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MOTORCYCLE

Pack 05

MOTORCYCLE ™ 22 The transmission cover 56 23 The engine assembly 58 24 The oil

MOTORCYCLE

MOTORCYCLE ™ 22 The transmission cover 56 23 The engine assembly 58 24 The oil filter

22 The transmission cover

56

23 The engine assembly

58

24 The oil filter

60

25 Fitting the oil filter

61

26 The distributor

63

27 The transmission cover

65

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. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown.

the age of 14. This product is not a toy and is not designed or intended
STEP-BY-STEP ASSEMBLY YOUR PARTS PARTS 22 B A PARTS 23 A A. Brake disc B.
STEP-BY-STEP ASSEMBLY YOUR PARTS PARTS 22 B A PARTS 23 A A. Brake disc B.

STEP-BY-STEP ASSEMBLY

STEP-BY-STEP ASSEMBLY YOUR PARTS PARTS 22 B A PARTS 23 A A. Brake disc B. Sprocket

YOUR PARTS

STEP-BY-STEP ASSEMBLY YOUR PARTS PARTS 22 B A PARTS 23 A A. Brake disc B. Sprocket
PARTS 22 B A
PARTS 22
B
A
PARTS 23 A
PARTS 23
A

A. Brake disc

B. Sprocket

A. Drive chain

PARTS 24 A B C D
PARTS 24
A
B
C
D

A.

B. Tappet guide

C. Plug

Crankcase

D. Washer screws

PARTS 25 A B
PARTS 25
A
B

A. Transmission case

B.

Screws

PARTS 26 B C A
PARTS 26
B
C
A
PARTS 27 B C D E A
PARTS 27
B
C
D
E
A

A.

Screws

A.

Screws

D. Gasket

B.

Oil filter top

B.

Transmission cover

E. Distributor

C.

Oil filter

C.

Distributor base

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Build the MOTORCYCLE from
Build the
MOTORCYCLE
from
Build the MOTORCYCLE from ™ STAGE 22: THE TRANSMISSION COVER In this stage, you will begin

STAGE 22: THE TRANSMISSION COVER

In this stage, you will begin assembly of the engine.

STEP 1
STEP 1

STEP 1 Prepare the tappet guide and plug from Parts 24.

STEP 2
STEP 2

STEP 2 Align the end of the plug with the hole in the guide.

STEP 3
STEP 3

STEP 3 Insert the end of plug into the hole.

STEP 4
STEP 4

STEP 4 Here is how the assembly should look.

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56
STEP 5
STEP 5

STEP 5 Prepare the transmission case (Parts 25) and the washer screw (Parts 24).

STEP 7
STEP 7

STEP 7 Place the hole at the end of the tab over the post, as shown.

the hole at the end of the tab over the post, as shown. STEP-BY-STEP ASSEMBLY STEP
the hole at the end of the tab over the post, as shown. STEP-BY-STEP ASSEMBLY STEP

STEP-BY-STEP ASSEMBLY

of the tab over the post, as shown. STEP-BY-STEP ASSEMBLY STEP 6 STEP 6 Take the
STEP 6
STEP 6

STEP 6 Take the guide and the transmission case, and hold them as shown.

the guide and the transmission case, and hold them as shown. STEP 8 STEP 8 Tighten
STEP 8
STEP 8

STEP 8 Tighten the washer screw into the hole in the post to secure the pieces together.

Stage complete 57
Stage complete
57
Build the MOTORCYCLE from
Build the
MOTORCYCLE
from
Build the MOTORCYCLE from ™ STAGE 23: THE ENGINE ASSEMBLY In this stage, you continue assembling

STAGE 23: THE ENGINE ASSEMBLY

In this stage, you continue assembling the engine by fitting the crankcase and transmission cases together.

STEP 1
STEP 1

STEP 1 Prepare the transmission case from the previous stage, as well as the crankcase (Parts 24) and the screws from Parts 25.

STEP 2
STEP 2

STEP 2 Take the crankcase and the transmission case, and hold them as shown.

STEP 3
STEP 3

STEP 3 Align the corresponding posts and holes of both parts.

STEP 4
STEP 4

STEP 4 Press the posts into the holes.

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STEP 5
STEP 5

STEP 5 Turn the assembly to the side and check that the holes are aligned, as shown.

STEP 7
STEP 7

STEP 7 Tighten a screw into each of the two

remaining holes to secure the two parts

together.

of the two remaining holes to secure the two parts together. STEP-BY-STEP ASSEMBLY STEP 6 STEP
of the two remaining holes to secure the two parts together. STEP-BY-STEP ASSEMBLY STEP 6 STEP

STEP-BY-STEP ASSEMBLY

to secure the two parts together. STEP-BY-STEP ASSEMBLY STEP 6 STEP 6 Tighten one of the
STEP 6
STEP 6

STEP 6 Tighten one of the screws into one of the aligned holes.

6 Tighten one of the screws into one of the aligned holes. STEP 8 STEP 8
STEP 8
STEP 8

STEP 8 Here you can see how the assembly should look with the screws in place.

Stage complete 59
Stage complete
59
Build the MOTORCYCLE from
Build the
MOTORCYCLE
from
Build the MOTORCYCLE from ™ STAGE 24: THE OIL FILTER In this stage, you assemble the

STAGE 24: THE OIL FILTER

In this stage, you assemble the oil filter.

STEP 1
STEP 1

STEP 1 Prepare the oil filter and oil filter top from Parts 26.

STEP 2
STEP 2

STEP 2 The posts of the oil filter top are two different sizes, so make sure before fitting the parts together that both are oriented correctly.

