Pack 11
MOTORCYCLE
™
Editorial and design by Continuo Creative Ltd, London.
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 © 2019
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
™
57 Combining assemblies 142
58 The transmission case 153
59 The handlebar 155
60 The kickstand 160
61 The footrests 163
62 The clutch cable 168
141
STEP-BY-STEP ASSEMBLY
A. Transmission case inner
B. Speaker
C. Screws
D. Switch
E. Brackets
AB
C
D E
PARTS 58
A. Throttle cable
B. Box and mount
C. Fittings
D. Lever and ttings
E. Grips
F. Clutch cable and sleeve
A
B
CDE
PARTS 60
A. Engine guard
B. Footrests
C. Pillion footrest
D. Fittings
ABCD
PARTS 62
A. Transmission case outer
B. Screws
A
B
PARTS 59
A. Kickstand
B. Pillion footrest
C. Clip
D. Bolts
A
B
CD
PAR TS 61
A. Cap
B. Cover
C. Washer
D. Axle and nut
E. Frame cover
A B C
D
E
PARTS 63
YOUR PARTS
F
142
MOTORCYCLE
Build the
from ™
STAGE 57: COMBINING ASSEMBLIES
STEP 1 Take the transmission case
inner, brackets and two of the
smallest screws from Parts 58.
STEP 4 Secure the other bracket
in the same way, as shown.
STEP 2 Place one of the brackets
over the recess at the front of the
transmission case.
STEP 5 Prepare the gearbox
assembly from Stage 53.
STEP1
STEP4
STEP2
STEP5
STEP 3 Secure the bracket with
one of the small screws.
STEP 6 Remove the pin and
linkage from the assembly.
STEP3
STEP6
In this stage, you t new parts and complete assemblies.
143
STEP-BY-STEP ASSEMBLY
STEP 7 Hold the gearbox as
shown and place it into the space
in the frame behind the engine.
STEP 10 Tighten the second
screw from Parts 41 into the holes
on the right.
STEP 13 Tighten the long screw
from Parts 51 into the hole in the
underside, as shown.
STEP 8 Position the gearbox
centrally in the frame, aligning the
corresponding holes of both parts.
STEP 11 Tighten one of the longer
screws from Parts 51 into the lower
hole in the gearbox.
STEP 14 Retrieve one self-tapping
screw from Parts 51, the rear
fender and two of the screws from
Parts 40.
STEP7
STEP10
STEP13
STEP8
STEP11
STEP14
STEP 9 Tighten one of the screws
supplied with Parts 41 into the
aligned holes on the left.
STEP 12 Tighten the second screw
from Parts 51 into the second
lower hole.
STEP 15 Place the rear fender up
against the back of the gearbox
and the frame, aligning the
corresponding holes of both.
STEP9
STEP12
STEP15
144
MOTORCYCLE
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STEP 16 Secure the fender to
the gearbox with the self-tapping
screw.
STEP 19 Place the thin end of the
lever into the end of the linkage.
STEP 22 Pass the other end of
the linkage through the frame,
under the gearbox.
STEP 17 Secure the fender to the
frame with the two screws from
Parts 40.
STEP 20 Insert one of the bolts
through both parts.
STEP 23 Align the hole at the end
of the linkage with the hole in the
bracket and pass a bolt through.
STEP19
STEP22
STEP16
STEP20
STEP23
STEP17
STEP 18 Retrieve the linkage,
lever, nuts and bolts from Parts 55.
STEP 21 Tighten a nut onto the
end of the bolt.
STEP 24 Tighten a nut onto the
end of the bolt.
STEP21
STEP24
STEP18
145
STEP-BY-STEP ASSEMBLY
STEP 25 Prepare the drive chain
supplied with Parts 23
STEP 28 Place the plate onto the
side of the frame, aligning the
holes of both.
STEP 31 Prepare the transmission
case inner, speaker, switch, three
long screws and one washer
screw from Parts 58.
STEP 26 Place the chain around
the sprocket on the gearbox.
STEP 29 Tighten the shorter bolt
(Parts 19) into the forward hole.
STEP 34 Pass the speaker cable
through the square hole in the
transmission case.
STEP28
STEP25
STEP31
STEP29
STEP26
STEP32
STEP 27 Retrieve the gearshift
assembly from Stage 19.
STEP 30 Tighten the washer
screw into the central hole.
STEP 33 Place the speaker into
the ring in the case.
STEP30
STEP27
STEP33
146
MOTORCYCLE
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STEP 34 Lead the speaker
cable up through the hole in the
mounting plate.
STEP 37 Tighten one of the
screws into the aligned holes of
the case and engine.
STEP 40 Place the switch onto
the post, positioning the other end
between the two black parts.
