Dissection of Exceed RC Buggy Subsystems

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Contents

Servos

Two mechanically identical servos are located on the car. The same process may be used to dissect either.

Figure 1: A servo after removal of the casing
Step # Part Dissection Process Tools Used Difficulty
1 Casing Remove four round head 1 1/8 in screws from bottom.
Top and bottom of plastic case slide off.
Phillips-head screwdriver 2
2 Thin gear Slide top center gear off of metal axle. None 1
3 Drive gear Remove black-centered gear through hole in servo casing. None 2
4 Three-stage gear Slide off gear on opposite side of drive gear. None 1
5 Final gear Remove remaining gear from the center axle. Needle nose pliers 2
6 Servo motor Pull servo motor, circuit board and other internal components out from bottom of metal servo casing.
Note: not actually performed in order to protect the electronics
Small tools for electronics 5

Table 1: Servo dissection process

Tire Assembly

Due to the symmetry of the axle assemblies, the dissection process is the same for all 4 wheels. The process below describes the dissection of only one tire assembly. The process is repeated twice per axle and 4 times for the whole car.

The tire assembly can be completely disassembled with exception to the wheels. The tire of the wheels does not come off without hindering performance of the product.

Step # Part Dissection Process Tools Used Difficulty Image
1 Wheel Remove the hex nut holding wheel on the axle and slide the wheel off Pliers 1 Link
2 Camber Adjustment Pop off sockets at each end from support posts located on the lower interior section of blue support frame, and upper interior section of wheel hub None 2
3 Spring/Dampener Remove top socket from ball support post on upper exterior of blue support frame.
Remove set screw from bottom of spring where it connects to X-frame.
2 mm Allen wrench 2 Link
4 Dogbone Dogbone shaped driveshaft slides out of sockets at the gearbox and tire hub None 1
5 Wheel hub Remove one E-clip attached to the pin holding the wheel hub to the X-frame.
Slide pin out opposite side.
None 3 Link
6 X-frame Locate pin connecting X-frame to the base support of the gear box, slide away from connecting pin None 2
Table 2: Tire assembly dissection process

Gear Box/Differentials

Similar to the servos, two identical differential gear sets exist on the car. The two subsystems are located one each on the front and rear axle.

Step # Part Dissection Process Tools Used Difficulty
1 Gear Box Remove 1/2 in flat top screw.
Pull gear box apart, remove central piece consisting of large gear, metal axle, and plastic casing.
Phillips-head screwdriver 1
2 Inner parts Unscrew four 1/2 in round top screws from the large gear.
Pull large gear from casing, metal axle, and two 1/3 in diameter gears are exposed too.
Note: much care is needed due to gear lubricant
Phillips-head screwdriver 4

Table 3: Differential dissection process

Transmission

Figure 3: The transmission subsystem fully assembled
Figure 4: The transmission disassembled
Step # Part Dissection Process Tools Used Difficulty
1 Metal Holders Remove the two pins on the rear of the transmission.
Pull off metal holders with plastic washer
1 mm Allen Wrench 1
2 Plastic Washer Slide off of metal holders
Note:these holders are very lightly fastened
None 1
3 Metal Throttle Holder Pull out bead-like plastic piece from the bottom of the throttle support.
Pull throttle holder out.
None 1
4 Plastic Throttle Frame Remove two flat top 1 in screws from the rear of the transmission.
Pull frame apart, causing gear and axle to come out as well.
Phillips-Head screwdriver 1
Table 4: Transmission dissection process









Engine & Exhaust

Step # Part Dissection Process Tools Used Difficulty
1 Pull Starter Remove four 1/4 in round head screws from base of pull starter Phillips-head screwdriver 1
2 Exhaust Vent Remove two 1/8 in hex head screws from side of vent where glow plug meets the engine 2.5 mm allen wrench 1
3 Glow Plug Remove four 7/16 in hex head screws located inside glow plug chamber connecting glow plug to top of engine.
*Note: removal of screws requires engine to be turned upside-down. Also, removal of glow plug reveals one washer.
2.0 mm allen wrench 3
4 Air Intake Intake comes free by gently pulling on base.
*Note: removal of intake allows pin at base of intake o slide out freely
None 1
5 Shaft Remove screw on top of main shaft.
*Note: removal allows four (4) washers and first gear to come loose. The remaining pieces are fixed on the shaft.
2.5 mm Allen wrench 1 (screw)
5 (fixed gears)
6 Two Engine Supports Remove two 7/16 in screws on each support. 2.5 mm Allen wrench 3
7 Air Filter Pull off. None 1
8 Intake Valve Remove one screw on side of valve.
*Note: there is a spring under tension inside valve
Flat-head screwdriver 2
9 Piston Chamber Cover Pull off nut on back of engine. Remove four 1/4 in screws from four corners of plate. Phillips-head screwdriver 2
10 Main Exhaust Chamber Disconnect tube at gas tank.
Remove two zip-ties from rubber connector.
Pull off rubber connector.
Flat-head screwdriver 2

Table 5: Engine & Exhaust dissection process

Figure 5: Gallery of engine dissection photos