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Carson IXO Porsche 917 KH 23 SALZBURG Manual

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Build the
PORSCHE 917 KH
#23 SƒLZBURG
DIFFICULTY
Over
LEVEL
839
839
Parts
158 in metal
FULL KIT
1:8
Die-cast

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Summary of Contents for Carson IXO Porsche 917 KH 23 SALZBURG

  • Page 1 Build the PORSCHE 917 KH #23 SƒLZBURG FULL KIT DIFFICULTY Over LEVEL Parts Die-cast 158 in metal...
  • Page 2 Build the PORSCHE 917 KH #23 SƒLZBURG Guide to the instructions • With M screws, first drive the screw in half-way. Then unscrew it to release the This set of step-by-step instructions will shavings created as the screw cuts its enable you to complete the build of your thread.
  • Page 3 1970 PORSCHE 917 KH Thanks to the new ‘short’ tail, the 917 redeems its uncertain debut in 1969 with a two-year reign as queen, taking its first overall victory at Le Mans he debut of Porsche in the top cate- 3 L cars, however, Sports cars up to 5 L gory of the World Endurance Cham- could also race, provided they were built...
  • Page 4 Porsche 917 KH he first 917 KH, from the German 9 Hours of Kyalami, confirming the goodness of ‘Kurzheck’ meaning ‘short tail’, debuts at the road taken. After some further refinement the end of a rather disappointing 1969 the 917 KH returns to the starting line-up for the due to some youthful defects.
  • Page 5 1970 An image from the 1971 24 Hours of Daytona: the Porsche 917 KH number 2 of Pedro Rodríguez and Jackie Olivier, future winner, duels with its direct rival, the Ferrari 512, in this case a 512 M of the team N.A.R.T.
  • Page 6 Porsche 917 KH Richard Attwood and Hans Herrmann Hans Herrmann can be said to have Porsche in his pionships between 1953 and 1969, but without any blood: born in Stuttgart in 1928, during his career victories. For Richard Attwood, the 1970 victory at he took part in various Sportscar, Grand Touring and Le Mans and second place with Herbert Müller the finally Sport prototype championships, mainly at the...
  • Page 7 Kits details 1-8 Porsche 917 KH Car 23 packaging list Your Porsche 917 KH full kit is broken down as follows: Pack 1 80A, screws box(G1) Pack 2 90A, 90B, 90C 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, screwdriver (red) Pack 3 2A, 2B, 2C, 2D, 2E, 2F, 2G Blister...

  • Page 8: Assembly Guide

    Assembly guide Arts of the issue Left side door Big headlight lens Hood cover with radiator air outflow niche Small headlight housing Left headlight plexiglass nacelle Small headlight lens Left headlight housing M1,7 x4mm (x2) Big headlight bezel M1,7 x4x5mm (x2) Big headlight reflector Left front Headlight Screwdriver...
  • Page 9 Parts of the issue 1 steP Fit 1I Small headlight lens to 1H Small headlight housing. Fit 1H Small headlight housing to 1D Left headlight housing and fix with BP screw.
  • Page 10 Assembly guide steP Fit 1E Big headlight be- zel to 1D Left headlight housing. Fit 1F Big headlight reflector into 1G Big headlight lens cup.
  • Page 11 Parts of the issue 1 steP Fit 1G Big headlight lens with installed 1F Big headlight reflector into 1D Left headlight housing. Fix 1F Big headlight reflector to 1D Left headlight housing with AP screw. Preassembled Left Headlight...
  • Page 12 Assembly guide enerAl view...
  • Page 13 Assembly guide Arts of the issue Steering wheel Inner front wheel rim Steering column Hub cover Steering wheel cap M1,7 x3mm (x2) Front left tire M2,0 x4mm (x4) Outer front wheel rim Steering wheel and front left wheel assembly ssembly diAgrAm...
  • Page 14 Assembly guide steP Fit 2A Steering wheel to 2B Steering column and fix with AM screw. Fit 2C Cap to 2A Steering wheel center.
  • Page 15 Parts of the issue 2 steP Preassembled Steering wheel Identify wheel rotation direction Front arrow marking on 2D Tire. Blue arrow points Left Front Wheel rotation.
  • Page 16 Assembly guide steP Put 2D Front left tire for two minutes into hot water, and then fit it over 2E Outer front wheel rim with FRONT arrow rotation direction marking facing its outer side (upper and lower illustrations). steP Fit 2F Inner front wheel rim to 2D Front tire and fix to 2E Outer front wheel rim with three...

