BKB Duo Assembly (V2)

Gather the wheels, bearings, T Tool, and one truck hanger

Use the T tool to remove the locknut and washers from one side of the truck

Place one bearing onto the truck with the black covered side towards the center

Push a wheel onto the bearing and truck to install it

Place one bearing onto the truck with the black covered side towards the center. Then add a silver spacer onto the truck

Push the wheel onto the bearing and truck to install it

Repeat this process to complete all four wheels

Later on in the tutorial you will need to know the difference between the front and rear truck.

The front truck has a wider hanger

The rear truck has a shorter hanger to accommodate the gear assembly and wheel pulley

IMPORTANT NOTE: If you have the TorqueMonster upgrade/Extended trucks, both front and back hangers are the same lengths.

Gather the truck baseplates, truck hangers, and T-Tool

Remove the locknut from each baseplate

Remove one bushing and washer from each baseplate

Place a truck hanger in the baseplate with the words facing inward

Place the bushing and washer back on and tighten the locknut

If your having trouble getting the locknut to start threading, make sure the hanger is pushed all the way into the base of the baseplate (where the hanger comes to a rounded point). You can also apply pressure down on the truck to compress the bushings

Repeat this process to complete two trucks

Gather the front truck, two wheels, and T-Tool

Remove one locknut and one washer from each side of the truck. Make sure there is still one washer on the truck

TorqueMonster/Extended Trucks require a silver spacer between the wheel and hanger for proper fitment.

Place one wheel on each side with the letters facing outward

Add the washer and locknut back onto the truck. From inside to outside the components should be arranged: washer, wheel, washer, locknut

Repeat on the other side to secure both wheels

Gather the allen wrench, motors, motor mounts, cross bar, Loctite, and motor hardware.

We no longer include the Red Cross bar with the motor mounts. So, do not expect it to be in your package

The motor hardware is labeled on the plastic bag for easy identification.

One motor mount has a dot cut out on each side. This needs to have the left motor (marked with an 'O' sticker) attached to it.

The 'left' motor is when the front of the board is pointing away from you, and the bottom of the board is facing up, this side has the padding on it.

One motor should have an 'O' sticker, but if it does not that is okay. You can use either motor and switch the motor direction later if need be

To open the loctite, break off the end cap and then flip it over to puncture a hole in the capsule using the prong on the inside of the cap.

If you will be doing this project in multiple stages, please don't proceed unless you are able to commit to a final location for all screws that have loctite applied. The loctite will dry in 24 hours making further assembly more difficult.

Place the motor mount on top of the motor with the wires oriented as shown

Add a drop of loctite to each motor screw before installing

Anytime there is a blue circle in a photo it represents where a drop of loctite needs to be added

Install 4 motor screws to attach the motor to the motor mount.

Repeat this process to attach the other motor to the motor mount

Ensure you use Loctite on each bolt

Gather the motor pulleys, 2mm Allen wrench, and Loctite

Remove the set screw from the motor pulley

Add Loctite to the set screw

Reinstall the set screw into the pulley. If you turn the set screw in too much to the point it is visible in the center of the shaft hole, it will not slide onto the motor

Repeat this process for the other motor pulley

Add two drops of Loctite to each motor shaft

Place the motor pulley onto the motor shaft

It is a tight fit and need to be aligned properly. If the motor pulley only goes part of the way on, use the Allen wrench to loosen the set screw

Ensure the motor pulley is pushed all the way on the motor shaft and then tighten the set screw

Repeat this process to install the motor pulley on the other motor

Use the 5mm Allen wrench to loosen the motor mount bolts

Slide the motor mounts onto the rear truck

They should go on the side of the truck with the "protrusion", not the large lock nut.

Align the motor mount assembly to the center of the truck. There should be even spacing on both sides of the truck, and the motors should be level with one another.

Tighten the bolts on the motor mount evenly. You should turn each bolt 1/4 to 1/2 a turn at a time. Then tighten the other bolt 1/4 to 1/2. This ensures there is even pressure on each bolt

There is a gap on the top and bottom in between the clamp and motor mount. This gap should be the same on the top and bottom. If they are different, loosen the bolts and retighten them

Since the cross bard is no longer included you will need to install the motor mounts in a different manner. You can align the motor mounts by eye (to the center) and then use the black 3d printed spacer to place between the wheel pulley and motor mount for final alignment.

Use the T Tool to remove the locknut and 1x washer from the truck

Slide the wheel pulley and belt onto the truck

Place the belt over the motor pulley. You will need to slide the motor all the way forward and the four bolts securing the motor will need to be loose to accomplish this

Slide the wheel onto the truck with the words facing outwards

Add the washer and locknut back onto the truck. Tighten with the T Tool

Do NOT over tighten the locknut. You should be able to move the wheel laterally on the axle back and forth ever so slightly

Now it is time to tension the belt. Pull back on the motor until the there is decent tension in the belt

While holding tension in the belt tighten one bolt

You can now test the tension by pressing down in the area located at the green area. The belt should move up and down 2-3mm with your press.

