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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,807 Points: 14,567 Location: ipswich
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STAGE 21A:
Oil filter, fittings and pipes.
Pic 1: Locate the cylinder head fittings 21E and 21F. They are marked ‘L’ and ‘R’.
Pic 2: Press the fittings into the end of the cylinder heads. They will only fit one way.
Pic 3: Press the two parts of the oil filter 21A and 21B together.
Pic 4: Attach the oil line 21I as shown.
Pic 5: Attach the oil line 21H as shown, using the hole nearest the end of the oil filter.
Pic 6: Attach the oil line 21G as shown, using the hole nearest the middle of the oil filter.
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: 4,807 Points: 14,567 Location: ipswich
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STAGE 21B:
Pic 7: Retrieve the chassis frame 20A from stage 20.
Note the bracket with two holes for fitting the oil filter.
Pic 8: Fit the oil filter to the bracket as shown and fix from behind with 2 x AP screws.
Pic 9: Fit the frame 20A up against the engine and connect the brake pipe 17C to the pin on the inside of the lower frame.
Pic 10: Fix the frame to the engine using 4 x AM screws.
Pic 11: Fix the end of the frame 20A to the cross member using 1 x BM screw.
Store the assembly and unused 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: 4,807 Points: 14,567 Location: ipswich
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STAGE 22A:
Rear suspension and oil pipes.
Pic 1: Retrieve the engine assembly and fit the oil pipe 21G into the hole in the engine front housing 3F.
Pic 2: Fit the oil pipe 21I to the pin on the side pipe of part 15C as shown.
Pic 3: Feed the pipe 21D between the side frames and connect the end to the engine housing 3F as shown.
Pic 4: Insert pipe 21C into the hole in the water pump 3G.
Pic 5: Fit the adjuster knob 22E to the shock absorber body 22D.
Pic 6: Fit the shock absorber to the frame 22C as shown and fix with 1 x BM screw.
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: 4,807 Points: 14,567 Location: ipswich
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STAGE 22B:
Pic 7: Fit the lower fork 22G through the side of the frame 22C. This fork is the shorter of the two supplied.
Fit the hub support 22B to the other side and fix with 1 x AM screw.
Pic 8: Fit the hub upright 22A to the assembly as shown and fix with 2 x AM screws and 1 x ABM screw.
NOTE: The printed instructions incorrectly label parts 22A and 22B.
Pic 9: Fit the coil spring 22F over the shock absorber body.
Pic 10: Turn the engine assembly upside down and fit the shock absorber body and coil spring over the damper as shown and then connect the end of the suspension arm 22C to the frame 17A.
Fix the parts with 1 x ADM screw.
Pic 11: Shows the stage so far. Save the unused fork 22H until next time.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: 4,807 Points: 14,567 Location: ipswich
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STAGE 23A:
Axle and brakes.
Pic 1: Locate the half-shaft parts 23A, 23B and 23C.
Pic 2: Fit the universal joint 23B into the yoke of the shaft 23C and fix with 2 x SM screws.
Pic 3: Fit the other half-shaft part 23A to the universal joint and fix with 2 x SM screws.
Pic 4: Press-fit the brake caliper parts 23E and 23F together as shown.
Pic 5: Fit the caliper part 23G as shown.
Pic 6: Note that all three holes should be on the same end of the caliper.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,807 Points: 14,567 Location: ipswich
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STAGE 23B:
Pic 7: Fit the curved pipe 23J to the holes in the caliper.
Pic 8: Fit the pipe 23J to the remaining upper hole in the caliper.
Pic 9: Fit the retaining bracket 23H as shown.
Pic 10: Push the tube 23K on to the end of the pipe 23J.
Pic 11: Retrieve the engine assembly and fit the hub part 23D to the upright 22A as shown and fix with 2 x AM screws.
Pic 12: Bend the upright 22A down and fit the caliper 23E as shown and fix using 2 x AM screws.
Pic 13: Connect the brake pipe 23K to the pin on the lower rail of the frame 20A.
Pic 13: Push the upper fork 22H from the previous stage through the end of the suspension arm 20D and then through the hole in the top of the upright 22A.
Fix from the other side with 1 x AM screw.
