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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 15A:
Tank system.
Pic 1: Retrieve the right engine half 7A and the spring 10H from the previous stages 7 and 10.
Pic 2: Fit the spring as shown between the brackets 10G and 9H.
Pic 3: Fit the support bracket 14D from stage 14 to the lower half of the tank 15E. The part will only fit one way.
Fix using 1 x AP screw.
Pic 4: Press-fit the lever and valve body parts 15I and 15J together.
The parts will only fit one way.
Pic 5: Fit the assembly into the hole in the end of part 15E and fix from underneath with 1 x AP screw.
Pic 6: Fit the tank cap parts 15F and 15G together as shown.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 15B:
Pic 7: Fit the cap assembly into the tank top 15D as shown and fix from below with 1 x KP screw.
Pic 8: Fit the two tank halves together and secure with 2 x AP screws.
Pic 9: Press-fit the pipe 15H onto the pin on the tank cap 15G.
Pic 10: Fit the small bracket 15K to the side of the engine as shown and fix with 2 x MP screws.
Pic 11: Fit the spring 13I from stage 13 between the two brackets 13H and 15K.
Pic 12: Fit the tank assembly to the engine half as shown and secure with 1 x SM screw through 14D from underneath.
Pic 13: Store the parts safely for now.roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 16A:
Left rear frame.
Pic 1: Fit the sump 9A from stage 9 to the engine assembly as shown.
Pic 2: Fit the pipe 15A from the previous stage as shown making sure the upper end locates in the side of the cylinder head.
Pic 3: Fit the other half of the engine in place, trapping the sump pins and the other side of the pipe 15A.
Pic 4: Fix the engine parts together with 4 x BM screws.
Pic 5: Fit the pipe 15B in place on the engine at the two locations indicated.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 16B:
Pic 6: Cut a 75mm piece of pipe from 13D, supplied in stage 13.
Fit one end to the upper pin on the end of the injection pump 9F and the other end to the 1st injector.
Pic 7: Cut an 80mm piece of pipe from 13D.
Fit one end to the second pin on the end of the injection pump 9F and the other end to the 2nd injector.
Pic 8: Cut a 95mm piece of pipe from 13D.
Fit one end to the lower pin on the end of the injection pump 9F and the other end to the 3rd injector.
Pic 9: Cut a 105mm piece of pipe from 13D.
Fit one end to the first pin on the middle of the injection pump 9B and the other end to the 4th injector.
Pic 10: Cut a 110mm piece of pipe from 13D.
Fit one end to the second pin on the middle of the injection pump 9B and the other end to the 5th injector.
Pic 11: Cut a 120mm piece of pipe from 13D.
Fit one end to the third pin on the middle of the injection pump 9B and the other end to the 6th injector. roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 16C:
Pic 12: Fit the intake box 14B from stage 14 onto the top of the cylinder head as shown.
Pic 13: Fit the 6 x intake trumpets 14C in place as shown.
Note that the trumpet nearest the front end of the engine is angled.
Pic 14: Store the engine assembly and unused pipe safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 17A:
Left rear frame.
Pic 1: Fit the shock absorber parts 16B, 16C and 16D from the previous stage together and fix with 1 x AM screw as shown.
Pic 2: Retrieve the frame 16A from the previous stage to fit the shock absorber.
Pic 3: Fit the shock absorber to the frame and fix from the other side with 1 x AM screw.
Pic 4: Fit the engine mounting bracket 16E to the engine and fix with 1 x BM screw. The large end of the bracket must face the rear of the engine.
NOTE: The printed instructions tell you to fit the bracket the wrong way round.
If you fit the bracket that way, the side frame will not fit later on.
Pic 5: Cut two lengths of pipe 17C to 110mm and 70mm.
Fit them to the union 17B as shown.
Pic 6: Fit the union 17B to the cross-member 17A.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 17B:
Pic 7: Fit the cross-member 17A to the frame 16A as shown and fix from the other side with 2 x AM screws.
