FG Modellsport 10007, 10008 Mounting Instruction
Mounting instruction for
F1 Competition 09 Chassis
Item N°. 10007, 10008
A.10007-10008-200409
FG Modellsport GmbH
Spanningerstr. 2
73650 Winterbach-Germany
Phone: +49 7181 9677-0
Fax: +49 7181 9677-20
info@fg-modellsport.de
www.fg-modellsport.de
Please thoroughly keep this construction manual for spare parts orders!
Weight of the individual bags/ boxes:
Bag A = 4 parts
Bag B = 0,871 kg
Bag C = 0,649 kg
Bag D = 0,617 kg
Bag E = 0,308 kg
Bag F = 0,136 kg
Bag G = 0,699 kg
Bag H = 0,729 kg
Bag I = 0,091 kg
Bag J = 0,125 kg
Bag K = 0,498 kg
Bag L = 0,442 kg
Bag M = 0,502 kg
Bag N = 0,355 kg
Bag O = 0,587 kg, only for Item N°. 10007
Bag P = 0,447 kg, only for Item N°. 10008
The RCS, accumulators and battery charger are not included in the delivery volume.
We congratulate you on buying this FG Competition model. Please check
the contents of the construction set, respectively of the bags. The individual bags had been thoroughly packed by us and their weight had been
checked. When purchasing the individual bags, please check their weight
and their closure by staples which must not have been removed or opened and closed several times. It is possible that the weight of an individual bag deviates by 5 grams. In case of claims due to missing parts, you
always need to present the label indicating the weight at your specialized dealer. By checking the weight of the bag, you may exclude that larger parts or several parts are missing.
The handling with fuels requires circumspective and careful handling. Imperatively observe the security advices.
- Refuel only if the engine is switched off!
- Take off the body.
- Thoroughly clean the area around the fuels nipple.
- Remove the fuel filler cap and carefully fill in the fuel mixture.
- Smoking or any kind of open fire is not admitted.
- Fuels might contain solvent-like substances. Avoid contact with skin and eyes. Wear gloves for refueling. Do not inhale fuel vapors.
- Do not spill any fuel. If you have spilled fuel immediately clean the engine
and the model.
- Make sure that no fuel will get into the soils (environmental protection). Use
an appropriate mat.
- Do not refuel in enclosed rooms. Fuel vapors accumulate at the soil (risk of
explosion).
- Transport and store fuels only in admitted and labeled canisters. Keep fuel
out of the range of children.
- The operator is responsible for any damages caused to third persons in the
operating range of the model, respectively of the engine, if they are injured
or in case of property damage.
- The model must only be passed on to persons who are familiar with this model and its operation, always provide the operating manual.
- Persons with implanted heart pacemakers must not work on running engines and on live parts of the ignition system when the engine is being started.
- The engine must neither be started nor operated in enclosed rooms (without sufficient ventilation).
- When starting the engine, avoid inhaling the exhausts.
- The model must neither be started nor operated without air filter or without
exhaust system.
- Before every start perform a functional check of the safety-relevant parts.
- The throttle rods must always return automatically to the idle position.
- Any cleaning, maintenance and repair works must only be performed with
the engine being switched off. The engine and silencers are getting very
hot. In particular do not touch the silencer.
Comments regarding the construction manual:
Before starting the assembly please see through this construction manual.
This way you will get an overview of the whole execution.
Please check by means of the parts or bag list if the construction kit is complete and also check the weight of the individual bags for the positions. Only
this way you may be sure that all parts which you need for the assembly are
available. If a part is missing, please immediately contact your specialized
dealer.
Table of contents
Position 1: Differential gear
Position 2-7: Rear axle, gearwheel drive
Position 8: Shock absorber
Position 9-10a: Assembly shock absorber, stabilizer - rear axle
Position 11-19a: Front axle
Position 14-17: Servos, receiver
Position 18-19a: Assembly shock absorber, stabilizer - front axle
Position 12-13: Servo saver, track rods, steering rods
Position 19-23: Engine, manifold, airbox, clutch
Position 23-24a: Engine assembly, tank
Position 25-25a: Tuning pipe
Position 18: Throttle rods
Position 28-29: Front spoiler, rear spoiler
Position 30-31b: FG Magura hydr. brake system front and rear
Position 32-33b: Tuning disk brake front and rear
All metric screws need to be secured
with thread lock fluid.