If it is too stiff and does not move, there is too much tension in the belt. Loosen the bolt and try again

If the belt depresses more than 4mm, there is not enough tension. Loosen the bolt and apply more tension.

When the proper tension has been achieved, tighten all four bolts to lock the motor in position

Repeat steps 18-20 to complete assembly of the other side of the drivetrain. Ensure proper belt tension

RailCore board? Time to switch back to your RailCore Tutorial! (Skip to step # 19!)

Gather the drivetrain, front truck, top rails, risers, truck hardware, wrench, 3mm Allen wrench, and deck

The risers are not 100% required. We would highly recommend starting with them as the enclosure is quite deep, they will provide more ground clearance. If you are using the 105mm Cloud Wheels we would only recommend the risers if you are over 200lb. The risers are not needed for the 6in AT Wheels

There are two different front rails, a left and a right. Take a left and right rail, place the truck bolts through them and then press the bolts through the front of the deck

The front of the deck does NOT have the large foam pad. The foam pad is for the enclosure and this is the rear of the deck

Add a riser to the underside of the deck over the bolts

Slide the front truck over the bolts and then secure it by installing a locknut on each bolt

Repeat this process for the rear truck. Place bolts through the top rails and then through the deck

Add a riser to the underside of the deck over the bolts

Add the drivetrain with the motors facing the rear to the bolts (do not add the locknuts yet)

Add a wire clip to each motor and orientate them as shown. Then slide a wire clip over each of the two inner bolts

Secure all four bolts with a locknut

If your Xenith was already installed in the enclosure do NOT remove it. You can skip the following steps where it is installed

NOTE: If you purchased the Bluetooth module it will be pre-installed under the silicone case of the Xenith. So it will not be visible, but it is there.

Gather the Xenith, Xenith gasket, M4x10 button head bolts, and 2.5mm Allen wrench

Remove the paper backing off of the gasket, then slide it over the red heatsink

Place the Xenith in the enclosure as shown

Add a drop of Loctite to each bolt and then secure the heatsink to the enclosure

Remove the locknut from the charge port

Slide the charge port through the hole in the left side of the enclosure

Reinstall the locknut to secure the charge port

Remove the locknut from the switch

Place the switch in the hole on the right side of the enclsoure

Reinstall the locknut to secure the switch

Place the battery inside the enclosure

If you have the standard 10s3p Battery please see the next step for placement

Plugin the battery to the Xenith

This step is only for users with the smaller 10s3p battery. Type R users can skip.

The10s3p battery has a wide side and a shorter side. Peel the paper backing off of the gasket on the wide side. Leave the paper on the short side

Firmly press the battery into the enclosure as shown so charge port and battery wires are near the charge port side

Plugin the switch to the SWITCH port on the Xenith

Tuck all of the wires in neatly

Peel the paper backing off of the receiver and then place it in the enclosure as shown next to the charge port

Plug the receiver into the UART port on the Xenith

Position the enclosure, deck, and motors as shown

Plug the upper motor cables into the Xenith cables as shown. Do NOT swap the cables. Be extra sure they are plugged in EXACTLY as shown

You plug the yellow motor connectors together as well as place the white motor connector into the MSENSOR port on the Xenith (there are two ports, reference the photo to see where to plug them in)

Then plug the lower motor cables into the upper Xenith cables. Double check the wiring is exactly as shown

To attach the enclosure you will need to fold all of the wires flat and ensure the large yellow connectors are laying flat as well.

Position all of the wires as shown. Then use your hand to keep all wires in place and flip the enclosure over. Ensure you are flipping it the correct direction so the motor wires untangle themselves. They should now be straight directly from the motor and into the enclosure

If the enclosure does not sit flat, use your hand to move the wires around inside the enclosure until everything fits

It is important to attach the bolts in the correct order so that all bolts, and correct alignment for the enclosure is achieved. Follow the steps below carefully.

Align the enclosure over the deck's bolt holes, note that these holes are threaded. Prepare the enclosure bolts. Add a metal washer and rubber washer to each bolt. The order of parts when assembled should be bolt, metal washer, rubber washer, enclosure. Add a drop of loctite to each bolt!

Add the bolt to the left side, second from the top (red circle). Do not tighten it fully, get the threads started (loctite)

Then add the bolt to the other side (right red circle). Do not tighten fully. You may need to provide some force to move the enclosure towards the bolt holes as shown in the second photo (loctite)

Then add the two bolts in the orange circles (loctite)

Add the bolts to the yellow circles (loctite)

Finally add the bolts to the green circles

After all bolts are started, tighten them in the same order to the point where the rubber washer is compressed, but not misshapen. If you cannot get a bolt to start threading, remove all of the bolts. Then start with the bolt that wouldn't start threading and continue adding all of the bolts.