  • Page 17: General View

    Parts of the issue 2 enerAl view...
  • Page 18 Assembly guide Arts of the issue Upper front wishbone Upright eye link (x2) Damper upper mount (marked 1) Brake discs Piston rod Inner rotor Suspension spring Outer rotor and hub Suspension damper Bracket Damper lower mount (marked 2) M 2,0x4mm (x4) Upright upper body M 2,0x3x5mm (x3) Upright lower body...
  • Page 19 Parts of the issue 3 ssembly diAgrAm steP Fit 3K Upright eye link to 3A Upper front wishbone and fix with DM screw from bigger hole direction (red arrow) forming moving joint. Fit 3G Upright upper body to 3K Upright eye link and fix with CM screw, forming rotating joint for enabling front wheels turn.
  • Page 20 Assembly guide steP Fit 3F Damper lower mount to 3I Lower front wishbone and fix with BM screw. Fit 3K Upright eye link to 3I Lower front wishbone and fix with DM screw through 3O Bracket. steP Fit 3H Upright lower body to 3K Upright eye link and fix with CM...
  • Page 21 Parts of the issue 3 steP Fit together 3M Inner rotor and 3N Outer ro- tor and hub and fix with two CP screws. steP Peel away (red arrow) backing paper from 3L Brake disc and apply with its self adhesive side to 3N Ou- ter rotor and hub (upper and lower illustrations).
  • Page 22 Assembly guide steP Peel away (red arrow) backing paper from 3L Brake disc and apply with its self adhesive side to 3M Inner rotor (upper and lower illus- trations). enerAl view...
  • Page 23 Assembly guide Arts of the issue Gearbox right side casing Outer shock absorber Right side mounting arm Drive shaft compensation sleeve Universal joint fork M2,0 x4mm (x2) Universal joint cross link M2,0 x3x5mm (x2) Universal joint fork M1,7 x4mm (x6) Inner shock absorber M1,7 x5mm (x5) Gearbox right side...
  • Page 24 Assembly guide steP Fit 4B Right side moun- ting arm to 4A Gearbox right side casing and fix with BM screw. Fit 4D Universal joint cross link to 4E Uni- versal joint fork and fix from both sides with two FM screws, froming moving joint.
  • Page 25 Parts of the issue 4 steP Fit 4D Universal joint cross link to 4C Universal joint fork and fix from both sides with two FM screws forming moving joint. Fit 4F Inner shock absor- ber to 4E Universal joint fork stub axle and fix with FM screw.
  • Page 26 Assembly guide steP Fit 4G Outer shock absorber to 4F Inner shock absorber and fix with two GM screws. Fit 4H Drive shaft com- pensation sleeve to 4G Outer shock absorber and fix with two GM screws.
  • Page 27 Parts of the issue 4 steP Fit 4C Universal joint fork stub axle to 4A Gearbox right side casing and fix with CM screw, forming rotation joint for right wheel drive shaft. enerAl view...
  • Page 28 Assembly guide Arts of the issue Gearbox casing bottom panel Exhaust pipe holder Inner connection bracket Starter motor Gearbox control support Starter drive side bracket Gearbox control joint Starter Stabilizing rod M2,0 x4mm (x4) Gearbox rear casing M1,7 x4x6 (x2) Gearbox rear cover M2,0 x5mm (x5) Gearbox rear pump...
  • Page 29 Parts of the issue 5 steP Fit 5D Gearbox control joint to 5C Gearbox control support. Fit 5E Stabilizing rod to 5D Gearbox control joint, and then with rotation motion (blue arrow) fit its end peg into 5C Gearbox control sup- port socket (lower illustrations).
  • Page 30 Assembly guide steP 5B Inner connection bracket attached to the inner side of 4A Gearbox right side casing. Fit 5L Starter and 5J Starter motor to 5K Starter drive side bracket. steP Assembled Starter Fit assembled Starter unit by its unit 5K Starter drive side bracket to 5A Gearbox casing bottom...
  • Page 31 Parts of the issue 5 steP Starter unit attached to Gearbox casing Fit 5A Gearbox casing bottom panel to 5B Inner connection bracket and fix with three BM screws. steP Preassembled 4A Gear- box right side and 5A Bottom Casing panels.
  • Page 32 Assembly guide steP Fit 5G Gearbox rear cover and 5H Gearbox rear pump to 5F Gear- box rear casing (top and bottom illustrations). enerAl view...
  • Page 33 Assembly guide Arts of the issue Gearbox left side casing Drive shaft compensation sleeve Left side mounting arm M2,0 x4mm (x4) Universal joint fork M2,0 x3x5mm (x2) Universal joint cross link M1,7 x4mm (x7) Universal joint fork M1,7 x5mm (x5) Inner shock absorber M1,7 x3,5mm (x8) Outer shock absorber...
  • Page 34 Assembly guide steP Fit 6B Left side mounting arm to 6A Gearbox left side casing and fix with BM screw. Fit 6D Universal joint cross link to 6E Universal joint fork and fix from both sides with two IM screws, forming moving joint.
  • Page 35 Parts of the issue 6 steP Fit 6G Outer shock absorber to 6F Inner shock absorber and fix with two GM screws. Fit 6H Drive shaft com- pensation sleeve to 6G Outer shock absorber and fix with two GM screws. steP Fit 6C Universal joint fork stub axle to 6A...
  • Page 36 Assembly guide steP Fit 5F Gearbox rear casing to 4A Gearbox right and 6A Gearbox left side casings ends and fix with three FM screws Fit 5I Exhaust pipe hol- der to 5F Gearbox rear casing and fix with four IM screws.
  • Page 37 Assembly guide Arts of the issue Right Engine block Cylinder lower part (x2) Camshaft drive housing Connection bracket Camshaft drive cover M2,0 x4mm (x4) Cylinder upper part (x2) M1,7 x3,5mm (x3) Engine assembly ssembly diAgrAm...
  • Page 38 Assembly guide steP Fit together 7D Cylinder upper and 7E Cylinder lower parts forming two preassembled Cylinders. Fit two preassembled Cylinders by ther 7E Lower parts to 7A Right Engine Block wall and fix with two IM screws. steP Fit 7F Connection bracket to inner side of 7A Right Engine block wall and fix with three...
  • Page 39 Parts of the issue 7 steP Attach 7C Camshaft drive cover to 7B Camshaft drive housing and fit the latter to 7A Right engine block on its two pins (upper and lower illustrations).
  • Page 40 Assembly guide enerAl view...
  • Page 41 Assembly guide Arts of the issue Front cover Cylinder upper part (x8) Distributor housing Cylinder lower part (x8) Oil hose (x2) M2,0 x4mm (x4) Oil filter M2,0 x3x5mm (x2) Oil filter cover Engine, and engine components assembly. Engine connection with transmission body Tweezers ssembly diAgrAm...
  • Page 42 Assembly guide steP Fit together 8F Cyliner upper and 8G Cylinder lower parts, forming eight preassembled Cylinders as shown on illustration below. steP Fit 8E Oil filter cover to 8D Oil filter. Fit two 8C Oil hoses to 8B Distributor housing. Fit 8B Distributor hou- sing on top of 8A Front cover.
  • Page 43 Parts of the issue 8 steP Fit 8A Front cover to 7A Right engine block end wall and fix with CM screw. Fit 7A Right engine block to 5B Inner connection bracket of preassembled Trans- mission and fix with three BM screws.
  • Page 44 Assembly guide steP Right engine block fitted to Transmission. enerAl view...
  • Page 45 Assembly guide Arts of the issue Right Cylinder head Partition (x2) Spark plug (x12 plus x6 extra) M1,7 x5mm (x5) Intake valve cover M1,7 x3,5mm (x3) Exhaust valve cover Right Cylinder head assembly Wire cutter and installation ssembly diAgrAm...
  • Page 46 Assembly guide steP Fit 9D Exhaust valve co- ver to 9A Right Cylinder head lower side and fix with two EP screws. Fit 9C Intake valve cover to 9A Right Cylinder head upper side and fix with two EP screws. steP Using precision nippers and tweezers, one by...
  • Page 47 Parts of the issue 9 steP 9C Intake, 9D Exhaust valve covers and Spark plugs installed on 9A Right Cylinder head. Fit first 9E partition, fa- cing its riveted side (red arrow), to 9A Right Cylin- der head left end side. steP Fit second 9E partition, facing its riveted side...
  • Page 48 Assembly guide steP Four preassembled Cylinders formed by parts 8G and 8F installed on 9A Right Cylinder head back wall. Fit preassembled 9A Right Cylinder head with its four Cylinders and two 9E Partitions to 7A Right engine block and two 7E Cylinders and fix to the latter with two IM screws.
  • Page 49 Parts of the issue 9 enerAl view...
  • Page 50 Assembly guide Arts of the issue 10A Crankcase top panel Distributor base (x2) Sheave M1,7 x4mm (x2) O-ring M2,0 x4mm (3) Generator (x2) M1,7 x3x5mm (x3) Front cover and axle (x2) M1,7 x5mm (x6) Sheave (x2) M1,7 x3x5mm (x2) O-ring (x2) Generators, Crankcase top panel and Oil Pump...
  • Page 51 Parts of the issue 10 steP Fit 10G O-ring followed by 10F Sheave on 10E Front cover and axle and fix with DP screw. Fit 10E Front cover and axle to 10D Generator and fix with EP screw. Assemble this way two generators.
