BUILD YOUR OWN. Pack 22

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Todd Booker
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1 BUILD YOUR OWN TM Pack 22 01

CONTENTS Assembly Guide 339 Stage 70: The front

Stage 72: Fitting the front fork assembly Editorial

Studios 2, 82 Silverthorne Road, London SW8 3HE.

Inc., 915 Broadway, Suite 609, New York, NY 10010.

2 CONTENTS Assembly Guide 339 Stage 70: The front brake lever Stage 71: The oil hose and the twistgrip Stage 72: Fitting the front fork assembly Editorial and design by Continuo Creative, 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., 915 Broadway, Suite 609, New York, NY All rights reserved 2015 Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown. TM

Stage 70 The front brake lever 1 Front brake lever

Front brake lever clamp Screws (type O) 2 Prepare the

Locate the two angled sections shown above, one at the

Polystyrene block or similar Front fork assembly (Stage10)

3 Stage 70 The front brake lever 1 Front brake lever assembly Handlebars Your parts Front brake lever assembly Front brake lever clamp Screws (type O) 2 Prepare the front fork assembly (Stage 10). Locate the two angled sections shown above, one at the right end of the handlebars and the other on the front brake lever assembly. 2 3 Tools Prepare Phillips screwdriver Masking tape Polystyrene block or similar Front fork assembly (Stage10) Prepare the two type O screws, a Phillips screwdriver and the front brake lever clamp. Align the angled sections of the brake lever assembly and the handlebar. Fit the brake lever assembly onto the handlebar, and adjust them so that their angled sections engage. 339

4 4 Hold the brake lever assembly in position and place the lever clamp on the underside of the handlebars, aligning its holes with those of the lever assembly Insert a type O screw into one of the holes and half-tighten it. Half-tighten another type O screw into the second hole, then fully tighten the first screw and then the second. The screws may have discoloured the finish of the parts when you tightened them. If they have, then you should touch up the discoloured areas with black paint. Stage complete 8 9 To protect the front assembly, and make it easier to work on in the next stage, tape it to a block of polystyrene foam or other suitable material. Pass the end of the brake hose through the gap between the forks. Be careful not to pull too hard on the hose, as the join (circled) is delicate. Insert the end of the brake hose into the hole in the back of the front brake. 340

5 Stage 71 The oil hose and the twistgrip 1 2 Remove the badge from the oil tank. Remove the type E screw from the centre of the tank. Your parts Right handlebar end Oil hose Grip plug Twistgrip Screws (type G) 2 3 Pin T-shaped end 4 T-shaped end Tools Prepare Phillips screwdriver Main frame (Stage 68) Left handlebar end assembly (Stage 69) Front fork assembly (Stage 70) Remove the oil tank from the main frame. Pin Identify the ends of the oil hose. 341

5 7 6 8 Line up the T-shaped end of the hose

tank cover. Push the end down into the cutout.

with the edge of the cover, as shown (green

11 10 Hold the oil tank in position on the side

Align the pin on the other end of the hose with

6 Line up the T-shaped end of the hose with the square cutout in the bottom of the oil tank cover. Push the end down into the cutout. Holding the T-shaped end as shown, line it up with the cutout. 9 The T-shaped end of the hose should be flush with the edge of the cover, as shown (green line) Hold the oil tank in position on the side of the frame. Align the pin on the other end of the hose with the hole below the clutch cover (circled, inset). The hole will be easier to see if you hold the brake pedal down Insert Hold the oil tank in position, release the brake lever and insert the pin at the end of the hose into the hole. Reinsert the type E screw into the hole in the centre of the oil tank. Tighten the type E screw into place.

7 Push the badge back into place. 16 Align the projection and the cutout, and push the grip onto the handlebar end. Push the twistgrip fully onto the handlebar end. Take the right handlebar end and the twistgrip, and locate the square projection on the handlebar end and the cutout on the grip (both circled) Insert a type G screw into the handlebar end. 20 Insert the grip plug into the end of the twistgrip. Tighten the type G screw into place. Push the plug fully into place. 343

8 Prepare the left handlebar end assembly (Stage 69). 24 Align the hole in the handlebar end with the shaped left-hand end of the handlebars. The left end of the handlebars is shaped to match the hole in the left handlebar end. 25 Stage complete 26 Align the hole in the right handlebar end with the right end of the handlebars. Push the right handlebar end into place on the handlebars. 344 Push the handlebar end onto the handlebars.