STEP 3
STEP 3

STEP 3 Push the posts of the top into the oil filter, then press the two parts together.

Stage complete
Stage complete
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60
STEP-BY-STEP ASSEMBLY STAGE 25: FITTING THE OIL FILTER In this stage, you fit the oil
STEP-BY-STEP ASSEMBLY STAGE 25: FITTING THE OIL FILTER In this stage, you fit the oil

STEP-BY-STEP ASSEMBLY

STEP-BY-STEP ASSEMBLY STAGE 25: FITTING THE OIL FILTER In this stage, you fit the oil filter
STEP-BY-STEP ASSEMBLY STAGE 25: FITTING THE OIL FILTER In this stage, you fit the oil filter

STAGE 25: FITTING THE OIL FILTER

In this stage, you fit the oil filter to the engine assembly.

STEP 1
STEP 1
STEP 2
STEP 2

STEP 1 Prepare the engine assembly (Stage 23), the oil filter (Stage 24) and the screws from Parts 26.

STEP 2 The oil filter 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
STEP 3

STEP 3 Insert the central post at the end of the oil

filter into hole in the mount on the engine

assembly.

STEP 4
STEP 4

STEP 4 Turn the oil filter so that the two pins engage with their corresponding holes. The filter can only fit one way.

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Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten a screw into one of

Build the

MOTORCYCLE

from

Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten a screw into one of the
Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten a screw into one of the

STEP 5
STEP 5

STEP 5 Tighten a screw into one of the aligned holes from inside the mount.

STEP 7
STEP 7

STEP 7 Tighten a second screw into the hole on the other side of the post.

STEP 6
STEP 6

STEP 6 Here you can see the screw in position.

STEP 8
STEP 8

STEP 8 Here is how the assembly should look with the oil filter fixed in place.

Stage complete 62
Stage complete
62
STEP-BY-STEP ASSEMBLY STAGE 26: THE DISTRIBUTOR In this stage, you fit the gasket and distributor
STEP-BY-STEP ASSEMBLY STAGE 26: THE DISTRIBUTOR In this stage, you fit the gasket and distributor

STEP-BY-STEP ASSEMBLY

STEP-BY-STEP ASSEMBLY STAGE 26: THE DISTRIBUTOR In this stage, you fit the gasket and distributor to
STEP-BY-STEP ASSEMBLY STAGE 26: THE DISTRIBUTOR In this stage, you fit the gasket and distributor to

STAGE 26: THE DISTRIBUTOR

In this stage, you fit the gasket and distributor to the engine assembly.

STEP 1
STEP 1
STEP 2
STEP 2

STEP 1 Prepare the engine assembly (Stage 25) and the gasket (Parts 27).

STEP 2 The central post on the reverse of the gasket is D-shaped, so will only fit into the engine one way.

STEP 3
STEP 3

STEP 3 Hold the gasket so that the D-shaped post is aligned with the matching hole in the engine.

STEP 4
STEP 4

STEP 4 Press the gasket into place.

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Build the MOTORCYCLE from ™ STEP 5 STEP 5 The posts and holes of the

Build the

MOTORCYCLE

from

Build the MOTORCYCLE from ™ STEP 5 STEP 5 The posts and holes of the distributor
Build the MOTORCYCLE from ™ STEP 5 STEP 5 The posts and holes of the distributor

STEP 5
STEP 5

STEP 5 The posts and holes of the distributor and distributor base (Parts 27) only fit together in one orientation.

STEP 7
STEP 7

STEP 7 Align the post on the distributor with the hole in the gasket.

STEP 6
STEP 6

STEP 6 Press the two parts of the distributor together, as shown.

STEP 8
STEP 8

STEP 8 Push the post into the hole.

Stage complete 64
Stage complete
64
STEP-BY-STEP ASSEMBLY STAGE 27: THE TRANSMISSION COVER In this stage, you will fit the transmission
STEP-BY-STEP ASSEMBLY STAGE 27: THE TRANSMISSION COVER In this stage, you will fit the transmission

STEP-BY-STEP ASSEMBLY

STEP-BY-STEP ASSEMBLY STAGE 27: THE TRANSMISSION COVER In this stage, you will fit the transmission cover
STEP-BY-STEP ASSEMBLY STAGE 27: THE TRANSMISSION COVER In this stage, you will fit the transmission cover

STAGE 27: THE TRANSMISSION COVER

In this stage, you will fit the transmission cover to the engine.

STEP 1
STEP 1
STEP 2
STEP 2

STEP 1 Prepare the engine assembly (Stage 26), the transmission cover and screws (Parts 27).

STEP 2 Align the edge of the transmission cover with the raised edge of the transmission case.

STEP 3
STEP 3

STEP 3 Place the cover onto the case, keeping the edges aligned.

STEP 4
STEP 4

STEP 4 Hold the two parts together, making sure that the holes of both are aligned.

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65
Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten one of the screws into

Build the

MOTORCYCLE

from

Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten one of the screws into the
Build the MOTORCYCLE from ™ STEP 5 STEP 5 Tighten one of the screws into the

STEP 5
STEP 5

STEP 5 Tighten one of the screws into the hole at the end, using a flat-head screwdriver.

STEP 7
STEP 7

STEP 7 Tighten a third screw into the next hole around the edge of the transmission cover.

STEP 6
STEP 6

STEP 6 Working around the edge, tighten another screw into the next hole.

STEP 8
STEP 8

STEP 8 Tighten the rest of the screws into the remaining holes to secure the cover to the case.

Stage complete 66
Stage complete
66