  • Page 52 Assembly guide steP Fit 8D Oil filter mount to 10A Crankcase top panel and fix with AP screw. Fit 10A Crankcase top panel to 7F Connection bracket and fix with two BM screws. enerAl view...
  • Page 53 Parts of the issue 10 enerAl view...
  • Page 54 Assembly guide Arts of the issue Left Engine block Cylinder lower part (x2) Camshaft drive housing M1,7 x3,5mm (x3) Camshaft drive cover M2,0 x5mm (x3) Cylinder upper part (x2) Left Engine block preassembly and installation on the engine ssembly diAgrAm...
  • Page 55 Parts of the issue 11 steP Fit together 11D Cy- linder upper and 11E Cylinder lower parts for- ming two preassembled Cylinders. Fit two preassembled Cylinders by ther 11E Lower parts to 11A Left Engine Block wall and fix with two IM screws. steP Fit 11C Camshaft drive cover to 11B Camshaft...
  • Page 56 Assembly guide steP Preassembled Left Engine block Fit 11A Left Engine block to 7A Right En- gine block and fix with two JM screws. enerAl view...
  • Page 57 Assembly guide Arts of the issue Intake valve cover Connector Master sprocket Toothed belt Bosch injector pump Gas injector nozzles fret (x15) Side cover (x2) End housing cover Injector end housing M1,7 x4mm (x6) Slave sprocket (note four rivets on flange) M1,7 x3x5mm (x3) Injector base M1,7 x4mm (x3, silver)
  • Page 58 Assembly guide steP Fit 12F Slave sprocket on 12C Bosch injector pump axle and fix with DP screw. Fit 12J Connector to 12C Bosch injector pump and fix with two AP screws. Fit 12D Side cover to 12C Bosch injector pump. steP Fit 12I Injector outer body to 12C Bosch...
  • Page 59 Parts of the issue 12 steP Fit 12E Injector end housing to 12I Injec- tor outer body and fix with two silver color JP screws. Fit 12M End housing cover and 12H Service hatch to 12E Injector end housing. steP Fit 12B Master sprocket to 12A Intake valve cover axle and fix with DP screw.
  • Page 60 Assembly guide steP Fit 12K Toothed belt over 12F Slave and 12B Master sprockets. Prepare twelve 12L Gas injector nozzles for installation by nipping them off (red arrows) 12L Gas injector nozzles fret. steP One by one, fit first, and then second row of six 12L Gas injector nozzles to 12I Injector outer body (note upper...
  • Page 61 Parts of the issue 12 enerAl view...
  • Page 62 Assembly guide Arts of the issue Left Cylinder head Inner sheave Spark plug (x12 plus x6 extra) Valve axle Exhaust valve cover M1,7 x4mm (x2) Partition (x2) M1,7 x3x5mm (x2) Outer sheave M1,7 x5mm (x5) Left Cylinder head assembly ssembly diAgrAm...
  • Page 63 Parts of the issue 13 steP Fit 13F Inner and 13E Outer sheaves on 13G Valve axle and fix with DP screw. Fit 13G Valve axle to inner wall of 12A Intake valve cover and fix with AP screw. steP Using precision nippers and tweezers, one by one, nip off twelve 13B...
  • Page 64 Assembly guide steP Preassembled Left cylinder head enerAl view...
  • Page 65 Assembly guide Arts of the issue Air cooling chamber top Generator bigger belt Top air flow guide Generator smaller belt Air intake mount (x12) M1,7 x3,5mm (x7) Air cooling chamber top, generators belts and Left cylinder Screwdriver head installation on engine ssembly diAgrAm...
  • Page 66 Assembly guide steP Fit 14B Top air flow guide to 10A Crankcase top panel. Fit 14E Generator smaller belt to 10F and 10B Sheaves (top and bottom illustrations). steP Fit 14A Air cooling chamber top to 10A Crankcase top pa- nel and fix with two IM screws (top illustra- tion) and then two more...
  • Page 67 Parts of the issue 14 steP Fit two 14C Air intake mounts to 11D Cylinder upper parts on the left side of engine. Fit one 10H Distributor base to 10A Crankcase top panel. steP Fit one more 10H Fit six 14C Air intake mounts Distributor base to 10A to four 8F and two 7D Cylinder Crankcase top panel.
  • Page 68 Assembly guide steP Fit two 8F Cylinder upper parts to 11A Left engine block with two 14C Air intake mounts passing through openings in 14A Air cooling chamber top as blue arrows point (upper and lower illustrations). steP Fit two more 8F Cylinder upper parts to 11A Left engine block with two 14C Air intake mounts...
  • Page 69 Parts of the issue 14 steP Fit 13A Left cylinder head to 11E Cylinder lower parts, taking care to fit two 13D Partitions to 11A Left engine block, and fix with two IM screws (top and bottom illustrations). steP Fit 14D Generator bigger belt to 10F and 13E Sheaves.
  • Page 70 Assembly guide steP Fit the loose end of 8C Oil hose to the intake peg on 13C Exhaust valve cover end side. enerAl view...
  • Page 71 Assembly guide Arts of the issue Intake trumpet base top Intake trumpet flange (x6) Intake trumpet base bottom M1,7 x4mm (x4) End cover (x2) M1,7 x3x3mm (x4, flat head) Intake trumpet (x6) Left side Intake trumpets installation on the engine ssembly diAgrAm...
  • Page 72 Assembly guide steP Fit six 15E Intake tru- mpet flanges on 15A Intake trumpet base top. Fit two 15C End covers to 15A Intake trumpet base top. steP Fit 15B Intake trumpet base bottom to 15A Intake trumpet base top and fix with three CP screws.
  • Page 73 Parts of the issue 15 steP Placing 15B Intake tru- mpet base on six 14C Air intake mounts, fit three 15D Intake trumpets through three respective 15E Intake trumpet flanges and down into three res- pective 14C Air intake mounts. Check the correct orientation towards the outside of the holes on...
  • Page 74 Assembly guide enerAl view...
  • Page 75 Assembly guide Arts of the issue Intake trumpet base top Intake trumpet flange (x6) Intake trumpet base bottom Generator strut End cover (x2) M1,7 x4mm (x8) Intake trumpet (x6) M1,7 x3x3mm (x4, flat head) Right side Intake trumpets installation on the engine ssembly diAgrAm...
  • Page 76 Assembly guide steP Fit six 16E Intake tru- mpet flanges on 16A Intake trumpet base top. Fit two 16C End covers to 16A Intake trumpet base top. steP Fit 16B Intake trumpet base bottom to 16A Intake trumpet base top and fix with three CP screws.
  • Page 77 Parts of the issue 16 steP Fit 16F Generator strut to 10D Generator ear and 14A Air cooling chamber top cover corner (top and bottom illustrations). steP Placing 16B Intake trumpet base on six 14C Air intake mounts, fit six 16D Intake trum- pets through six respec- tive 16E Intake trumpet flanges and down into...
  • Page 78 Assembly guide steP Fix each one of 16D Air intake trumpets to four 8G and two 7E Cylin- der lower parts, star- ting with endmost 8G pointed by red arrow, with six AP screws (top and bottom illustra- tions). enerAl view...
  • Page 79 Assembly guide Arts of the issue Return spring (x2) Rocker Generator strut Bracket (x2) Control rod Damper (x2) Rocker axle M1.7 x4mm (x4) Control lever Throttle control installation on the engine ssembly diAgrAm...
  • Page 80 Assembly guide steP Fit three 15D Intake trumpets into three 15E Intake trumpet flanges. steP Fix three 15D Intake trumpets to 11E and 8G Cylinder lower parts with three AP screws (top and bottom illustra- tions).
  • Page 81 Parts of the issue 17 steP Fit 17H Damper to 17D Rocker axle. steP Start fitting 17D Rocker axle by passing its free end into 15A Intake trumpet base eye plate (green arrow) and 17H Damper into 16A Intake trumpet base (red ar- row).
  • Page 82 Assembly guide steP Fit 17H Damper into 15A Intake trumpet base (blue arrow) and 17F Rocker to 17D Rocker axle (red arrows). Fit 17C Control rod to 17E Control lever. steP Fit 17E Control lever to 17D Rocker axle end, and 17C Control rod to 12E Bosch injector pump.
  • Page 83 Parts of the issue 17 steP Fit 17A Return spring between 17G Bracket and 17F Rocker. 17A Return spring is installed between 17G Bracket and 17F Rocker. steP Fit 17G Bracket to 16A Intake trumpet base. Fit 17A Return spring between 17G Bracket and 17D Rocker axle.
  • Page 84 Assembly guide steP Fit 17B Generator strut between 17G Bracket and 10D Generator (upper and lower illustrations).
  • Page 85 Parts of the issue 17 enerAl view...
  • Page 86 Assembly guide Arts of the issue Fuel line guide (x4) Fan housing M1,7 x3x5mm (x2) Hub cover Cooler fan installa- tion on the engine ssembly diAgrAm...
  • Page 87 Parts of the issue 18 steP Fit two 18D Fuel line guides to one side of 18B Fan housing and two more to its oppo- site side (top and bot- tom illustrations). steP Fit 18B Fan housing to 10A Crankcase top panel stub axle.
  • Page 88 Assembly guide enerAl view...
