avoid using excessive force,

as the threaded holes in motor could become stripped.

5. SOLDER MOTOR POWER WIRES

(skip this step if motor is wired to ESC)

• Determine the best routing in vehicle for the motor's silicone

power wires--avoid any moving parts & suspension.

• Prepare ends of power wires by stripping 1/8-1/4" of

insulation from end of wire. Tin wire ends with solder.

• Lay tinned end of the wire flat on the solder tab and solder

wires to proper tabs of the motor (refer to phase markings

below solder tabs). Apply heat with soldering iron to the power

wire and solder tab--begin adding solder to tip of iron and to

wire--Add just enough solder to form a clean & continuous joint

from the solder tab up onto the wire.

WARNING: Be sure no wire strands have strayed to an adjacent solder tab--this

will cause short-circuiting, damage electronics, & void product's warranty.

IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS

Prolonged or excessive heating of the solder tabs will

cause damage & void the product's warranty.

6. CONNECT MOTOR SENSOR HARNESS

• Determine the best routing in vehicle for the motor's sensor

harness--securing sensor harness to the motor power wires with a

tie-wrap can provide a good location & also act as a strain relief.

• Connect one end of the harness to the ESC & the other end

to the motor's sensor harness connector located under the

back bearing cap. Be sure the plug on the end of the harness

inserts all the way into the sensor harness connector--the plug

& connector are keyed and will only go together one direction.

w w w . t e a m n o v a k . c o m

BALLISTIC MOTOR

Exploded View

fish paper

insulator

outer sleeve

front end bell

TIMING WARNING ( Important )

Due to the nature of timing advance speed controls, motor tolerances & settings, vehicle

performance, and track conditions, it has become virtually impossible to provide installa-

tion and operation recommendations that will allow you to use these speed controls and

motors at their highest performance levels without the potential for unwanted damage.

You must, use extreme caution when setting up these electronics and carefully test your

application to avoid overloading and overheating either the speed control or the motor.

These are racing electronics used in racing conditions, and therefore damage as the

result of excessive overheating will not be covered under the product's factory warranty.

GEAR SELECTION ( Important )

Motor operating temperature is the ONLY

way to properly set the maximum vehicle gearing

The motor should be 160-175°F MAX at end of run!

Temperatures above 175°F will weaken the magnet & may

melt the coils! This voids warranty & can damage ESC!

Change the gearing to avoid overheating.

Because of the potential danger of overheating, ESC/motor damage & failure, you must

start with VERY small pinion sizes and check ESC & motor temperatures at multiple times

throughout a run. This is the only way to ensure that you are not causing excessive heating.

If ESC & motor temperatures remain low & stable, you can slowly increase the pinion size

while again monitoring the temperatures to determine the safe gearing for your vehicle,

motor, and climate/track conditions. Because these variables can change or be modified, you

MUST continually monitor ESC & motor temperatures to protect your electronics from damage.

If you do not change gearing after switching to brushless, you will be over

geared and will have slow acceleration & excessive temperatures!

Because of the broad power band of brushless, you can go 1-2 teeth higher pinion than

the above recommendations for more top speed, but remember any higher will produce

excessive ESC & motor heating.

Ballistic Crawler Brushless Motors

When properly geared for use with gear reduction transmissions found in rock crawling

vehicles, your brushless crawler motor and ESC should not get very hot--if you notice excessive

temperatures, check motor & drive train for free operation or adjust gearing to lower temperature.

Additionally, refer to your vehicle's instruction manual for gearing recommendations.

See our website for additional gearing information or if your motor is not listed above.

MOTOR TIMING ADJUSTMENT

The Ballistic motor's timing is adjustable by simply loosening the three M2.5 flat

head screws on the back bearing cap, rotating the bearing cap to desired setting,

and re-tighten the screws.

The motor's factory timing is marked with a timing label located on the side of the

back bearing cap and lines up with a groove milled into the top of the back end bell.

Novak motors are factory timed to the most efficient setting for their given wind.

Advancing the timing will increase the motor's RPM range & reduce its torque, but

will also make it less efficient and it will pull more current, resulting in higher ESC &

motor operating temperatures.

Adjusting the timing beyond the 45° mark on the timing label will result in

dangerously high current draw and heating that can lead to ESC & motor

failure, and will void the product's warranty.

Retarding the timing will reduce the motor's RPM range & increase torque--this usu-

ally also reduces current draw and lower operating temperatures. For each timing

mark (on label) reduced, increase pinion gear size by one tooth to accommodate

lower RPM range.

sensor harness

low-loss solder tabs

timing groove

connector

silicone

timing

grommet

back

assembly

fiberglass

hand-wound

end bell

stamping

Refer to 'Accessories' section for

stator