Sportwerks Mayhem Pro Assembly and Tuning Manual Specifications: Length: Width: Track: Wheelbase: Weight: Gear ratio: 19.4 in (492mm) 12.2 in (310mm) Front - Adjustable 10.6–12.2 in (270–310mm) Rear - 12.2 in (310mm) Adjustable 12.8–13.0 in (325–330mm) 7.6 lb (3450 g) (Depending on equipment installed) 10.
Introduction Thanks for your purchase. If you’re an experienced off-road gas racer, you’ll find the Sportwerks™ Mayhem™ to be a nocompromise competition racing buggy of the highest caliber. If you’re new to gas off-road, hang on! You’re about to discover just how much fun trying to tame an overpowered 1/8-scale monster can be.
Table of Contents Introduction ..............................................................................2 Table of Contents ....................................................................3 Required Tools ........................................................................4 Additional Equipment Required ..............................................5 Preparing the Engine ..............................................................7 Engine and Exhaust System Installation .....................
Required Tools Tools required: • • • • • • • • • • • • Page 4 1.5mm hex wrench 2mm hex wrench 2.
Additional Equipment Required Additional equipment required for assembly (not included): • 2- or 3-channel car radio w/ 2 servos (steering servo should have minimum of 80 oz/in of torque) • Rechargeable 5-cell flat receiver pack and charger (DYN1415 1100mAh Ni-MH RX pack recommended) • RC car paint for polycarbonate bodies Page 5
Additional Equipment Required Additional items needed to operate • Glow Igniter • Air Filter Oil • Car fuel • Fuel Bottle • Starter Box and Battery DYN1925 DYN2502 DYN2270 DYN2000 DYN5610C SWK1100 requires the following additional items (not included) • .21–.
Preparing the Engine Note: If you’re assembling the Mayhem Pro with engine version (SWK1150), the engine, clutch and exhaust system are already installed. Skip this section and proceed to page 13, Radio System Installation.
Figure A Figure B Step #3 Step #2 Using a 10mm deep socket wrench, tighten the clutch nut securely. A piston locking tool or crank lock tool should be used to prevent the engine from turning over while tightening. If one is not available, adjustable pliers can be used, carefully gripping the circumference of the flywheel while tightening the clutch nut. Install the clutch shoes and springs on the flywheel pins. Note the springs must be positioned such that the ends are in the groove on the clutch nut.
Step #5 Install the engine mounts to the engine using the provided 3x12mm cap screws. Important: Note the orientation of the carburetor in the above illustration. Be sure that the carburetor on your engine is installed per the illustration with the throttle arm on the correct side as shown. It may be necessary to rotate the carburetor 180° to position the throttle on the correct side.
Engine and Exhaust System Installation Items needed The prepared engine from previous step The assembled buggy Four 5x8mm Engine Mounting Screws (SWK2074) Tuned Pipe Mounting Wire (SWK3238) Tuned Pipe Mount (SWK3240) Exhaust system (not included) 4x4mm Set Screw (SWK2440) 4x8mm Flathead Screw (SWK2054) Air Filter (SWK3232) Air filter oil (not included) Fuel tubing (not included) Step #1 Step #2 Using the four 5x8mm engine mounting screws, mount the engine to the chassis, tightening lightly.
Step #3 Step #4 Step #5 Assemble and install the tuned pipe mount and mounting wire on the chassis using the 4x4mm set screw and the 4x8mm flathead screw. Don’t tighten these screws at this time. Assemble the exhaust system (not included) and trial fit it in place. Note that the mounting wire should be adjusted to allow the pipe to naturally align with the engine exhaust outlet. When you’re satisfied with the position of the pipe mount and mounting wire, securely tighten the screws.
Step #6 Step #7 Attach the fuel lines as shown. Apply air filter oil to the air filter and install on the carburetor. Use the included cable ties to attach the air filter securely in place.
Radio System Installation Items needed (not included) 2 servos (steering servo with 80 oz/in of torque or greater recommended) Receiver Rechargeable 5-cell flat receiver pack (DYN1415 recommended) Switch harness Servo tape Items needed-(included) Steering Arm (SWK3108) Servo Adaptors (SWK3108) Steering Linkage (SWK2550) Antenna (SWK3114) Antenna Cap (SWK3114) Switch Cover (SWK3118) 8-3x10mm Button-Head Screws (SWK2226) 2-2x10mm Switch Mounting Screws (SWK2306) 2-3x8mm Flathead Screws (for servo arms) (SWK20
Step #1 Step #2 Step #3 Remove the three 3x10mm flathead screws on the top of the radio tray and the four 3x10mm flathead screws on the bottom of the chassis that attach the radio box and remove the assembly from the chassis. Install the grommets and eyelets included with your radio system in both servos. Using the eight 3x10mm button-head screws included in the kit, install the servos in the tray as shown, noting the position of the output shafts.