Pic 8: Fit the 110mm pipe to the pin on the frame.
Pic 9: Fit the front cross-member 17D to the end of the frame 16A and fix from the other side using 1 x BM screw.
Pic 10: Fit the assembled frame to the side of the engine as shown and fix with 3 x AM screws.
You will now see why the front engine mount has to be fitted with the larger end facing the rear.
Pics 11, 12 and 13: Close up of the three screw fixing points.
Pic 14: Store the assembly safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 18:
Left rear suspension.
Pic 1: Press-fit the adjuster 18E into the side of the shock absorber 18D.
Pic 2: Fit the shock absorber to the swing arm 18C as shown and fix with 1 x BM screw.
Pic 3: Insert the lower fork 16G into the swing arm as shown.
Pic 4: Fit the support plate 18B to the assembly as shown and fix with 1 x AM screw.
Pic 5: Fit the hub support 18A as shown and fix with 2 x AM screws.
Pic 6: Turn the assembly around and fix the other end with 1 x ABM screw.
Pic 7: Fit the coil spring 18F over the shock absorber.
Pic 8: Fit the assembly to the engine as shown with the silver upper part of the shock absorber going into the orange body of the lower shock absorber.
Pic 9: Turn the assembly over and fit the end of the swing arm 18C into the bracket on the frame 17A.
Fix the parts together using 1 x ADM screw.
Pic 10: Store the assembly and unused fork part 18H safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 19A:
Axle and brake caliper.
Pic 1: Locate the axle parts 19A, 19B and 19C.
You will also need the SM screws.
Pic 2: Fit the universal joint 19B between the yoke on the half-shaft, 19C.
Fix from either side with 2 x SM screws.
Pic 3: Fit longer half-shaft in place as shown and fix using another 2 x SM screws.
Pic 4: Press-fit the caliper parts 19E and 19F together as shown.
Pic 5: Press-fit the other part of the caliper 19G in place as shown.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 19B:
Pic 6: Shows an end view of the assembly.
Pic 7: Press-fit the brake pipe 19J into the holes on each side of the caliper.
NOTE – Use the lower hole on part 19F.
Pic 8: Fit the other brake pipe 19I in the upper hole on part 19F as shown.
Pic 9: Press-fit the small bracket 19H to 19F, also fitting it over the brake pipe 19I.
Pic 10: Press the flexible hose 19K onto the end of the brake pipe 19I.
Pic 11: Store the parts safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 20A:
Right rear chassis.
Pic 1: Retrieve the engine assembly and fit the brake back plate 19D to the upright 18A and fix with 2 x AM screws.
Pic 2: Fit the brake caliper assembly from the previous stage to the upright as shown and fix with 2 x AM screws.
Pic 3: Fit the brake line 19K to the pin on the side of the frame as shown.
Pic 4: Retrieve the half shaft assembly from the previous stage and pass the longer end 19A through the hub upright.
Attach the other end 19C to the shaft 3C as shown.
Pic 5: Fit the yoke 18H through the hole in the end of the arm 16D, and then through the hole in the top of the upright 18A.
Pic 6: From the other side of the upright, fix the parts with 1 x AM screw.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,771 Points: 14,459 Location: ipswich
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STAGE 20B:
Pic 7: Locate the shock absorber parts 20B, 20C and 20D.
Assemble them as shown and fix the parts using 1 x AM screw.
Pic 8: Fit the assembly to the frame 20A as shown.
Pic 9: Fix from the other side using 1 x AM screw.
Pic 10: Fit the bracket 20E to the side of the engine as shown, fixing with 1 x BM screw.
NOTE – The printed instructions are incorrect.
The picture is correct but the text says to have the larger end of the bracket facing forwards. If this is done, the side frame will not fit later on.
Pic 11: Store the parts safely for now.
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