7080/3
6069/2
8600/13
8600/3 8600/4
8602/1
8493
8600/11
8602/2
8600/13 8600/13
8602/2
8600/2
8600/13
8600/9
8600/10
8493
6924/20
6069/2
7080/3
6924/20
8600/8
6067
6068
8500/3
6067
8600/8
8600/11
8600/1
8600/11
8600/6
Steel gearwheel
large 48t.
Screw M4x8
Flat side
O-ring
Ball diff.
axle
Assembly
The flange bushes 8602/2, roller bearing 8602/1 as well as the rotary shaft seals 8600/6 and the ball bearing 8493 have professionally been mounted on
the alloy differential housing A/B by the manufacturers FG .
Now mount the steel gearwheel 48 teeth on the alloy differential housing A.
Check the internal and external fins on production birs, if necessary remove
them with an emery cloth. Do not bend the fins.
Now mount the set of fins according to illustration 1: Insert a differential gearwheel with square on a differential bevel wheel axle. Then slide on the
square one after another in the following order 1x internal fin, 1x O-ring 14x1.5,
1x external fin, 1x internal fin, 1x O-ring 14x1.5, 1x external fin, 1x internal fin,
1x external fin. Grease the shim ring 8600/13 a little and put the differential
housing on the flange bush 8602/2. Now insert the whole package into the
differential housing A according to the illustration. Now push the differential
gearwheel with a screw driver with the fin package towards the housing and
carefully pull out the differential axle.
Push both bronze bushes 8600/8 from the inside to the outside into the borings of the differential housing, position 1a. Insert the differential gearwheels
B into the housing and push in the differential bevel differential gear axle
6068. Grease the 8mm shaft of the ball diff. axle 6069/2 plentifully and push
it from outside into the differential housing. The borings of the alloy differential housing need to align with the borings of the differential gearwheels.
If the borings are offset, the gearwheels need to be disassembled and reassembled once again displaced by one tooth until the parts can be easily turned. Mount the O-rings 3x1 and 42x1.5 according to the illustration.
Now join the two halves of the housing, check them for free movement and
assemble them using the two enclosed M3x20 screws.
Fill in about 15ml of the enclosed silicon oil into the boring of the alloy differential housing B. Add about 5ml 2-stroke engine oil for better lubrication. Then
close the boring by means of the locking screw M8x1/ copper disk. You may
influence the locking effect by the number of fins by the viscosity of the filled in oil as well as by the filling quantity.
When driving an overpressure is building up in the diff. housing. Therefore you
should unscrew the locking screw after a few laps of driving time in order to
release the overpressure.
Insert the fin package
into housing A.
O-ring 42x1,5
O-ring 3x1
Bronze bush
7x18x5
Position 1
Parts are in
bag C
Position 1b
Parts are in
bag C
Position 1a
Parts are in
bag C
Press the bearing shafts into the right alloy rear axle mounts
and mount the alloy cross bracing with M4x18 countersunk
screws to the left and right alloy rear axle mounts.
Before assembling, impress the alloy diff. bearings into the guidings of the left and right alloy rear axle mounts and check if they
are running smoothly, it may be necessary to rework the guidings a little with an emery cloth. Then press them on the ball
bearings of the pre-assembled differential and press them in
evenly (with the gearwheel in direction to the left alloy rear axle mount) into the left and right alloy rear axle mounts. Mount the
alloy diff. bearings to the alloy rear axle mounts by using pan-head screws M5x14.
Insert the body supports in the left and right alloy diff. bearings,
align the borings for the body clips in driving direction and clamp
them by using headless pins M4x10.
Mount the complete gearwheel drive on the alloy chassis by
using M4x14 countersunk screws.
Hint: The left and right alloy diff. bearings are different, please pay
attention to the mounting direction. Make sure that the gearwheels are running smoothly. If this is not the case, look for the reason and remedy the defect, mount it again, if necessary.