  • Page 89 Assembly guide Arts of the issue Flange (x6) Exhaust pipe Exhaust pipe Exhaust manifold Exhaust pipe Exhaust manifold Exhaust pipe M1,7 x3x5mm (x7) Exhaust pipe M1,5 x3mm (x10) Exhaust pipe M1,5 x3mm (x5) Left exhaust mani- fold installation on the engine ssembly diAgrAm...
  • Page 90 Assembly guide steP Fit six 19A Flanges consecutively on 19B, 19C, 19D, 19E, 19F and 19G Exhaust pipes and fix with six DP screws (upper and lower illustrations). steP Fit 19A Flange of 19B Fit 19A Flange of 19C Exhaust pipe to 11E Exhaust pipe to 8G Cylinder and fix with two LM screws.
  • Page 91 Parts of the issue 19 steP Fit 19I Exhaust mani- fold to connecting pins of 19B, 19C and 19D Exhaust pipes. steP Fit 19A Flange of 19E Exhaust pipe to 8G Cylinder and fix with two IP screws (upper and lower illustrations).
  • Page 92 Assembly guide steP Fit 19F Exhaust pipe pin to middle socket of 19H Exhaust manifold (red arrow), ali- gning at the same time 19A Flange to 11E Cylinder (blue arrow). Fix 19A Flange of 19F exhaust pipe to 11E Cylinder with two LM screws. steP Fit 19G Exhaust pipe pin to top socket of 19H Exhaust manifold (red arrow), aligning...
  • Page 93 Assembly guide Arts of the issue Flange (x6) Exhaust pipe Exhaust pipe Exhaust manifold Exhaust pipe Exhaust manifold Exhaust pipe M1,7 x3x5mm (x7) Exhaust pipe M1,5 x3mm (x10) Exhaust pipe M1,5 x3mm (x5) Right exhaust mani- fold installation on the engine ssembly diAgrAm...
  • Page 94 Assembly guide steP Fit six 20A Flanges consecutively on 20B, 20C, 20D, 20E, 20F and 20G Exhaust pipes and fix with six DP screws (upper and lower illustrations). steP Fit 20A Flange of 20B Exhaust pipe to 8G Cylinder and fix with two IP screws.
  • Page 95 Parts of the issue 20 steP Fit 20I Exhaust mani- fold to connecting pins of 20B, 20C and 20D Exhaust pipes. steP Fit 20A Flange of 20E Exhaust pipe to 8G Cylinder and fix with two IP screws (upper and lower illustrations).
  • Page 96 Assembly guide steP Fit 20H Exhaust ma- nifold lower socket to 20E Exhaust pipe pin (red arrow) and then fit 20H Exhaust manifold other extremity socket to 20I Exhaust manifold pin (blue arrow), refer- ring to top and bottom illustrations. steP Fit 20F Exhaust pipe pin to middle socket of...
  • Page 97 Parts of the issue 20 steP Fit 20G Exhaust pipe pin to top socket of 20H Exhaust manifold (red arrow), aligning at the same time 20A Flange to 8G Cylinder (blue arrow). Fix 20A Flange of 20G Exhaust pipe to 8G Cylinder with two IP screws.
  • Page 98 Assembly guide Arts of the issue Left upper exhaust pipe Right lower exhaust pipe Left lower exhaust pipe M1,7 x4mm (x3) Exhaust pipe end bracket (x2) M1,7 x4x5mm (x3) Right upper exhaust pipe M1,7 x3,5mm (x3) Exhaust pipes instal- lation on the engine ssembly diAgrAm...
  • Page 99 Parts of the issue 21 steP Fit 21B Left lower exhaust pipe to 19H Exhaust manifold and fix with BP screw. steP Fit 21A Left upper exhaust pipe on top of 21B Left lower exhaust pipe, and fix with AP screw (upper and lower illustrations).
  • Page 100 Assembly guide steP Align and fit 21C Ex- haust pipe end bracket to 21A, 21B Exhaust pipe and 5I Exhaust pipe holder, and fix to the latter with IM screw. Fit 21E Right lower exhaust pipe to 20H Exhaust manifold and fix with BP screw.
  • Page 101 Parts of the issue 21 steP Align and fit 21C Ex- haust pipe end bracket to 21D, 21E Exhaust pipe and 5I Exhaust pipe holder, and fix to the latter with IM screw. enerAl view...
  • Page 102 Assembly guide Arts of the issue Ignition distributor Ignition wire (x12) Distributor cover M1,7 x4mm (x2) Ignition wire plugs (x18) Left side Ignition wires and Ignition distributor installation on the engine ssembly diAgrAm...
  • Page 103 Parts of the issue 22 steP Fit 22B Distributor cover to 22A Ignition distributor and fix with AP screw. Nip off fourteen 22C Ignition wire plugs from the molded fret. steP Fit fourteen 22C Ignition wire plugs to 22B Distributor cover. Fit 22A Ignition distributor to 10H Distributor base, note its orientation when fitted on next...
  • Page 104 Assembly guide steP Fit first 22D Ignition wire to 13B Spark plug (upper illustration), then lead and fit to 22C Ignition wire plug (lower illustration). Turn 22B distri- butor cover (blue arrow) to match its below illustrated position. steP Cut second 22D Ignition wire 100mm long from the Ignition wire roll and fit it to next 13B Spark...
  • Page 105 Parts of the issue 22 steP Cut third 22D Ignition wire 120mm long from the Ignition wire roll and fit it to next 13B Spark plug (upper illustration), then lead and fit to 22C Ignition wire plug (lower illustration). steP Cut fourth 22D Ignition wire 125mm long from the Ignition wire roll and...
  • Page 106 Assembly guide steP Cut fifth 22D Ignition wire 120mm long from the Ignition wire roll and fit it to next 13B Spark plug (upper illustration), then lead and fit to 22C Ignition wire plug (lower illustration). steP Cut sixth 22D Ignition wire 120mm long from the Ignition wire roll and fit it to next 13B Spark...
  • Page 107 Parts of the issue 22 steP First six 22D Ignition wires are attached to the engine steP Cut seventh 22D Igni- tion wire 100mm long from the Ignition wire roll and fit it to next 13B Spark plug (upper illus- tration), then lead and fit to 22C Ignition wire plug (lower illustration).
  • Page 108 Assembly guide steP Cut nineth 22D Ignition wire 120mm long from the Ignition wire roll and fit it to next 13B Spark plug (upper illustration), then lead and fit to 22C Ignition wire plug (lower illustration). steP Cut tenth 22D Ignition wire 115mm long from the Ignition wire roll and fit it to next 13B Spark...
  • Page 109 Parts of the issue 22 steP Cut eleventh 22D Igni- tion wire 105mm long from the Ignition wire roll and fit it to next 13B Spark plug (upper illus- tration), then lead and fit to 22C Ignition wire plug (lower illustration). steP Cut twelveth 22D Igni- tion wire 105mm long...
  • Page 110 Assembly guide enerAl view...
  • Page 111 Assembly guide Arts of the issue Ignition distributor Ignition wire (x 12) on a roll Distributor cover M1,7 x4mm (x2) Ignition wire plugs (x17) Right side Ignition wires and Ignition distributor installation on the engine ssembly diAgrAm...
  • Page 112 Assembly guide steP Fit 23B Distributor cover to 23A Ignition distributor and fix with AP screw. Nip off fourteen 23C Ignition wire plugs from the molded fret. steP Fit fourteen 23C Ignition wire plugs to 23B Distributor cover. Fit 23A Ignition distributor to 10H Distributor base, note its orientation when fitted on next illustration.
  • Page 113 Parts of the issue 23 steP Fit first 23D Ignition wire to 9B Spark plug (upper illustration), then lead and fit to 23C Ignition wire plug (lower illustration). Turn 23B distributor cover (blue arrow) to match its below illustrated position. steP Cut second 23D Ignition wire 82 mm long from...
  • Page 114 Assembly guide steP Cut third 23D Ignition wire 98 mm long from the Ignition wire roll and fit it to next 9B Spark plug (upper illustration), then lead and fit to 23C Ignition wire plug (lower illustration). steP Cut fourth 23D Ignition wire 120 mm long from the Ignition wire roll and fit it to next 9B Spark...
  • Page 115 Parts of the issue 23 steP Cut fifth 23D Ignition wire 85mm long from the Ignition wire roll and fit it to next 9B Spark plug (upper illustration), then lead and fit to 23C Ignition wire plug (lower illustration). steP Cut sixth 23D Ignition wire 90 mm long from the Ignition wire roll and...
  • Page 116 Assembly guide steP First six 23D Ignition wires are attached to the right side of the engine steP Cut seventh 23D Ignition wire 105mm long from the Ignition wire roll and fit it to next 9B Spark plug (upper illustration), then lead and fit to 23C Ignition wire plug (lower illustration).
  • Page 117 Parts of the issue 23 steP Cut nineth 23D Ignition wire 105mm long from the Ignition wire roll and fit it to next 9B Spark plug (upper illustration), then lead and fit to 23C Ignition wire plug (lower illustration). steP Cut tenth 23D Ignition wire 95 mm long from the Ignition wire roll and...
  • Page 118 Assembly guide steP Cut eleventh 23D Igni- tion wire 105 mm long from the Ignition wire roll and fit it to next 9B Spark plug (upper illus- tration), then lead and fit to 23C Ignition wire plug (lower illustration). steP Cut twelveth 23D Igni- tion wire 110mm long from the Ignition wire...