Store the assembly 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: 4,807 Points: 14,567 Location: ipswich
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STAGE 24A:
Rear stabilizer bar.
Pic 1: Locate the stabilizer bar mount 24A.
It will fit to the engine assembly where shown.
Pic 2: Fit the stabilizer mount 24A to the tops of the shock absorber mounts as shown and fix using 2 x TM screws.
Pic 3: Close up detail of the left side fixing.
Pic 4: Close up detail of the right side fixing.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,807 Points: 14,567 Location: ipswich
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STAGE 24B:
Pic 5: Assemble the stabilizer bar parts 24B and 2 x 24C and fix using 2 x BM screws.
Pic 6: Fit the stabilizer bar 24B in place on the top of the mount 24A.
Pic 7: Fit a securing bracket 24D in place as shown and fix with 1 x AM screw.
Pic 8: Fix the other side in the same way.
Pic 9: Fit the two lower ends of the stabilizer bars 24C to the protrusions on each lower end of parts 18C and 22C.
Lock them in place using one of the circlips 24E on each part.
This assembly will be easier with the engine upside down.
Pic 10: Stabilizer bar fitted.
Store the assembly 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: 4,807 Points: 14,567 Location: ipswich
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STAGE 25A:
Ignition coils.
Pic 1: Locate the ignition coil parts 25E and 25F.
Pic 2: Press-fit the parts together as shown.
Pic 3: Assemble the other three coils in the same way.
Pic 4: Locate the mounting bracket 25C and fit the coils in place from behind.
Pic 5: All coils fitted to the bracket 25C.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,807 Points: 14,567 Location: ipswich
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STAGE 25B:
Pic 6: Fit the 4 x small coil parts 25D as shown making sure the raised ‘dot’ is at the top left.
Pic 7: Fit the coil assembly to the frame 25A and fix using 2 x AP screws.
Pic 8: Fit the other frame 25B as shown and fix with 2 x AM screws.
Pic 9: Locate the wire 25G and cut off 4 x pieces:
2 x 25mm, 1 x 40mm and 1 x 45mm.
Fit them to the forward facing pins on the coil assembly in the order as shown.
Pic 10: From the wire 25G, cut another 4 x pieces:
2 x 40mm and 2 x 45mm.
These attach to the vertical pins on the coils.
Note the position of the coil assembly when fitting the wires.
Pic 11: Fit the coils and frame assembly to the top of the engine as shown.
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: 4,807 Points: 14,567 Location: ipswich
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STAGE 25C:
Pic 12: This shows the attachment of the coil frame on the left side.
Fix using 2 x AM screws through frame 16A.
Pic 13: This shows the attachment of the coil frame on the right side.
Fix using 2 x AM screws through frame 20A.
Pic 14: Locate the two forward facing 25mm wires from the first two coils on the left.
These attach to the two pins facing the rear on either side of the left distributor.
Pic 15: Locate the two forward facing wires from the two coils on the right.
The first wire is 40mm and the second one is 50mm.
These attach to the two pins facing the rear on either side of the right distributor.
Pic 16: Take the two 40mm wires from the top of the left coils and fit them to the two pins in the centre of the left distributor.
Pic 17: Take the two 45mm wires from the top of the right coils and fit them to the two pins in the centre of the right distributor.
Store the engine 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: 4,807 Points: 14,567 Location: ipswich
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STAGE 26:
Frame and pedals.
Pic 1: Fit the clutch pedal parts 26B and 26C together and fix using 1 x ABP screw.
Pic 2: Fit the brake pedal parts 26D and 26E together and fix using 1 x ABP screw.
Pic 3: Fit the accelerator pedal parts 26F and 26G together and fix using 1 x ABP screw.
Pic 4: Fit the accelerator cable 26H to the pin of the pedal lever 26G.
Pic 5: Fit the clutch pedal lever 26C to the frame 26A as shown.
Fix using 1 x MP screw.
Pic 6: Fit the brake pedal lever 26E to the frame 26A as shown.
Fix using 1 x MP screw.
Pic 7: Fit the accelerator pedal lever 26G to the frame 26A as shown.
Fix using 1 x MP screw.
Fit the end of the accelerator cable 26H to the pin on the lower end of the frame 26A.
Pic 8: Frame and pedals completed.roymattblack attached the following image(s):
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