Position 2
Parts are in
bag A+B
CFRP chassis
right side part
D
riv
in
g
d
ire
c
tio
n
Disk Ø 4,3
Screw 4x8
Stop nut
M5
Alloy chassis
Screw
5x25
Screw
5x30
Screw 3x6
Ball bush
Rear lower alloy
wishbone
CFRP chassis
left side part
Bevel
washer
Bevel
washer
Alloy bush
5x10x5,5
Position 3
Parts are in
bag C+D
Alloy rear axle
mount right
Ball bearing
8x16x5
Distance
bush
11x8x1
Ball bearing
8x16x5
Bearing
shaft
Gearwheeel
38 teeth
Distance
bush
11x8x6
Guide bush
Guide bush
Differential
mounted
Alu-Querverstrebung
Alloy cross
bracing
Alloy rear axle
mount left
Screw
4x18
Screw 4x18
Screw
4x18
Headless
pin 4x10
Headless
pin 4x10
Alloy wishbone fixing
M4
Alloy wishbone fixing
M4
Plastic wishbone fixing
Ø4
Plastic wishbone fixing
Ø4
Screw
4,2x19
S
cre
w
4
,2
x1
9
Left alloy
diff. bearing
Screw
5x14
Screw
5x14
Screw
5x14
Body support
Disk
Ø 5,3
Disk
Ø 5,3
Screw
5x14
Alloy chassis
Position 4
Parts are in
bag C+D
Alloy rear
axle mount
right
Alloy rear
axle mount
left
Screw
4x14
Screw the CFRP chassis side parts to the alloy chassis using M4x8 pan-head screws and
disks Ø4,3.
The CFRP chassis side parts left and right
differ, pay attention to the mounting direction.
Impress the ball bushes into the alloy
wishbones and secure them with M3x6
pan-head screws.
Mount the rear lower alloy wishbones to the front alloy chassis by using M5x25
countersunk screws, bevel washers and stop nuts M5. Fix the rear alloy wishbone by using M5x30 countersunk screws, alloy bushes 5x10x5,5 (between alloy chassis and bevel washer), bevel washers and stop nuts M5.
Mount the bevel washers always with the thinner side facing towards the ball bush.
Press the guide bushes into the alloy rear axle mounts.
Mount the lower alloy wishbone fixings M4 and the upper
plasic wishbone fixings Ø4 to the alloy rear axle mounts
by using M4x18 and 4,2x19 countersunk screws. Press
each 2 ball bearings 8x16x5 and a distance bush 11x8x1
into the gearwheels 38 teeth, then insert the bearing shafts
from the square side. Now press the bearings shafts with
the distance bushes 11x8x6 into the left alloy rear axle
mount and fix them by using M5x14 pan-head screws and
disks Ø5,3.
Push the distance disks into the round recess of the ball driving
axle as well as into the ball diff. axle. Mount the protection bellows to the ball driveshafts according to the illustration. Lubricate the ball range a little when putting on the protection bellow. Apply lubrication grease on the ball holes of the driveshafts and press in the balls. The balls will be held by the lubrication grease
and this way the driveshaft can be mounted more easily. Now press the complete
ball driveshaft into the ball differential axle and the ball driving axle. Shift the protection bellows over the ball diff. axles and the ball driving axles.
Position 7
Parts are in
bag B
Driving
shaft
mounted
Left alloy
upright
Headless
pin 6x6
Wheel nut
M6
Square wheel
14 mm
Screw
4x12
Distance
bush
Ball bearing
8x22x7
Ball bearing
8x22x7
Pay attention
to the slant
Screw
5x16
Screw
5x16
Screw
5x20
Rear axle
plate left
Screw
5x20
Bevel
washer
Driving direction
Track rod
mounted
Screw
2,9x13
Screw
2,9x13
Rear upper
wishbone
left mounted
Screw
4x35
Screw
4x35
Ball diff. axle
Alloy rear axle
mount left
approx.
21,5mm
approx.
39mm
approx.
10,5mm
Hint: The left and right upper wishbones are different,
mounting direction of the steel ball with collar on the
alloy upright is showing to the bottom and the shorter
side faces the rear. The clearance of the balls in the
ball-and-socket joints can be adjusted with the help of
the screws 2.9x13. The left and right rear axle plates
differ, pay attention that the slant shows to the top when
assembling.
Apply
lubrication
grease.
Lubricate ball driveshaft a little.
Protection bellow
Ball diff. axle
Ball driving
axle
Distance
disks
Balls for driving shaft
Position 5
Parts are in
bag B
1. Press the cylinder pins into the square wheel 14mm as
described in position 6, use high-strength screw retention.
Press the ball driving axles of the pre-assembled driveshafts into the alloy uprights which are equipped with
ball bearings and then mount the square wheel driver
14mm with recess facing the ball bearing on the flat side of the ball driving axle by using the headless pins
M6x6.
Mount the alloy upright between alloy upright and alloy
wishbones using a countersunk screw M5x20 and bevel
disk (thin side facing the ball bush). The left and right alloy uprights are different. The milled surface for the brake has to face the rear.
2. Mount 2,9x13 pan-head screws into all
plastic ball-and-socket joints.