  • Page 119: General View

    Parts of the issue 23 enerAl view...
  • Page 120 Assembly guide Arts of the issue V-Frame Windscreen washer reservoir Saddle clip Washer fluid pump Brake fluid reservoir Clip Brake fluid reservoir Cap (x2) Washer fluid hose Plank M1,7 x4mm (x2) Brake fluid hoses (x2) Brake and Washer fluid reservoirs as- sembly ssembly diAgrAm...
  • Page 121 Parts of the issue 24 steP Fit 24K Cap to 24H Windscreen washer reservoir. Fit 24L Washer fluid hose to 24H Windscreen washer reservoir peg and 24I Washer fluid pump peg, connec- ting the latter to 24H Windscreen washer reservoir too.
  • Page 122 Assembly guide steP Fit 24E Cap and 24G Brake fluid hose to 24D Brake fluid reservoir, fitting the latter to 24B Saddle clip. Fit 24B Saddle clip to 24F Plank. steP Fit 24F Plank to 24A V-Frame (upper and lower illustrations).
  • Page 123 Parts of the issue 24 enerAl view...
  • Page 124 Assembly guide Arts of the issue Chassis lower frame M1,7 x4mm (x3) Engine front mount Chassis frame assembly ssembly diAgrAm...
  • Page 125 Parts of the issue 25 steP Fit 25B Engine front mount to 25A Chassis lower frame and fix with two FM screws (upper and lower illustrations).
  • Page 126 Assembly guide enerAl view...
  • Page 127 Assembly guide Arts of the issue Foot plate Pushrods (x2) Clutch cord Pedals fixture Brake light switch cable Gas pedal M1,7 x4mm (x2) Clutch pedal M1,2 x5mm (x2) Brake pedal M1,7 x3,5mm (x3) Fork M1,7 x3x5mm (x3) Master cylinders M1,2 x9,5mm (x2) Chassis assembly, pedals installation ssembly diAgrAm...
  • Page 128 Assembly guide steP Fit KP screw via 26E Clutch pedal and 26G Fork into 26I Pushrod. Fit GP screw via 26D Gas pedal into 26I Pushrod. steP Fit 26D Gas pedal to 26C Pedals fixture and lock it with 26B Pin. One by one fit 26F Brake pedal and 26E Clutch pedal to 26C...
  • Page 129 Parts of the issue 26 steP Bend 26K Brake light switch cable sideways (blue arrow) and fit the switch into 26C Pedals fixture nest. Preassembled pedals block...
  • Page 130 Assembly guide steP Fit 26C Pedals fixture to 25A Chassis lower frame plate and fix with two KM screws. Pedals block is installed on chassis steP Fit 26H Master cylin- ders to 25A Chassis lower frame, inserting at the same time two 26I Pushrods into 26H Master cylinders holes (blue arrows).
  • Page 131 Parts of the issue 26 steP Fix 26H Master cylin- ders to 25A Chassis lower frame with AP screw. Fit 26J Clutch cord to 26C Pedals fixture nozzle. steP Fit 26A Foot plate on its three pegs to 25A Chas- sis lower frame, passing 26J Clutch cord through the slot pointed by green arrow (upper and next...
  • Page 132 Assembly guide steP 26A Foot plate is fitted on chassis Fit 24G Brake fluid hoses to 26H Master cylinders front nozzles (continued on next illustration) steP Continue to fit 24A V-Frame to 25A Chassis lower frame and fix with two IM screws from be- low (upper and lower illustrations).
  • Page 133 Parts of the issue 26 enerAl view...
  • Page 134 Assembly guide Arts of the issue Dashboard subframe Horn Tie down plank (x2) M2,0 x4mm (x4) Wiper drive M1,7 x3,5mm (x2) Dashboard subframe and Front left suspension preassembly ssembly diAgrAm...
  • Page 135 Parts of the issue 27 steP Fit 27C Wiper drive and 27D Horn to 27A Dashboard subframe, fixing the latter with IM screw. Fit 3A Upper front wishbone to 27A Dashboard subframe. steP Fix 3A Upper front wishbone to 27A Dashboard subframe via two 27B Tie down planks with two BM screws.
  • Page 136 Assembly guide enerAl view Views of Front left suspension in its antici- pated working position...
  • Page 137 Assembly guide Arts of the issue Clip Extinguisher lever Bracket M1,7 x4mm (x3) Bracket M1,7 x3,5mm (x5) Clip Steering wheel attach- ment to dashboard subframe ssembly diAgrAm...
  • Page 138 Assembly guide steP Fit 28B Bracket to 27A Dashboard subframe and fix with IM screw. Fit 28C Bracket to 27A Dashboard subframe and fix with IM screw. steP Fit 28E Extinguisher lever to 27A Dashboard subframe.
  • Page 139 Parts of the issue 28 steP Fit 2B Steering column to 28B Bracket (blue arrow) and fix to 28C Bracket by aid of 28D Clip with two AP screws. Note 2B Steering column end pin orien- tation (red arrow). steP Fix 2B Steering column to 27A Dashboard subframe by aid of 28A Clip with two IM screws.
  • Page 140 Assembly guide enerAl view...
  • Page 141 Assembly guide Arts of the issue Upper front wishbone Lower front wishbone Tie down plank (x2) Lower wishbone mounts (x2, marked 3) Damper upper mount (marked 1) Upright eye link (x2) Piston rod Bracket Suspension spring M2,0 x4mm (x8) Suspension damper M2,0 x3x5mm (x3) Damper lower mount (marked 2) M2,0 x8mm (x4)
  • Page 142 Assembly guide steP Fit 29L Upright eye link to 29A Upper front wishbone and fix with DM screw from bigger hole direction (red arrow) forming moving joint. Fit 29H Upright upper body to 29L Upright eye link and fix with CM screw, forming rota- ting joint for enabling front wheels turn.
  • Page 143 Parts of the issue 29 steP Fit 29I Upright lower body to 29L Upright eye link and fix with CM screw, forming rotating joint for ena- bling front wheels to turn. Fit 29I Upright lower body to 29H Upright upper body and fix with two BM screws.
  • Page 144 Assembly guide steP Fit 29C Damper up- per mount (marked 1) to 27A Dashboard subframe and fix with BM screw. steP Fit 29A Upper front wishbone to 27A Dashboard subframe with 29B Tie down planks on top of it and fixing them to 27A Dashboard subframe with two BM screws (upper and lower illustrations).
  • Page 145 Assembly guide Arts of the issue Left caliper Steering link Cylinders housing (x2) Steering rod Left air blower support M2,0x4mm (x8) Right inner brake disc M2,0 x3x5mm (x3) Right inner rotor M1,7 x3x3mm (x3) Right outer rotor and hub M1,7 x3,5mm (x10) Right caliper M1,7 x3x5 (x2) Right air blower support...
  • Page 146 Assembly guide steP Fit 30I Steering link to 27A Dashboard subframe socket, aiming to catch 2B Steering co- lumn peg in its end slot (red arrow), and fix with KM screw. Fit 30J Steering rod to 29H and 3G Upright upper bodies arms, aiming 30J Steering rod bracket to catch 30I Steering link peg (red arrow), and fix with two CM screws.
  • Page 147 Parts of the issue 30 steP Fit 3M-3N Left rotor with brake discs to 3G Upright stub axle, en- tering into 30C Left air blower support (blue ar- rows). Upper and lower illustrations. steP Fit 30A Left caliper to 3G Upright upper body and fix with two IM screws.
  • Page 148 Assembly guide steP Peel away (red arrow) backing paper from 30D Brake disc and apply with its self adhesive side to 30F Outer rotor and hub. Peel away (red arrow) backing paper from 30D Brake disc and apply with its self adhesive side to 30E Inner rotor.
  • Page 149 Parts of the issue 30 steP Fit 30B Cylinders housing to 30G Right caliper. Preassembled Front suspen- sion and Steering gear steP Install preassembled Front suspension by fitting two 3J Lower wi- shbone mounts to 25A Chassis lower frame and fixing with two BM screws.
  • Page 150 Assembly guide steP Fix 27A Dashboard subframe front legs to forward extremities of 25A Chassis lower frame with two BM screws. Align two 29K Lower wishbone mounts to 25A Chassis lower frame upper right side nests. steP Fix two 29K Lower wi- shbone mounts to 25A Chassis lower frame with two BM screws.
  • Page 151 Assembly guide Arts of the issue Frame M2,0 x4mm (x5) Frame M1,7 x3,5mm (x5) Junction panel Cockpit framework assembly on chassis ssembly diAgrAm...
  • Page 152 Assembly guide steP Fit 31C Junction panel to 31A Frame and fix with two IM screws. Fit 31B Frame to 31A Frame and fix with IM screw. steP Install preassembled 31A-31B Framework (il- lustration above) to 25A Chassis lower frame and 27A Dashboard subframe (red and blue arrows on lower illustra- tion).
  • Page 153 Parts of the issue 31 steP Fix 31A Frame to 27A Dashboard subframe with two BM screws. Fix 31A Frame to 25A Chassis lower frame with two BM screws. steP Fix 31B Frame to 25A Chassis lower frame with IM screw. Resulting Cockpit area close up view...
  • Page 154 Assembly guide enerAl view...
  • Page 155 Assembly guide Arts of the issue Top panel Spacer washers Left fuel tank M1,7 x4x5mm (x5) Low filler neck M2,0 x3x5mm (x2) Circuit board with wires Left fuel tank and circuit board installation ssembly diAgrAm...
  • Page 156 Assembly guide steP Fit 32D Circuit board to four pegs inside 32B Left fuel tank and then fit four 32E Spacer washers on top of them (upper and lower illustrations). steP Fix 32D Circuit board to 32B Left fuel tank via 32E Spacer washers with four BP screws.
  • Page 157 Parts of the issue 32 steP Fit 32B Left fuel tank to 25A Chassis frame pegs and fix with one CM screw (upper and lower illus- trations). Refer to next page illustrations showing contact wires passage arrangement. steP 32D Contact wires should be passing between 25A and 31B Frame bars...
  • Page 158 Assembly guide Arts of the issue Top panel Switch cable (twin red) Right fuel tank M1,7 x3,5mm (x2) Low filler neck Right fuel tank installation ssembly diAgrAm...
  • Page 159 Parts of the issue 33 steP Fit 33A Top panel to 33B Right fuel tank connecting them on three pin joints (red arrows). Fit 33C Low filler neck to 33A Top panel of Right fuel tank. steP Fit 33B Left fuel tank to 25A Chassis frame pegs and fix with one IM screw (upper and...
  • Page 160 Assembly guide steP Plug 33B Red - black cable (note its passage through framework bars) of battery com- partment to 32D Circuit board Red - black cable socket (upper and lower illustrations). steP Lead 26K Twin black cable along 26A Foot plate, then through the chassis framework bars and plug to 32D Circuit...
  • Page 161 Assembly guide Arts of the issue Frame Horn sound switch (green cable) Frame M2,0 x4mm (x5) Speaker (yellow cable) M1,7 x3,5mm (x3) Engine sound switch (blue cable) Cockpit framework assembly on chassis. (34C, 34D and 34E will be used later, in next assembly stages) ssembly diAgrAm...
  • Page 162 Assembly guide steP Fit 34B Frame to 34A Frame and fix with IM screw (upper and lower illustrations). Preassembled 34A-34B Framework steP Install preassembled 34A-34B Framework (illustration above) to 25A Chassis lower frame and 27A Dashboard subframe (red and blue arrows). To better understand the connection points, study the next two illustrations.
  • Page 163 Parts of the issue 34 steP Fix 34A Frame to 25A Chassis lower frame with two BM screws. Fix 34B Frame to 25A Chassis lower frame with IM screw. steP The installation of 34A-34B Framework on 25A Chassis lower frame is completed. enerAl view...
  • Page 164 Assembly guide Arts of the issue Left mudguard Rear light LED cable (black - white) Right mudguard Light switch cable (white) Washer Instrument light LED cable (red-white) Left brake line Tape strips (x6) Right brake line M1,7 x3,5mm (x5) Headlight LED cable (white-green) M2,0 x5x5mm (x2) Electric cables instal- lation and functions...
  • Page 165 Parts of the issue 35 steP The above preview shows 35E Right and 35D Left brake lines overall layout, to be achieved in following four assembly steps. steP Fit 35E Right brake line to 30B Cylinders hou- sing lower pin. Lead and attach the other end of 35E Right brake line to 26H Right master cylin-...
  • Page 166 Assembly guide steP Connect 35G Rear light LED cable (black - white) and 33D Switch cable (red) to same color cables of 32D Circuit board. Take note of longer and shorter (black- white) cables 35G on lower image. steP Lead 33B Right fuel tank cable (black-red), 33D Switch cable (red) and 35G Rear light LED...
  • Page 167 Parts of the issue 35 steP 33B Right fuel tank cable (black-red), 33D Switch cable (red) and 35G Rear light LED cable (black - white) ins- talled on chassis frame. Connect 35F Headlight LED cable (white-green) with same color cable of 32D Circuit board, note Longer and Shorter ends of 35F Cable, their...
  • Page 168 Assembly guide Fit two AAA size batte- ries (not included) into 33B Battery compart- ment (red arrows). Turn 33D Power switch ON (blue arow). steP Press 34E Horn sound switch (green cable) to hear Horn sound from 34C Dynamic. Press 34D Engine sound swit- ch (blue cable) to hear Engine sound from 34C...
  • Page 169 Parts of the issue 35 steP Disconnect 34C Spea- ker yellow cable from 32D Circuit board yellow cable, to keep it safe during next assembly steps. Fit 35A Left mudguard to 31A Frame (hiding 35F and 26K cables behind it) and fix with two IM screws.
  • Page 170 Assembly guide steP Fix 2E Wheel rim hub with MM screw via 35C Washer. Fit 2G Hub nut to 2E Wheel rim hub. Fit 35B Right mud- guard to 34A Frame and fix with two IM screws. enerAl view...
  • Page 171 Assembly guide Arts of the issue Front tire Washer Outer front wheel rim M2,0 x4mm (x4) Inner front wheel rim M2,0 x5x5mm (x2) Hub nut Right front wheel assem- bly and installation ssembly diAgrAm...
  • Page 172 Assembly guide steP Identify wheel rotation direction Front arrow marking on 36A Tire. Blue arrow points Right Front Wheel rotation. Put 36A Front right tire for two minutes into hot water, and then fit it over 36B Outer front wheel rim with FRONT arrow rotation direction marking on its outer side (upper and lower illustrations).
  • Page 173 Parts of the issue 36 steP Preassembled Front wheel steP Fit Right front wheel by 36B Wheel hub to 29H Axle (turning slightly to catch into 30F Hub slot). Fix 36B Wheel rim hub with MM screw via 36E Washer. Fit 36D Hub nut to 36B Wheel rim hub.
  • Page 174 Assembly guide enerAl view...
  • Page 175 Assembly guide Arts of the issue Cockpit partition frame M2,0 x4mm (x5) Oil hose Cockpit Screwdriver partition frame and oil hose attachment to the engine ssembly diAgrAm...
  • Page 176 Assembly guide steP Fit 37A Cockpit partition frame to 25A Chassis lower frame sockets and 31A Left, 34A Right Side frames. Illustration above shows the attachment points on chassis in closer detail. steP Fix 37A Cockpit par- tition frame to 31A Left and 34A Right Side frames with two BM screws.
  • Page 177 Parts of the issue 37 steP 37A Cockpit partition frame installed on chassis steP Fit 37B Oil hose to 8A Front cover upper pin.
  • Page 178 Assembly guide enerAl view...
  • Page 179 Assembly guide Arts of the issue Left side frame Connector Fuel filter M2,0 x4mm (x4) Fuel hose M2,0 x5mm (x2) Fuel filter, side frame and Engine installation on chassis ssembly diAgrAm...
  • Page 180 Assembly guide steP Fit 38D Connector to 38B Fuel filter right pin. Fit 38C Fuel hose to 38B Fuel filter left pin. steP Fit 38B Fuel filter to 38A Left side frame. steP Fit 38A Left side frame to 37A Cockpit partition frame and 25A Chassis frame.
  • Page 181 Parts of the issue 38 steP Fix 38A Left side frame to 25A Chassis frame with BM screw. steP Fix 38A Left side frame to 37A Cockpit partition frame with BM screw. steP Fit Engine assembly to Chassis, aligning two immediate attachment points (red arrows) Lead 37B Oil hoses as...
  • Page 182 Assembly guide steP Pass the 37B Oil hose above 38A Left side frame V-bars. Upturn Chassis with Engine and fix 8A Front cover of the Engine to 25B Engine front mount with BM screw. steP Fix Engine 6B Left side mounting arm to 38A Left side frame with JM screw.