Step #4 Step #5 Step #6 Feed the servo leads through the opening in the radio box. It may be necessary to loosen the 2x10mm radio box screws and slightly separate the center of the radio box from the bottom to allow the servo connectors to pass through. Using servo tape, secure a 5-cell receiver battery pack (not included) in place as shown. A waterproof switch cover is included. Install the switch (not included) in the switch cover using two 2x10mm screws; fasten the switch in place.
Step #8 Install the antenna tube and thread the antenna through the tube, allowing several inches to be exposed at the tip of the tube. Place the antenna cap over the end of the antenna to fasten it in place. Note: A single drop of thin CA glue can be used to secure the antenna tube to the radio box, preventing the tube from falling out during a crash. Step #9 Step #7 Hook up the servos, battery and switch per the instructions included with the radio system and charge the receiver pack.
Step #12 Turn on the transmitter and receiver and center the trims, which will also center the servos. Install the steering servo arm on the steering such that it is positioned exactly vertically as shown in Step 13; secure it in place with a 3x8mm flathead screw and 3mm cone washer. Step #11 Step #13 Select the two servo adapters that fit your brand of radio and install them on the servo output shafts. Install the 6.8mm pivot ball in the arm and secure it with a 3mm locknut.
Brake Linkage Setup Step #4 Step #8 Adjust the position of the return spring collar until the correct tension is achieved. With the throttle at neutral, the spring should just close the carburetor barrel with light tension. With the throttle at neutral, pull the rear (red knob) brake linkage through the molded pivot such that the rear brakes are slightly applied.
Painting the Body Note: A clear protective film is applied to the outside of the body to protect it from overspray during painting. Remove this film after painting. The body comes cut, trimmed and mounted— ready for paint. Before painting, clean the inside of the body with warm soapy water to remove any remaining mold release that may be present from the manufacturing process. Use masking tape to tape the windows.
Your First Run Note: If this is your first gas car, we highly recommend that you have an experienced gas-car driver or local hobby dealer help during the first startups and runs. He will be able to properly adjust your engine for breakin and then tune your engine for reliable performance. Before attempting to start your new buggy, be sure to read the instruction manual that was included with your engine. If your Mayhem™ came with an engine, carefully read the engine instructions on the following pages.
The Sportwerks .21 engine features a slide-valve carburetor and includes three inserts of various diameters. These carburetor inserts are used to alter the power curve of the engine. The three diameters included have the following effect: 6.5mm 7.5mm 9mm – Gives smooth controllable acceleration; offers best fuel mileage; best-used for slick tracks/surfaces or beginning gas drivers.
Tuning your Engine Fine-Tuning Your Engine Tuning the Low-Speed Needle When tuning the needle valves for maximum performance, adjust them in small increments, 1⁄16 turn at a time. An engine should not be run too lean; doing so severely shortens the life of the engine. When an engine is set too lean, it will run very strong at first but will soon begin to sag and hesitate or stall when accelerating.
