Pack 05
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
™
22 The transmission cover 56
23 The engine assembly 58
24 The oil lter 60
25 Fitting the oil lter 61
26 The distributor 63
27 The transmission cover 65
55
STEP-BY-STEP ASSEMBLY
A. Brake disc
B. Sprocket
A
B
PARTS 22
A. Crankcase
B. Tappet guide
C. Plug
D. Washer screws
A
BC
D
PARTS 24
A. Screws
B. Oil lter top
C. Oil lter
A
B C
PARTS 26
A. Drive chain
A
PARTS 23
A. Transmission case
B. Screws
A
B
PARTS 25
A. Screws
B. Transmission cover
C. Distributor base
D. Gasket
E. Distributor
A
BC D E
PARTS 27
YOUR PARTS
56
MOTORCYCLE
Build the
from ™
STEP1
STAGE 22: THE TRANSMISSION COVER
STEP 1 Prepare the tappet guide and plug from
Parts 24.
STEP2
STEP3
STEP 2 Align the end of the plug with the hole in
the guide.
STEP 3 Insert the end of plug into the hole. STEP 4 Here is how the assembly should look.
STEP4
In this stage, you will begin assembly of the engine.
57
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 Prepare the transmission case (Parts 25) and
the washer screw (Parts 24).
STEP 6 Take the guide and the transmission case,
and hold them as shown.
STEP8
STEP 7 Place the hole at the end of the tab over the
post, as shown.
STEP 8 Tighten the washer screw into the hole in the
post to secure the pieces together.
58
MOTORCYCLE
Build the
from ™
STEP1
STAGE 23: THE ENGINE ASSEMBLY
STEP 1 Prepare the transmission case from the
previous stage, as well as the crankcase (Parts 24)
and the screws from Parts 25.
STEP2
STEP3
STEP 2 Take the crankcase and the transmission
case, and hold them as shown.
STEP 3 Align the corresponding posts and holes of
both parts.
STEP 4 Press the posts into the holes.
STEP4
In this stage, you continue assembling the engine by
tting the crankcase and transmission cases together.
59
STEP-BY-STEP ASSEMBLY
Stage complete
STEP7
STEP5STEP6
STEP 5 Turn the assembly to the side and check that
the holes are aligned, as shown.
STEP 6 Tighten one of the screws into one of the
aligned holes.
STEP8
STEP 7 Tighten a screw into each of the two
remaining holes to secure the two parts together.
STEP 8 Here you can see how the assembly should
look with the screws in place.
60
MOTORCYCLE
Build the
from ™
STEP1
STAGE 24: THE OIL FILTER
STEP 1 Prepare the oil lter and oil lter top from
Parts 26.
STEP2
STEP3
STEP 2 The posts of the oil lter top are two
different sizes, so make sure before tting the parts
together that both are oriented correctly.
STEP 3 Push the posts of the top into the oil lter,
then press the two parts together.
In this stage, you assemble the oil lter.
Stage complete
61
STEP-BY-STEP ASSEMBLY
STEP1
STAGE 25: FITTING THE OIL FILTER
STEP 1 Prepare the engine assembly (Stage 23),
the oil lter (Stage 24) and the screws from Parts 26.
STEP2
STEP3
STEP 2 The oil lter has two pins and two holes
around the centre post at one end, and these
correspond with only one point on the engine
(see following steps).
STEP 3 Insert the central post at the end of the oil
lter into hole in the mount on the engine assembly.
STEP 4 Turn the oil lter so that the two pins
engage with their corresponding holes. The lter
can only t one way.
STEP4
In this stage, you t the oil lter to the engine assembly.
62
MOTORCYCLE
Build the
from ™
Stage complete
STEP7
STEP5STEP6
STEP 5 Tighten a screw into one of the aligned
holes from inside the mount.
STEP 6 Here you can see the screw in position.
STEP8
STEP 7 Tighten a second screw into the hole on the
other side of the post.
STEP 8 Here is how the assembly should look with
the oil lter xed in place.
63
STEP-BY-STEP ASSEMBLY
STEP1
STAGE 26: THE DISTRIBUTOR
STEP 1 Prepare the engine assembly (Stage 25)
and the gasket (Parts 27).
STEP2
STEP3
STEP 2 The central post on the reverse of the gasket
is D-shaped, so will only t into the engine one way.
STEP 3 Hold the gasket so that the D-shaped post is
aligned with the matching hole in the engine.
STEP 4 Press the gasket into place.
STEP4
In this stage, you t the gasket and distributor to the engine assembly.
64
MOTORCYCLE
Build the
from ™
Stage complete
STEP7
STEP5STEP6
STEP 5 The posts and holes of the distributor
and distributor base (Parts 27) only t together
in one orientation.
STEP 6 Press the two parts of the distributor
together, as shown.
STEP8
STEP 7 Align the post on the distributor with the
hole in the gasket.
STEP 8 Push the post into the hole.
65
STEP-BY-STEP ASSEMBLY
STEP1
STAGE 27: THE TRANSMISSION COVER
STEP 1 Prepare the engine assembly (Stage 26),
the transmission cover and screws (Parts 27).
STEP2
STEP3
STEP 2 Align the edge of the transmission cover with
the raised edge of the transmission case.
STEP 3 Place the cover onto the case, keeping the
edges aligned.
STEP 4 Hold the two parts together, making sure
that the holes of both are aligned.
STEP4
In this stage, you will t the transmission cover to the engine.
66
MOTORCYCLE
Build the
from ™
Stage complete
STEP7
STEP5STEP6
STEP 5 Tighten one of the screws into the hole at the
end, using a at-head screwdriver.
STEP 6 Working around the edge, tighten another
screw into the next hole.
STEP8
STEP 7 Tighten a third screw into the next hole
around the edge of the transmission cover.
STEP 8 Tighten the rest of the screws into the
remaining holes to secure the cover to the case.
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