STEP 35 Insert the D-shaped post
at the end of the linkage into the
hole at the top of the case.
STEP 38 Tighten the other two
screws into the other two holes.
STEP 41 Tighten the washer screw
into the hole in the post to secure
the switch.
STEP37
STEP40
STEP34
STEP38
STEP41
STEP35
STEP 36 Place the case inner
onto the side of the engine and
gearbox.
STEP 39 The switch has a hole
that matches the D-shaped post.
STEP 42 Test that when the gear
lever is shifted, that the switch
moves forward in the case.
STEP39
STEP42
STEP36
147
STEP-BY-STEP ASSEMBLY
STEP 43 Prepare the screws and
oil tank mounting plate (Parts 50)
and the circuit board (Parts 49).
STEP 46 Insert the assembly into
the oil tank, circuit board rst.
STEP 49 Pull the ends through
the top of the tank.
STEP 44 Place the circuit board
onto the corresponding posts
of the plate and secure with the
three screws.
STEP 47 Secure the parts
together with the screws.
STEP 50 Place the oil tank in the
frame, on top of the mounting
plate above the gearbox.
STEP46
STEP43
STEP49
STEP47
STEP44
STEP50
STEP 45 Retrieve the oil tank and
three screws from Parts 48.
STEP 48 Pass the cable ends up
through the hole in the oil tank.
STEP 51 Secure the oil tank from
inside the rear fender with two
screws (Parts 48).
STEP48
STEP45
STEP51
148
MOTORCYCLE
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STEP 52 Secure the front of the
oil tank with screws from Parts 58.
STEP 55 Pass the bolt back
through the linkage into the post,
and tighten into place.
STEP 58 Place the U-shaped
clamp over the inside of the frame
into the two holes on the inside of
the linkage.
STEP 53 Retrieve the linkage
removed in Step 6.
STEP 56 Retrieve the clutch
linkage from Stage 18, and the
U-shaped clamp and nuts from
Parts18.
STEP 59 Tighten the two nuts onto
the end of clamp.
STEP55
STEP58
STEP52
STEP56
STEP59
STEP53
STEP 54 Pass the linkage through
the frame, above the gearbox,
aligning the hole with the post.
STEP 57 Place the linkage onto
the left side of the frame, as
shown.
STEP 60 Place the end of the
linkage rod into the end of the
linkage. Use pliers to press
the parts together. Use glue to
strengthen the connection.
STEP57
STEP60
STEP54
149
STEP-BY-STEP ASSEMBLY
STEP 61 Prepare the rear wheel
from Stage 54 and the parts
shown from Parts 54 and 22.
STEP 64 Place the rear wheel
between the sides of the frame,
lifting the chain onto the sprocket.
STEP 67 Pass the axle through
the frame, bushing and wheel and
out the other side.
STEP 62 Place the bushing (Parts
54) into the centre of the rear
wheel.
STEP 65 Pull the chain around all
of the sprocket as shown, placing
the wheel into the ends of the
frames.
STEP 68 Fit the plate over the end
of the axle.
STEP64
STEP61
STEP67
STEP65
STEP62
STEP68
STEP 63 Place the brake disc
(Parts 22) onto it, as shown.
STEP 66 Place the bushing shaft
between the centre of the wheel
and the right side of the frame.
STEP 69 Tighten the nut onto the
end of the axle.
STEP66
STEP63
STEP69
150
MOTORCYCLE
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STEP 70 Place the lever onto the
post on the disc.
STEP 73 Tighten two nuts onto
the tensioner bolt on the other
side of the wheel.
STEP 76 Push the pins into the
holes in the tank.
STEP 71 Tighten the bolt into the
post to secure the lever.
STEP 74 Prepare the chain cover
(Stage 56), the bolt (Parts 58) and
the bracket (Parts 48).
STEP 77 Tighten the bolt into the
aligned holes of the bracket and
case.
STEP73
STEP76
STEP70
STEP74
STEP77
STEP71
STEP 72 Tighten two nuts onto
the tensioner bolt.
STEP 75 Take the bracket and
locate the corresponding holes
in the transmission case and the
oil tank.
STEP 78 Place the hole in the
chain cover plate over the post in
the frame.
STEP75
STEP78
STEP72
151
STEP-BY-STEP ASSEMBLY
STEP 79 Place the sissy bar
(Stage 16) either side of the
frame.
STEP 82 Slide the sissy bar
forward, making sure the strut is
inside the rear fender. Then secure
it in place with the screws from
Parts 47.
STEP 85 Tighten the shorter bolt
into the upper hole.
STEP 80 Align the end of the sissy
bar with the post in the frame that
the chain cover plate is on.