Center Differential 96 2 89 20 18 156 37 89 166 37 93 90 79 91 166 96 57 93 81 82 41 3 50 4 86 83 85 84 50 84 82 84 20 91 88 89 57 89 79 89 18 90 Page 23
Front and Rear Differential 78 87 57 84 88 83 86 84 85 83 82 84 50 84 83 84 50 57 83 82 80 4 78 Page 24
Front and Rear Shocks 63 73 73 64 67 26 73 72 33 34 73 63 74 74 75 73 64 67 74 72 74 73 67 72 74 73 73 70 74 73 26 34 67 75 74 73 68 73 66 74 74 65 77 73 71 72 73 33 72 71 72 72 73 73 45 72 73 71 73 44 72 71 73 74 72 74 72 74 74 69 76 74 72 74 72 74 74 75 73 70 74 73 75 45 44 75 Front Shock Rear Shock Page 25 75
Steering Bellcrank 3 95 56 3 56 95 95 165 95 34 36 95 95 34 95 95 95 95 95 13 95 34 95 13 95 45 52 51 45 95 45 56 13 95 45 95 52 45 95 95 56 95 Page 26 45
Front Suspension 111 47 110 160 35 111 116 28 B 160 24 48 130 109 6 25 13 106 107 107 57 23 54 118 57 34 50 128 106 127 107 107 40 127 23 Page 27 28
Front Gearbox Mount 37 5 115 37 99 3 8 162 3 34 163 19 161 23 61 112 125 62 163 18 3 24 18 108 17 112 133 37 133 3 45 133 133 44 133 38 133 45 133 44 133 Page 28 112
Center Driveshaft - Front 50 132 132 14 132 40 39 91 132 91 57 54 57 94 91 Page 29
Rear Suspension 45 44 53 45 40 127 19 111 57 54 128 34 119 57 111 130 28 6 28 120 160 46 35 28 24 117 48 25 160 28 Page 30
Rear Gearbox Mount 8 26 8 37 134 44 134 134 3 45 134 18 137 38 134 45 134 134 6 44 134 136 136 121 136 62 6 61 34 164 26 18 19 99 136 17 4 4 44 24 125 121 121 24 163 34 18 34 Page 31 163
Center Driveshaft - Rear 14 91 94 57 54 57 50 132 132 91 91 40 132 39 Page 32 132
Chassis 34 105 104 2 152 159 39 153 2 9 7 10 34 3 105 11 4 8 4 104 3 8 3 3 10 Page 33 9
Radio Tray Assembly 98 37 96 96 96 96 96 98 30 97 37 96 96 37 96 97 2 96 96 96 96 96 96 4 96 96 96 37 96 100 22 96 23 31 A 96 96 23 97 30 97 12 95 97 27 23 45 22 97 34 95 5 2 3 3 158 97 99 99 99 A Page 34 157 95 51
Engine/Clutch/Air Filter 148 149 149 149 154 150 32 149 151 155 17 139 138 141 142 147 140 143 144 145 146 55 55 26 140 15 Page 35 149
Fuel Tank 27 135 49 135 135 135 1 135 135 135 23 71 135 22 135 71 43 Page 36 43
Wheel and Tire 126 60 60 59 Page 37
Key # Stock# 1 SWK2022 2 SWK2024 3 SWK2026 4 SWK2028 5 SWK2032 6 SWK2036 7 SWK2054 8 SWK2056 9 SWK2062 10 SWK2064 11 SWK2074 12 SWK2087 13 SWK2089 14 SWK2106 15 SWK2122 16 SWK2124 17 SWK2128 18 SWK2130 19 SWK2139 20 SWK2141 21 SWK2222 22 SWK2224 23 SWK2226 24 SWK2232 25 SWK2254 26 SWK2282 27 28 29 30 31 32 SWK2290 SWK2292 SWK2296 SWK2306 SWK2311 SWK2324 Qty 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 2 8 8 8 8 8 8 8 Description 3mm x 6mm Flathead Screw 3mm x 8mm Flathead Screw 3mm x 10mm Flathead S
Key # Stock# 52 SWK2560 53 SWK2570 54 SWK2600 55 SWK2620 56 SWK2640 57 SWK2660 58 SWK2700 59 SWK2740 60 SWK2840 61 62 63 64 65 66 67 SWK3000 SWK3002 SWK3004 SWK3006 SWK3008 SWK3010 SWK3012 68 69 70 71 72 SWK3016 SWK3018 SWK3020 SWK3022 SWK3024 Qty 2 2 4 2 4 4 1 2 2 2 4 4 2 4 2 2 2 2 2 2 4 4 2 2 4 2 2 2 Description Tie Rod / Turnbuckle 4x50mm Camber Link / Turnbuckle 5x60mm Bearing Crush Sleeve Clutch Bearings 5x10x4mm Rubber Sealed Bearings 6x10x3mm Rubber Sealed BEarings 8x16x5mm Mayhem Buggy Body (C
Key # Stock# 74 SWK3028 Qty 2 2 2 2 4 2 2 2 2 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 Description Rear Shock Set Shock bladder Washer 2.5x5mm Adjustment collar O-ring Adjustment collar Shock O-ring Shock shaft bushing 3.4mm Shock shaft bushing 1mm 7mm snap ring Shock cap 1mm spring clip 2mm spring clip 3mm spring clip 4mm spring clip 5mm spring clip 6.8mm shock rod end Upper spring retainer Lower spring retainer Shock eyelet 3mm washer 3mm lock nut Shock adjustment collar 2.6mm lock nut Shock piston 2-hole 1.