Mount the pre-assembled upper wishbones
and track rods to the alloy rear axle mounts
using the pan-head screws M4x35.
Fix the rear axle plates with the slant showing
upwards to the alloy uprights by using M5x16
pan-head screws.
Mount the upper wishbones to the rear axle
plates using countersunk screws M5x20.
Mount the track rods to the rear axle plates
using cylinder screws M4x12.
Hint: The left and right track rods are different, pay attention to the balls in the ball-andsocket joints, mount the ball with lowering
using the cylinder screw.
All metric screws need to be secured with thread lock fluid.
Position 6
Parts are in
bag B
Position 8
Parts are in
bag E
Position 8a
Parts are in
bag E
Position 8b
Parts are in
bag E
Position 8e
Parts are in
bag E
Position 8c
Parts are in
bag E
Position 8d
Parts are in
bag E
Disk
Ø 4,3
Disk Ø
4,3
Rear alloy
baffle
Screw
5x25
Disk
Ø 5,3
Ball bearing
7x11x3
Headless
pin 4x20
Headless
pin 4x20
Nut
M4
Alloy damper
reversing
Alloy damper reversing
Screw the ball-and-socket joints
6mm and 7mm on the rods to the
length of approc. 72mm, then
press the steel balls 6mm and ball
collets 7mm in the same direction into the ball-and-socket joints 6mm and 7mm.
Mount the stabilizer into the ball
collets 7mm with an excess
length of approx. 8mm by using a
headless pin M4x4.
Press the stabilizer shaft with
shim rings 6x12x1 between the
alloy rear axle mounts, insert the
two stabilizer rods in the stabilizer
shaft, connect the stabilizer rods
with the shim rings between the
alloy rear axle mounts and mount
them using headless pins M4x4.
Mount the ball-and-socket joint
with steel ball 6mm to the inside
of the damper reversings using
pan-head screws M3x16. Pay attention to position 10a.
Screw
5x25
Push-Rod
mounted
Screw
2,9x13
approx.
53mm
Position 9
Parts are in
bag F
Position 10
Parts are in
bag F
Stabilizer
Stabilizer shaft
Ball collet
7mm
Ball joint
7mm
Linkage
Headless
pin 4x4
Shim ring
6x12x1
Screw
3x16
Stop
nut M4
Damper fixing
brace
Disk
Ø 4,3
Screw
4x12
Rear alloy
baffle
Screw
4x14
Disk
Ø 5,3
Screw
5x25
Ball bearing
7x11x3
Ball joint
6mm
Steel ball
6mm
Screw
4x20
Nut
M4
Screw
3x12
Bearing
bush
Nut
M4
Disk Ø
4,3
Assemble the M4x20 pan-head screws into
the damper fixing brace and secure them
with M4 nuts. Now mount the fixing brace
to the alloy rear axle mounts by using M4x12
pan-head screws and Ø4,3 disks.
Screw the M4x20 headless pins into the alloy baffle as pictured and secure them by using Ø4,3 disks and M4 nuts.
Mount the alloy baffle to the alloy rear axle mounts using
M4x12 pan-head screws.
Press the ball bearing 7x11x3 into the alloy damper reversing, insert the bearing bushes through the alloy damper reversings which are equipped with ball bearings and mount
them to the alloy baffle using M5x25 pan-head screws and
Ø5,3 disks.
Fix the rear dampers to the damper fixing brace by using Ø4,3 disks and M4 stop nuts.
Fix the front dampers from the outside at the
alloy damper reversings with M3x12 pan-head
screws.
Mount the 2,9x13 pan-head screws into the plastic ball joints of the push-rods.
Fix the pre-assembled lower push-rod
with the collar of the steel ball to the rear lower alloy wishbones by using
M5x25 pan-head screws.
Mount the pre-assembled upper pushrod to the alloy damper reversings by
using M4x14 cylinder screws.
Hint: Left and right push-rods are different, pay attention to the balls in the ball
joints, mount the ball with lowering with
the cylinder screw. An arising clearance
in the ball joints can be adjusted with
the 2,9x13 screws.
All metric screws need to be secured with thread lock fluid.