  • Page 183: General View

    Parts of the issue 38 enerAl view...
  • Page 184 Assembly guide Arts of the issue Right side frame Connectors (x2) Hose manifold M2,0 x4mm (x3) Right side frame and fuel hose attachment ssembly diAgrAm...
  • Page 185 Parts of the issue 39 steP Fit 39A Right side frame to 25A Chassis frame and 37A cockpit partition frame. steP Fix 39A Right side frame to 37A cockpit partition frame with BM screw. steP Fix 39A Right side frame to 25A Chassis frame with BM screw from under side of chassis.
  • Page 186 Assembly guide steP Fit two 39C Connectors to 39B Hose manifold. steP Pass 38C Hose under 39A Right side frame (green arrow), and leave it loose for now. Fit 39B Hose manifold to 39A Right side frame socket. enerAl view...
  • Page 187 Assembly guide Arts of the issue X- Frame Brake line (x2) Ignition coils (x2) Brake line (x2) High tension wire (x2) M1,7 x3,5mm (x3) Connector (x2) M2,0 x5mm (x2) Ignition coils and rear brake line installation ssembly diAgrAm...
  • Page 188 Assembly guide steP Fit 40C High tension wires to both 40B Ignition coils and fit them to 40A X-frame (note notch orienta- tion pointed by green arrows). steP Fit 40A X-Frame to 38A Left and 39A Right side frames. steP Fix 40A X-Frame to 38A Left side frame with IM screw.

  • Page 189: Table Of Contents

    Parts of the issue 40 steP Fix 40A X-Frame to 39A Right side frame with IM screw. Fix 4B Mounting arm to 39A Right side frame with JM screw. steP Fit both 40C High ten- sion wires ends on two 23C Plugs. steP Fit 40F and 40E Brake lines to 40D Connector.
  • Page 190 Assembly guide steP Fit 40D Connector with attached 40E and 40F Brake lines to 38A Left side frame bar (upper and lower illustrations). steP Fit 40F and 40E Brake lines to 40D Connector. Fit 40D Connector to 39A Right side frame bar (upper and two lower illustrations).
  • Page 191 Parts of the issue 40 enerAl view...

  • Page 192: Parts Of The Issue

    Assembly guide Arts of the issue Rear left upright Suspension damper Radius arm with upper link Suspension spring Bottom wish bone M2,0 x4mm (x2) Radius arm M2,0 x3x5mm (x2) Bracket M2,0 x8mm (x3) Piston rod M1,7 x3x5mm (x2) Bracket M2,0 x7mm (x2) Left rear suspension preassembly ssembly diAgrAm...

  • Page 193: Step

    Parts of the issue 41 steP Fit 41C Bottom wish bone to 41A Rear left upright and fix with two DM screws. Fit 41H Suspension damper to 41A Rear left upright and fix with CM screw. steP Fit 41B Radius arm with upper link to 41A Left rear upright and fix with NM screw (upper...
  • Page 194 Assembly guide steP Fit 41D radius arm to 41E Bracket and fix with KM screw. Fit 41G Bracket to 38A Left side frame and fix with BM screw. enerAl view...
  • Page 195 Assembly guide Arts of the issue Rear right upright Suspension damper Radius arm with upper link Suspension spring Bottom wish bone M2,0 x4mm (x2) Radius arm M2,0 x3x5mm (x2) Bracket M2,0 x8mm (x3) Piston rod M1,7 x3x5mm (x2) Bracket M2,0 x7mm (x2) Right rear suspension preassembly...
  • Page 196 Assembly guide steP Fit 42C Bottom wish bone to 42A Rear right upright and fix with two DM screws. Fit 42H Suspension damper to 42A Rear left upright and fix with CM screw. steP Fit 42B Radius arm with upper link to 42A Right rear upright and fix with NM screw (up- per and lower illustra-...
  • Page 197 Parts of the issue 42 steP Fit 42D radius arm to 42E Bracket and fix with KM screw. Fit 42G Bracket to 39A Right side frame and fix with BM screw. enerAl view...
  • Page 198 Assembly guide Arts of the issue Rear axle Universal joint (x2) Drop links (x2) M2,0 x9mm (x3) Rear anti roll bar M1,7 x3,5mm (x16) Tie down planks (x2) M2,0 x5mm (x6) Half shaft (x2) M1,7 x3x5mm (x5) Half shaft (x2) M2,0 x4x5mm (x5) Rear axle and suspension...
  • Page 199 Parts of the issue 43 steP Fit 43B Drop link to 41A Rear left upright and fix with KM screw. Fit 43B Drop link to 42A Rear right upright and fix with KM screw. steP Fit 43A Rear axle (note its ribs orientation) to 41C Bottom wish bone of 41A Left upright and fix with EM screw.
  • Page 200 Assembly guide steP Assemble 2 sets of Half shafts following upper and lower illustrations: Fit 43G Universal joint to 43F Half shaft and fix with two IM screws. Fit 43E half shaft to 43G Universal joint and fix with two IM screws. steP Fit 43A rear axle to 25A Chassis frame and...
  • Page 201 Parts of the issue 43 steP Elevate 41A Left upright to catch the stub of 43E Half axle (blue arrow), at the same time aligning 41B Radius arm with upper link to 38A Left side frame attachment points (orange and green arrows). Fix 41B Radius arm with upper link to 38A Left side frame with JM...
  • Page 202 Assembly guide steP Fix 43A Rear axle to 25A Chassis frame with two JM screws. Fix preassembled 41D radius arm with 41E Bracket to 25A Chassis frame by OM screw, and 41A Left upright by IM screw respectively. steP Fix preassembled 42D radius arm with 42E Bracket to 25A Chassis frame by OM screw, and...
  • Page 203 Parts of the issue 43 steP Fix 43C Rear anti roll bar to 38A Left side frame via 43D Tie down plank with two IM screws. Fix 43C Rear anti roll bar to 39A Right side frame via 43D Tie down plank with two IM screws.
  • Page 204 Assembly guide enerAl view...
  • Page 205 Assembly guide Arts of the issue Left caliper Inner rotor (x2) Right caliper Outer rotor and hub (x2) Cylinders housing (x2) M1,7 x3x3mm (x5) Brake disc (x4) M1,7 x3,5mm (x5) Rear rotors and ca- lipers preassembly and installation ssembly diAgrAm...
  • Page 206 Assembly guide steP Fit together 44E Inner rotor and 44F Outer rotor and hub and fix with two CP screws. Assemble two sets. Peel away (red arrow) backing paper from 44D Brake disc and apply with its self adhesive side to 44F Outer rotor and hub.
  • Page 207 Parts of the issue 44 steP Fit 40E Brake line to 44C Cylinders housing lower pin (blue arrow). Fit 44A Left caliper to 41A Rear left upright and fix with two IM screws (upper illustrations). steP Fit 40E Brake line to 44C Cy- linders housing lower pin (blue arrow).
  • Page 208 Assembly guide enerAl view steP...
  • Page 209 Assembly guide Arts of the issue Support frame Flare end Left column Bracket right column M1,7 X4mm (x4) Transmission cooling duct M1,7 x3,5mm (x3) Transmission cooling duct M1,7 x3x5mm (x3) Support frame installation and transmission cooling duct assembly ssembly diAgrAm...
  • Page 210 Assembly guide steP Fit 45G Bracket to 45E Transmission coo- ling duct and fix with AP screw. Connect 45E and 45D Transmission cooling duct halves and fix with two AP screws. steP Fit 45F Flare end to 45E, 45D Transmission cooling duct.