Stage 72 Fitting the front fork assembly 1 2 Remove the front fork

Locate the hole on the rear of the right front fork, and insert

Your parts Speedometer cable Steering stem and nut Brake hose

adhesive Main frame (Stage 71) Front fork assembly (Stage 71) 4

If the cable is a loose fit, put a small drop of multi-purpose

9 Stage 72 Fitting the front fork assembly 1 2 Remove the front fork assembly from the polystyrene block. Locate the hole on the rear of the right front fork, and insert one end of the speedometer cable into it. Your parts Speedometer cable Steering stem and nut Brake hose Black adhesive tape 3 Tools Prepare Pliers Tweezers Multi-purpose adhesive Main frame (Stage 71) Front fork assembly (Stage 71) 4 Push the speedometer cable fully into the hole. If the cable is a loose fit, put a small drop of multi-purpose adhesive into the hole to secure it. Hold the front assembly upright and gently pull the two cables wired into the green connector, to extend them fully. 345

5 6 Speedometer cable Left-hand cable Pass

the right front fork, then pass it across

two cables wired to the green connector,

7 Wrap the tape around the cables to fix

10 5 6 Speedometer cable Left-hand cable Pass the free end of the speedometer cable up the right front fork, then pass it across and hold it against the left-hand of the two cables wired to the green connector, as shown. 7 Wrap the tape around the cables to fix them together. 346 Using tweezers, place the black adhesive tape flat against the two cables. 8 Remove the nut from the steering stem, and put it safely to one side.

9 10 Block Support the main frame assembly on a

frame, and align the upper and lower yokes with the

Make sure the cables are not in the way by holding

11 12 Bring the front fork assembly towards the main

of the headstock as indicated in the previous step.

11 9 10 Block Support the main frame assembly on a block about 5cm high, as shown, to make it easier to work on. Then remove the fuel tank. Hold the front fork assembly in front of the main frame, and align the upper and lower yokes with the indicated points on the headstock. Make sure the cables are not in the way by holding them out to the sides Bring the front fork assembly towards the main frame, positioning the yokes at the top and bottom of the headstock as indicated in the previous step. Insert the steering stem into the hole in the top yoke, and push it down through the headstock and out through the bottom yoke. 347

12 Place the nut back onto the end of the steering stem, and hold it in place with your fingertip. Using your fingers, turn the top of the steering stem to screw it into the nut. 16 Hold the nut with pliers and keep turning the stem with your fingers. Don t turn the stem using the cross wrench or other tool, because then you risk overtightening it. That will restrict the movement of the fork assembly Gather up the three connectors on the cables coming from the headlight, instruments and indicators. Align the white connector with the white socket. Locate the three free sockets on the circuit board (circled). 348 Remove the block from under the frame and fold down the centre stand, as shown, to test it. Plug the white connector fully into its socket.

21 23 22 Push the yellow connector into the yellow

24 Carefully straighten out the cable coming from the

Then insert the green connector into the green 25 Pass

the headlight, and gently draw it back towards the

The cables 26 The cable that you just fitted into the

cables on the real motorcycle: the throttle and

This is done to reduce the number of cables on the

to the hole in the top of the cylinder head cover.

13 Push the yellow connector into the yellow socket. 24 Carefully straighten out the cable coming from the right handlebar end. Then insert the green connector into the green socket. 25 Pass the free end of the cable between the upper yoke and the headlight, and gently draw it back towards the engine. The cables 26 The cable that you just fitted into the cylinder head cover is designed to replicate two of the cables on the real motorcycle: the throttle and tachometer cables. This is done to reduce the number of cables on the model, which could potentially obstruct the interactive parts. 27 Using tweezers, thread the cable down past the horn to the hole in the top of the cylinder head cover. Insert the end of the cable into the hole in the cylinder head cover. If it won t stay in place, secure it with a drop of multi-purpose adhesive. Take the end of the cable coming from the left handlebar end, and pass it through the space between the speedometer and the tachometer. 349

14 Gently pull the cable downwards and backwards. Pass the end of the cable behind the frame, then back past the cylinders. Locate the hole in the front of the clutch cover, and align the end of the cable with it About 2.5cm (1in) Pin Insert the cable into the hole. Bend the tip towards you Take the brake hose and hold it with the pin at one end pointing upwards (red arrow). Bend the other end around until it is hooked over, as shown in the inset. 350 Insert the end of the brake hose into the indicated hole at the top of the brake assembly, just behind the back of the left fork. Pull the brake hose up, making sure that the bent end stays in the hole.

15 Hold Holding the bent end in place, pass the hose between the forks and down to the brake caliper. Push the pin into the hole. Insert the pin at the end of the brake hose into the circled hole in the brake caliper The brake hose should now look like this. Put the fuel tank temporarily back into position. Adjust the shape of the brake hose to keep it clear of the forks. Stage complete 351

16 Honda CB750 FOUR: TM 20

BUILD YOUR OWN. Pack 01

BUILD YOUR OWN. Pack 01 BUILD YOUR OWN TM Pack 01 01 CONTENTS Assembly Guide 03 Stage 1: The fuel tank Stage 2: The cylinder head cover and breather Stage 3: The front wheel and the instruments Stage 4: The handlebars Editorial