Alloy servo saver A 04
ball-beared
Alloy servo saver B 04
ball-beared
Flange sleeve for
alloy servo saver
Servo saver spring
Servo saver axle
Countersunk screw M5x25
Securing disk 6mm
Shim ring 7x13x0,3
O-rings
Ball bearing 7x14x5
Ball bearing
7x11x3
Position 12
Parts are in
bag H
approx. 8mm
a
p
p
ro
x
. 7
2
m
m
Screw
4x14
Screw
4x14
Stop nut
M5
Screw
3x6
Screw
3x6
Bevel
disk
Bevel
disk
Front axle
carrier right
Alloy chassis
Alloy front
chassis
Position 11
Parts are in bags
G+A+H
Front lower alloy
wishbone left
Ball-type
nipple
Screw
5x25
Screw
5x25
Body mount
Screw
4,2x19
Position 10a
Parts are in
bag F
The stabilizer rod should be mounted parallel to the shock absorber.
Make sure the stabilizer 3mm projects approx. 8mm at the top. Please check if the
stabilizer does not contact any other parts
when deflecting.
Secure the ball-type nipples which are moulded
in the alloy wishbones
using the binding head
screws M3x6.
Mount the front lower alloy wishbone with the shorter side facing the front to the
alloy chassis and the alloy front chassis by using M5x25 countersunk screws, bevel disks and M5 stop nuts. Mount bevel disks always with the thinner side facing
the ball-type nipple.
Fix the body mounts to the left and right front axle carriers using 4,2x19 countersunk
screws. Mount the right front axle carrier to alloy chassis and alloy front chassis
with M4x14 countersunk screws.
Push the ball bearing in the alloy servo saver parts A and B. Mount the
servo saver spring on the alloy servo saver part A, then mould the flange sleeve in the alloy servo saver part A. Press the servo saver axle
through the flange sleeve into the two servo saver parts and secure it
using the shim rings and the securing ring 6mm. Check if the servo saver is running smoothly, mount the o-rings on the servo saver.
Hint: You can adjust the effect of the servo saver with the number of the
used o-rings. The more o-rings, the harder is the effect of the servo saver.
All metric screws need to be secured
with thread lock fluid.
Servohebel
Screw
3x18
Screw
4x20
Screw
2,9x13
Ball joint
Ball joint
6mm
Alloy joint
ball
Track rod
mounted
Steering rods
mounted
Stop nut
M4
Stop nut
M3
Steel ball
6mm
Servo saver
mounted
Position 13
Parts are in
bag H
approx. 45mm
Front axle
carrier right
Screw
3x18
Screw
4,2x16
Screw
5x25
Distance
disk
Distance
bolt
Stop nut
M3
Steering servo
Steering servo
Servo fixing
brace
S
teering ro
d
s
m
o
unted
Disk Ø
5,3
Screw
4,2x19
Mount the assembled steering rods through the steel balls 6mm with
the collar facing the servo saver into the outer thread holes of the alloy servo saver by usin g M3x18 pan-head screws and secure them
with M3 stop nuts. Screw 2,9x13 pan-head screws into the plastic
ball-and-scket joints of the track rods.
Fix the mounted track rod into the front outer hole of the servo saver
by using M4x20 cylinder screws. The cylinder screw must go through
the alloy joint ball, the collar must face the alloy servo saver. Fasten
it all with M4 stop nuts.
Hint: The ball clearance can be adjusted with the 2,9x13 screws in the
ball-and-socket joints.
Steering servo
Steering servo
Servo fixing
brace
Position 14
Parts are in
bag H
Mount the steering servos with the enclosed fixing rubber bushings and screws to the servo fixing braces as described in position 14. Switch on
your RCS and bring the steering servos in neutral position. The servo arms have to be shortened
slightly corresponding the type. For competition
we recommend to use alloy servo arms. Press the
servo arms on the servos as pictured and fix them
with the enclosed screws. Preferably the servo
arms should be in a 90° position to the servo.
Mount the servo fixing braces on the right front axle carrier by
using 4,2x16 countersunk screws.
Mount the distance bolt with a 4,2x19 countersunk screw to
the right front axle carrier.
Mount the servo saver with a M5x25 countersunk screw, Ø 5,3
disk and distance disk between servo saver and alloy chassis in the rear hole of the alloy chassis.
Switch on the RCS, bring the trim of the steering into central
position. Align servo saver in centre of the chassis. First mount
one servo rod using M3x18 pan-head screw and M3 stop nut,
then the second in the same way. Adjust both servo rods in
the same length. You should be able to fix the servo rods easily and without any resistance on the servo arms of the steering servos.
Hint: Adjust both steering rods in the same length by turning
the ball-and-socket joints. Servo saver and servo arm should
be parallel.
Servo arm
Steering servo
Servo fixing
brace
Position 14
Parts are in
bag H
Position 15
Parts are in
bag H
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