  • Page 211: Right Side Frame With

    Parts of the issue 45 steP Fit 45A Support frame to 25A Chassis frame and 38A Left, 39A Right Side frames. Fix 45A Support frame to 38A Left and 39A Right Side frames with two IM screws as shown on next page two illus- trations.
  • Page 212 Assembly guide steP Fit 41I Suspension spring on 41H Sus- pension damper (red dashed lines). Fit 41F Piston rod through 41I Suspension spring and into 41H Sus- pension damper cylinder. Fit 41F Piston rod to 41G Bracket pin and fix with KM screw.

  • Page 213: General View

    Parts of the issue 45 enerAl view...
  • Page 214 Assembly guide Arts of the issue Strut Bracket Engine oil catch tank wall Hood strut mount Engine oil catch tank Hood strut link Engine oil catch hose Hood strut link Transmission cooling duct M1,7 X4mm (x9) Transmission cooling duct M1,7 x3x5mm (x3) Flare end Engine oil catch tank, right side...
  • Page 215 Parts of the issue 46 steP Fit 46B Wall to 46C En- gine oil catch tank and fix with two AP screws. Fit 46A Strut to 46C Engine oil catch tank and fix with two AP screws. steP Fit 46D Oil hose to 46B Engine oil catch tank wall.
  • Page 216 Assembly guide steP Fit together 46F and 46E Transmis- sion cooling duct halves and fix them with two AP screws. Fit 46G Flare end to 46F and 46E Transmis- sion cooling duct. steP Fit 46J Hood strut link (note its free end orientation pointed by red arrow) to 46K Hood strut link and fix with KM screw.
  • Page 217 Parts of the issue 46 enerAl view...
  • Page 218 Assembly guide Arts of the issue Upper frame M1,7 x3mm (x8) Front lower strut (x2) M2,0 x3x5mm (x3) Bracket (x2) M1,7 x3x5mm (x2) Preassembly of upper frame. Front lower sus- pension struts installation ssembly diAgrAm...
  • Page 219 Parts of the issue 47 steP Fit 45B Left and 45C Right columns to 47A Upper frame and fix each one with AM screw (upper and lower illustrations). steP Fit 46K-46J Folding hood strut by its 46I Mount to 47A Upper frame and fix with KM screw.
  • Page 220 Assembly guide Upper frame is preas- sembled steP Fit two 47C Brackets to both 47B Front lower struts and fix with two AM screws. steP Fit 47B Front lower strut by its free and to 3O Bracket and its other end 47C Bracket to 25A Chas- sis frame, fixing with AM and CM screws respec- tively (Left under side).
  • Page 221 Parts of the issue 47 steP 47B Front lower struts attached to Front suspension, view from above Please note that here and until rear wheels attachment stage, 44F Brake disks are shown being put inside 44A Left and 44B Right calipers only for visual information. Please keep both 44F Brake disks stowed aside until rear wheels attachment.
  • Page 222 Assembly guide enerAl view...
  • Page 223 Assembly guide Arts of the issue Left rear tripod Left rear lamp lens Left rear lamp housing M1,7 x3mm (x6) Left rear lamp reflector M1,7 x4mm (x2) Upper frame preassembly and left rear lamp installation ssembly diAgrAm...
  • Page 224 Assembly guide steP Fit 48A Left rear tripod to 47A Upper frame and fix with three AM screws (upper and lower illus- trations). steP Fit 48D Left rear lamp lens into 48B Left rear lamp housing. Fit 48C Left rear lamp reflector to 48B Left rear lamp housing and fix with AP screw.
  • Page 225 Parts of the issue 48 steP Fit 48B Left rear lamp housing to 47A Upper frame left rear end and fix with two AM screws (upper and lower illustrations). enerAl view...
  • Page 226 Assembly guide Arts of the issue Right rear tripod Tape (x6) Right rear lamp housing M1,7 x3mm (x15) Right rear lamp reflector M1,7 x4mm (x4) Right rear lamp lens M2,0 x4mm (x3) Upper frame preassembly with right rear lamp, transmission cooling ducts and engine oil catch tank installation.
  • Page 227 Parts of the issue 49 steP Fit 49A Right rear tripod to 47A Upper frame and fix with three AM screws. Fit 49D Right rear lamp lens into 49B Right rear lamp housing. steP Fit 49C Right rear lamp reflector to 49B Right rear lamp housing and fix with AP screw.
  • Page 228 Assembly guide steP 47A Upper frame is ready for installation on Chassis steP Fit 46C Engine oil catch tank by its 46A Strut to 25A Chassis lower frame. steP Fit 46D Engine oil catch hose to 4A Gearbox right side casing pin.
  • Page 229 Parts of the issue 49 steP Align and fit (pin and socket connections) 47A Upper frame and 45C Right column to 25A Chas- sis lower frame, 39A Right side frame and 37A Cockpit partition frame. steP Align and fit (pin and socket connections) 47A Upper frame and 45B Left column to 25A...