STEP 83 Prepare the rear lights
and bolts from Parts 46 and 47.
STEP 86 Tighten the longer bolt
into the lower hole.
STEP82
STEP79
STEP85
STEP83
STEP80
STEP86
STEP 81 Align the other end with
the hole in the frame, as shown.
STEP 84 Place the left rear lights
onto the end of the frame, aligning
the corresponding holes of both.
STEP 87 Place the right rear lights
onto the frame, aligning the holes.
STEP84
STEP81
STEP87
152
MOTORCYCLE
Build the
from ™
Stage complete
STEP 88 Tighten the short bolt into the upper hole. STEP 89 Tighten the long bolt into the lower hole.
STEP88 STEP89
153
STEP-BY-STEP ASSEMBLY
STEP1
STAGE 58: THE TRANSMISSION CASE
STEP 1 Prepare the cover and cap from Parts 56,
and the transmission case outer and screws (Parts
59).
STEP2
STEP3
STEP 2 Place the transmission case outer onto
the case inner, aligning the holes around the edges
of both.
STEP 3 Take one of the athead screws and tighten
it into the aligned holes at the back.
STEP 4 Tighten the two other athead screws into
the hole in the top and at the front.
STEP4
In this stage, you continue to assemble the transmission case.
154
MOTORCYCLE
Build the
from ™
Stage complete
STEP7
STEP5STEP6
STEP 5 Tighten the long screw into the hole at the
bottom of the transmission case.
STEP 6 Align the posts of the cover with the holes
in the transmission case.
STEP8
STEP 7 Press the cover into place. STEP 8 Fit the cap to the two holes in the middle of
the transmission case.
155
STEP-BY-STEP ASSEMBLY
STAGE 59: THE HANDLEBAR
STEP 1 Prepare all the Parts 60.
STEP 4 Fit the two parts together.
STEP 2 Take the box and mount,
and prepare the main assembly.
STEP 5 The two pins on the
bottom of the mount t into two
holes at the front of the engine.
STEP1
STEP4
STEP2
STEP5
STEP 3 The two pins on the box
t into two corresponding holes in
the mount.
STEP 6 Here is how the box
should look when tted to the
engine.
STEP3
STEP6
In this stage, you continue the main and handlebar assemblies
156
MOTORCYCLE
Build the
from ™
STEP 7 Prepare the ttings shown
above.
STEP 10 Place the bolt into the
hole in the linkage, as shown.
STEP 13 Fully tighten the bolt
through the bracket, into the
hole on the other side.
STEP 8 Place the hollow screw up
through the hole at the top of the
clutch linkage.
STEP 11 Place the U-shaped
bracket between the two holes
(see next step).
STEP 14 Prepare these parts.
STEP7
STEP10
STEP13
STEP8
STEP11
STEP14
STEP 9 Tighten the nut onto the
screw.
STEP 12 Turn the bolt through the
bracket to hold it in place.
STEP 15 Place the hinge over the
lever, aligning the holes, as shown.
STEP9
STEP12
STEP15
157
STEP-BY-STEP ASSEMBLY
STEP 16 Pass the bolt through the
aligned holes.
STEP 19 Prepare the headlight
(Stage 3), screws (Parts 58) and
the front fork assembly (Stage 9).
STEP 22 Tighten the second
screw into the second hole.
STEP 17 Tighten the nut onto the
other side of the bolt.
STEP 20 Align the pins and holes
of the headlight bracket with the
corresponding holes in the lower
triple trees.
STEP 23 Lead the cable back
between the forks.
STEP19
STEP22
STEP16
STEP20
STEP23
STEP17
STEP 18 Insert the post into the
hole in the lever.
STEP 21 Tighten one of the
screws into the holes.
STEP 24 Prepare the throttle
parts, shown above.
STEP21
STEP24
STEP18
158
MOTORCYCLE
Build the
from ™
STEP 25 Place the handlebar
clamp with the cable on the
underside of the right end of the
handlebar, as shown.
STEP 28 Place the spring onto
the handlebar, up against the
clamp. Insert the end of the spring
into the hole in the clamp.
STEP 31 Make sure you can still
twist the throttle. If not, loosen the
screw slightly.
STEP 26 Place the handlebar
clamp upper over the bar, onto
the lower part.
STEP 29 Slide the throttle sleeve
over the handle, engaging it with
the spring.
STEP 32 Slide the grip onto
the sleeve.
STEP28
STEP25
STEP31
STEP29
STEP26
STEP32
STEP 27 Secure the clamp halves
together with the two screws.
STEP 30 Tighten a screw into the
end of the handlebar to secure the
sleeve.
STEP 33 Push the grip all the way
up to the clamp.
STEP30
STEP27
STEP33
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