Pack 07
MOTORCYCLE
™
Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP.
Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE.
Published in the USA by De Agostini Publishing USA, Inc.,121 E. Calhoun Street, Woodstock, IL 60098.
All rights reserved © 2018
Warning: Not suitable for children under the age of 14.
is product is not a toy and is not designed or intended for use in play.
Items may vary from those shown.
MOTORCYCLE
™
32 The front cylinder 81
33 The rear wheel 83
34 The carburettor 85
35 The carburettor 87
36 The frame 89
37 The air lter 91
38 The ignition 93
80
STEP-BY-STEP ASSEMBLY
A. Cylinder head
B. Cylinder head top
C. Exhaust spigot
A B
C
PARTS 34
A. Float bowl
B. Gasket
C. Spring
D. Bracket plate
E. Air intake
F. Manifold
G. Bracket
H. Fuel valve
I. Screws
AB
C
D
EF
GHI
PARTS 36
A. Air lter cover
B. Air lter
C. Air lter back plate
ABC
PARTS 38
A. Rear wheel
B. Air valve
A
B
PARTS 35
A. Screws
B. Nut and bolt
C. Mounting plate
D. Bracket
E. Frame cross member
F. Bolts (short)
AB
C
D
E
F
PARTS 37
A. Hose A
B. Hose B
C. Hose C
D. Hose D
E. Ignition switch
F. Ignition key
ABCD
E
PARTS 39
YOUR PARTS
F
81
MOTORCYCLE
Build the
from ™
STEP1
STAGE 32: THE FRONT CYLINDER
STEP 1 Prepare the engine assembly, the cylinder
(Parts 28) and Parts 34.
STEP2
STEP3
STEP 2 Take the cylinder from Parts 28, stamped ‘2’
on the inside, and the engine.
STEP 3 Align the hole in the centre of the cylinder
with the post on the cylinder base.
STEP 4 Place the cylinder onto the post, then,
turn the cylinder so the bottom matches the base.
STEP4
In this stage, you continue tting parts of the front cylinder.
82
STEP-BY-STEP ASSEMBLY
Stage complete
STEP 5 Align the bottom of the
cylinder head with the post and
the top of the cylinder.
STEP 8 Press the top into place.
STEP 6 Place the head in position.
STEP 9 This is how the assembly
should look now.
STEP5
STEP8
STEP6
STEP9
STEP 7 Align the pins on the
clyinder head top with the holes in
the cylinder head.
STEP 10 Insert the pin of the
exhaust spigot into the hole in the
cylinder head.
STEP7
STEP10
83
MOTORCYCLE
Build the
from ™
STEP1
STAGE 33: THE REAR WHEEL
STEP 1 Ypu will need the rear tyre from Parts 30
and the wheel and valve from 35.
STEP2
STEP3
STEP 2 Take the rear wheel and valve, and locate
the hole in the inside of the outer part of the wheel.
STEP 3 Align the D-shaped pin on the valve
correctly with the hole in the wheel.
STEP 4 Insert the pin into the hole.
STEP4
In this stage, you t the rear tyre and valve to the rear wheel.
84
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 This is how the valve should look when
in place.
STEP 6 Gently push the solid rim of the wheel into
the inside of the tyre.
STEP8
STEP 7 Work your way around the wheel, pulling
the tyre onto the wheel.
STEP 8 Turn them over and repeat on the
other side.
85
MOTORCYCLE
Build the
from ™
STEP1
STAGE 34: THE CARBURETTOR
STEP 1 Prepare all of the Parts 36. Take the oat
bowl and air intake.
STEP2
STEP3
STEP 2 Align the post in the centre of the oat bowl
with the hole in the air intake.
STEP 3 Press the two parts together. STEP 4 Align the post at the end of the intake
with the matching hole in the gasket.
STEP4
In this stage, you will assemble the carburettor.
86
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 Push the gasket onto the intake. STEP 6 Align the post on the other side of the
gasket with the matching hole in the manifold.
STEP8
STEP 7 Insert the post into the hole. STEP 8 Push the parts together.
87
MOTORCYCLE
Build the
from ™
STEP1
STAGE 35: THE CARBURETTOR
STEP 1 Prepare the carburettor and the bracket
plate, bracket and screws from Parts 36.
STEP2
STEP3
STEP 2 Align the holes in the bracket plate with
those in the air intake.
STEP 3 Place the bracket over the bracket plate,
aligning the holes of all the parts.
STEP 4 Tighten one of the screws into one of the
aligned sets of holes.
STEP4
In this stage, you continue the carburettor assembly.
88
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 Tighten a second screw into the other hole
to secure the parts.
STEP 6 This is how the parts should now look.
STEP8
STEP 7 Take the fuel valve and align the D-shaped
hole with the matching post on the side of the bowl.
STEP 8 Push the valve into place.
89
MOTORCYCLE
Build the
from ™
STEP1
STAGE 36: THE FRAME
STEP 1 Prepare the frame assembly Stage 17
and the components from Parts 37, apart from
the two bolts (F).
STEP2
STEP3
STEP 2 Align the holes at each end of the frame
cross member with the corresponding holes in the
frame sides.
STEP 3 Tighten a screw into the aligned holes on the
left side of the frame.
STEP 4 Then tighten another screw into the
aligned holes on the right side. Look over the
following steps before proceeding.
STEP4
In this stage, you continue work on the frame.
90
STEP-BY-STEP ASSEMBLY
Stage complete
STEP 5 Insert the longer bolt (B)
through the hole in the mounting
plate, as shown.
STEP 8 Place the nut onto the end
of the bolt.
STEP 6 Insert the post at the
end of the bracket into the hole
in the frame.
STEP 9 Holding the nut in place,
tighten the bolt.
STEP5
STEP8
STEP6
STEP9
STEP 7 Take the mounting plate
and insert the end of the bolt
through the frame into the hole in
the bracket.
STEP 10 The mounting plate and
bracket should now be secured.
STEP7
STEP10
91
MOTORCYCLE
Build the
from ™
STEP1
STAGE 37: THE AIR FILTER
STEP 1 You will need the three air lter components
from Parts 38, plus the carburettor assembly.
STEP2
STEP3
STEP 2 Prepare the air lter cover and the air lter.
STEP 3 Turn the parts around, and align the holes
with the posts.
STEP 4 Place the lter into the cover, keeping the
holes aligned.
STEP4
In this stage, you will assemble the air lter.
92
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 Now take the air lter back plate and insert
the three posts into the holes.
STEP 6 Press the back plate into place.
STEP8
STEP 7 Align the post at the end of the air intake
with the hole in the centre of the back plate.
STEP 8 Insert the post into the hole, and press the
parts together.
93
MOTORCYCLE
Build the
from ™
STEP1
STAGE 38: THE IGNITION
STEP 1 Prepare the ignition switch and the ignition
key from Parts 39.
STEP2
STEP3
STEP 2 Hold the key and switch as shown. The key
ts only one way.
STEP 3 Push the key into the switch. STEP 4 Here is the key in place. The switch won’t
be tted until a later stage, so remove the key and
keep both parts safely to one side.
STEP4
In this stage, you test-t the ignition key.
/