Key # Stock# 91 SWK3098 Qty 1 1 1 1 1 1 93 94 95 SWK3104 SWK3106 SWK3108 1 1 2 1 1 1 1 1 4 1 1 1 1 2 1 1 3 3 1 2 2 1 1 1 1 Description Diff Housing Bag Lower diff housing Upper diff housing Bearing support Center diff housing (upper) Center diff housing (lower) Brake stand-off Brake Cam Bag Rear brake cam Front brake cam Brake post bushings 13T Differential Pinion Steering Servo Saver Bag Servo horn adapter 23T Servo horn adapter 24T Servo horn adapter 25T Steering servo arm Steering bellcrank bushin
Key # Stock# 99 SWK3116 100 104 SWK3118 SWK3126 Qty 2 2 1 1 1 2 1 1 1 105 SWK3128 1 1 106 SWK3130 4 4 4 4 8 107 108 109 110 111 SWK3132 SWK3134 SWK3136 SWK3137 SWK3138 4 4 2 2 2 2 2 2 2 4 112 SWK3140 1 1 Description Mount Bag Servo mounting pads Stand-up servo mounting pads Front body mount Rear body mount Transponder mount Steering servo mounts Switch Cover Bumper Bag Front bumper Rear bumper Chassis Mud Guard Bag Mud guard left Mud guard right Pillow Ball Assembly Bag Pillow ball 14.
Key # Stock# 134 SWK3182 Qty 2 2 4 1 2 4 2 135 SWK3184 1 1 1 1 1 1 1 2 1 1 1 2 136 137 138 139 140 141 142 SWK3186 SWK3188 SWK3190 SWK3192 SWK3194 SWK3196 SWK3198 2 2 2 1 1 1 1 4 3 3 Description Rear Sway Bar Bag Sway bar pivot ball 3mm x 14mm set screw 3mm x 3mm set screw Rear sway bar Sway bar mounts 6.8mm short rod end 6.
Setup Sheet Gearing: Driver Date Lap times Front Shocks: Clutch Bell Pistons Spur Gear Oil Clutch Shoe Position Springs Track Conditions: Lower mounting position on arm: In Out In Mid Differential Fluids: Traction: Slick Medium High Surface: Smooth Bumpy Rough Front Layout: Tight Medium Open Center Rear Front Suspension: Engine: Track/Width Type Camber Angle Plug Caster Position Forward Rearward Deck Clearance Rear Shocks: Toe In Exhaust Pistons Droop Fuel Oil Roll Ba
Setup Sheet - Stock Settings Gearing: Driver Track Lap times Front Shocks: Clutch Bell 14 Pistons 2 hole - 1.5mm (stock) Spur Gear 46 Oil 30 wt Clutch Shoe Position Trailing Springs Black Track Conditions: Lower mounting position on arm: Slick Medium High Surface: Smooth Bumpy Rough Front 5000 Layout: Tight Medium Open Center 5000 Rear 1000 Engine: Track/Width 12.1 in Camber Angle 1.5 degrees Forward Caster Position Droop Not used Roll Bar Stock Sportwerks .
Specifications and Other Information Brake Knob - Color Code Red - Rear brake Silver - Front brake Blue - Throttle The Mayhem Comes Filled with the Following Fluids Shocks - 30 wt. oil front and rear Differentials - Center - 5000 wt Front - 5000 wt Rear - 1000 wt Specifications - Chassis Overall Length - 492mm / 19.4 in Width - 310mm / 12.2 in Wheelbase - Adjustable 325mm–330mm / 12.8–13.0 in Caster angle - Adjustable 17–24 degrees Fuel tank capacity - 126cc Internal gear ratio - 3.
Differential Fluids Changing the viscosity of the fluid in the differentials affects the way the car handles and performs. The Mayhem differentials come prefilled with 5000 wt. fluid in the center and front and 1000 wt. fluid in the rear. For most conditions, this is a good place to start. Center: Changing the fluid in the center differential affects the front to rear drive. To conceptually understand how the center differential affects handling, think of it as frontwheel vs. rear-wheel drive.
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