  • Page 230: 39A Right Side Frame

    Assembly guide steP Fix 47A Upper frame to 39A Right side frame with two AM screws. Fix 47A Upper frame to 38A Left side frame with two AM screws. steP Fix 47A Upper frame to 45A Support frame with two AM screws. Fix 47A Upper frame to 37A Cockpit par- tition frame with two...
  • Page 231 Parts of the issue 49 steP Fix 25A Chassis lower frame rear ends to 48A Left and 49A Right rear tripods with two BM screws. steP Pass 35G Rear light LED cable (black-white) behind 39A Right side frame, tying it with two 49E Tapes to upper right bar of 47A Upper frame, and fitting into 49C Right rear lamp reflector.
  • Page 232 Assembly guide steP Pass 35G Rear light LED cable (black-white) behind 38A Left side frame, tying it with two 49E Tapes to upper left bar of 47A Upper frame, and fitting into 48C Left rear lamp reflector. Upper frame installation on Chassis is completed...
  • Page 233 Parts of the issue 49 enerAl view...
  • Page 234 Assembly guide Arts of the issue Left rear tire M1,7 x3,5mm (x3) Removable brace Removable brace fitting on upper frame ssembly diAgrAm...
  • Page 235 Parts of the issue 50 steP Fit 50B Removable brace to 47A Upper frame brackets and fix with two IM screws (upper and lower illustrations). enerAl view...
  • Page 236 Assembly guide Arts of the issue Outer rear wheel rim Washer Inner rear wheel rim M2,0 x4mm (x4) Hub nut M2,0 x5x5mm (x2) Rear left wheel assembly and mounting on chassis ssembly diAgrAm...
  • Page 237 Parts of the issue 51 steP Identify wheel rotation direction Front arrow marking on 50A Tire. Blue arrow points Left Rear Wheel rotation. To fit 51A Outer rear wheel rim into 50A Tire (from its deeper recess side, green arrows), put 50A Tire in hot water for a minute or more to get it softened.
  • Page 238 Assembly guide steP Fix 51B Inner and 51A Outer rear wheel rims with three BM screws. steP Note the positioning rib on 51A Outer rear wheel rim hub axle (red arrow). Put 44F Rotor on 41A Rear left upright axle. Attach Rear left wheel by its 51A Outer wheel rim hub to 41A Rear left...
  • Page 239 Parts of the issue 51 steP Fix 51A Outer wheel rim hub with MM screw via 51D washer. Fit 51C Hub nut to 51A Outer rear wheel rim hub. Rear left wheel is installed on Chassis...
  • Page 240 Assembly guide enerAl view...
  • Page 241 Assembly guide Arts of the issue Left rear tire M1,7 x3,5mm (x3) Removable brace Removable brace fitting on upper frame ssembly diAgrAm...
  • Page 242 Assembly guide steP Fit 52B Removable brace to 47A Upper frame brackets and fix with two IM screws (up- per and lower illustra- tions). enerAl view...
  • Page 243 Assembly guide Arts of the issue Outer rear wheel rim Washer Inner rear wheel rim M2,0 x4mm (x4) Hub nut M2,0 x5x5mm (x2) Rear right wheel assembly and mounting on chassis ssembly diAgrAm...
  • Page 244 Assembly guide steP Identify wheel rotation direction Front arrow marking on 52A Tire. Blue arrow points Right Rear Wheel rotation. steP In order to fit 53A Outer rear wheel rim into 52A Tire (from its deeper re- cess side, green arrows), put 52A Tire in hot wa- ter for a minute or more to get it softened.
  • Page 245 Parts of the issue 53 steP Note the positioning rib on 53A Outer rear wheel rim hub axle (red arrow). steP Put 44F Rotor on 42A Rear right upright axle. Attach Rear right wheel by its 53A Outer wheel rim hub to 42A Rear right upright axle, spinning sideways (blue arrow) for the positioning rib to engage in 44F Outer rotor hub slot.
  • Page 246 Assembly guide steP Fix 53A Outer wheel rim hub with MM screw via 53D washer. steP Fit 53C Hub nut to 53A Outer rear wheel rim hub.
  • Page 247 Parts of the issue 53 enerAl view...
  • Page 248 Assembly guide Arts of the issue Cockpit partition Electric wire (red) Voltage regulator Left frame strut Electric wire (blue) Right frame strut Cockpit partition - firewall preassembly ssembly diAgrAm...
  • Page 249 Parts of the issue 54 steP Fit 54C Blue and 54D Red Electric wires to 54A Cockpit partition (gray side), and tighten them. steP Fit 54B Voltage regula- tor above 54C Blue and 54D Red Electric wires to 54A Cockpit partition (gray side).
  • Page 250 Assembly guide steP Using nippers, cut away (red arrows) excess lengths of 54C Blue and 54D Red Electric wires to remain flush with 54A Cockpit partition (silver color side) surface. steP Fit 54E Left frame strut to 54A Cockpit partition left silver color side.
  • Page 251 Parts of the issue 54 enerAl view...
  • Page 252 Assembly guide Arts of the issue Partition plexiglass Lower buckle (x2) Safety belt holders (x2) Lock buckle (x2) Safety belt (x2) Double side tape (x3) Upper buckle (x2) Safety belts assembly and cockpit partition preassembly completion ssembly diAgrAm...
  • Page 253 Parts of the issue 55 steP Fit 55A Partition plexi- glass on its six pins to 54A Cockpit partition. steP Fit 55D Upper buckle to 55C Safety belt by passing it through the buckle as shown by red arrow. Repeat for both 55C Safety belts.
  • Page 254 Assembly guide steP Pass 55F Lock buckle on 55C Safety belt. Apply 55G Double side tape at the end of 55C Safety belt. Remove backing paper (red arrow) from 55G Double side tape and close the loop over 55F Lock buckle by sticking exposed side of 55G Tape back to 55C Safety belt (blue arrow).
  • Page 255 Parts of the issue 55 enerAl view...
  • Page 256 Assembly guide Arts of the issue Ignition coil (x2) Blue cable Resistor box 2 Black cable Brown cable Fire extinguisher Red cable Black cable Fire extinguisher Black hose Spark box Tape White cable Spark box Tape (x6) Red cable Rev-limiter relays M2,0 x4mm (x3) Yellow cable Resistor box 1...
  • Page 257 Parts of the issue 56 steP Fit 56L Spark box to 54A Cockpit partition. Cut the above listed quantities and lengths of respective color cables. steP Fit previously cut 35mm long cables; 56F Red, 56I Brown, 56G Yellow, 56H Blue and 56E White into two holes in 54A Cockpit partition, and then fit their ends in 56L Spark box upper slots as shown below.
  • Page 258 Assembly guide steP Fit previously cut 35mm long cables; 56F Red, 56G Yellow, 56E White and supplied 56J Black cable into 56D Black hose. Pass 56D Hose (with assortment of thinner cables inside) through 54A Cockpit partition as shown below. steP Fit the ends of yellow, white, red and black cables into upper slots of 56K Spark box.
  • Page 259 Parts of the issue 56 steP Fit two 56A Ignition coils to 54A Cockpit partition. Cut the res- pective quantities and lengths of 56B-1, 56B-2 and 56B-3 Black cables as shown above. steP Fit previously prepared Fit two previously prepared two 56B-2 Black two 56C Red Cables cables to central pins of 56A Ignition coils and and two 56B-1 Black...
  • Page 260 Assembly guide steP Cockpit partition is ready for attachment to Chassis steP Start aligning Cockpit partition to its place on Chassis.
  • Page 261 Parts of the issue 56 steP Prior to fixation of 54A Cockpit partition on Chassis, we need to connect to its both lower pins two 40F Brake lines (red arrows). Connect two 56B-2 Black cables to both remaining vacant 22C Ignition plugs, shown by blue arrows on illustration above and next page upper close up illustration.
  • Page 262 Assembly guide steP Fix 54A Cockpit partition to 25A Chassis frame with two BM screws. Fix 26J Clutch cord to 54A Cockpit partition pin. steP Cockpit partition is attached to Chassis.
  • Page 263 Parts of the issue 56 steP Put together 56P and 56Q Fire extin- guisher halves. Keep assembled Fire Extinguisher and 56R Tape for later use. enerAl view...
  • Page 264 Assembly guide Arts of the issue Right trumpets panel Fuel line Trumpet cap (x6) Spacer bar Trumpet flare (x6) M1,7 x3,5mm (x3) Nozzles (x6) Right Intake trumpets panel and fuel lines assembly and attachment to engine ssembly diAgrAm...
  • Page 265 Parts of the issue 57 steP Nip away six 57D Nozzles from molded fret and fit them to 57A Right trumpets panel (upper and lower illus- trations). steP Cut 57E Fuel line to three 57E-1 lengths and 57E-2, 57E-3, 57E-4 lengths, passing them through 57A Right trumpets panel and...
  • Page 266 Assembly guide steP Undo two IM screws and remove 50B Brace. Carefully lift up 22B Distributor head to gain access to pass 57E-1 Fuel lines through two 18D Spacer bars. Observe the order as indicated by red, blue and green colors.
  • Page 267 Parts of the issue 57 steP Fit back 50B Brace, passing it under topmost 57E-2 Fuel line, and fix with two IM screws to engine cage. Make sure there are no wires crossing tops of 16D Intake trumpets (red arrows) and fit 57A Right trumpets panel on them.
  • Page 268 Assembly guide enerAl view...
  • Page 269 Assembly guide Arts of the issue Left trumpets panel Nozzles (x6) Trumpet cap (x6) Fuel line Trumpet flare (x6) Spacer bar Left Intake trumpets panel and fuel lines assembly and attachment to engine ssembly diAgrAm...
  • Page 270 Assembly guide steP Nip away six 58D Nozzles from molded fret and fit them to 58A Left trumpets panel (upper and lower illus- trations). steP Cut 58E Fuel line to 58E- 1, 58E-2, 58E-3, 57E-4, 57E-5, 57E-6 lengths, passing them through 58A Left trumpets panel and fitting on six respec- tive 58D Nozzles (upper...
  • Page 271 Parts of the issue 58 steP Pass 57E-2, 57E-3 and 57E-4 Fuel lines through 58F Spacer bar. Observe red, blue, green indicated order. Fit three 58E-4, 58E-5 and 58E-6 Fuel lines to three 12L Injector nozzles of the outer row. Observe red, blue, green indicated order.
  • Page 272 Assembly guide steP Fit six 58C Trumpet flares on 15D Intake trumpets and 58A Left trumpets panel. Fit six 58B Trumpet caps to 15D Intake trumpets over 58C Trumpet flares.
  • Page 273 Parts of the issue 58 enerAl view...
  • Page 274 Assembly guide Arts of the issue Left air intakes cover Engine cover Right air intakes cover M1,2 x3,5mm (x13) Engine and air intakes covers attachment ssembly diAgrAm...
  • Page 275 Parts of the issue 59 steP Fit 59C Engine cover (ge- neric color is shown during assembly) to 58A Left and 57A Right trumpets panels and fix with five LP screws (upper and lower illustrations). steP Fit 59A Left air intakes cover to 58A Left trum- pets panel and fix with two LP screws.
  • Page 276 Assembly guide steP All covers are attached to engine enerAl view...
  • Page 277 Assembly guide Arts of the issue Battery box Clamp Battery cover Battery tray Contact clamps (x2) Gear lever with linkage Battery lead Gear linkage Battery lead M1,2 x3,5mm (x3) Battery and gear lever assembly and attachment ssembly diAgrAm...
  • Page 278 Assembly guide steP Fit 60D and 60E Bat- tery leads to both 60C Contact clamps. Fit both 60C Contact clamps to 60A Battery box and fix with two LP screws. Fit 60A Bat- tery box to 60G Battery tray. Fit 60B Battery cover to 60A Battery box.
  • Page 279 Parts of the issue 60 steP Connect 60H Gear lever linkage with 60I Linkage and pass through 54A Cockpit partition opening (upper and lower illustra- tions). steP Lead and connect 60I Gear linkage to 5D Trans- mission control shoe pin (upper and lower illustra- tions).
  • Page 280 Assembly guide steP Fit 60H Gear lever to 34A Right side frame of Cockpit. enerAl view...
  • Page 281 Assembly guide Arts of the issue Driver’s seat upholstery Waist belt Driver’s seat Seat adjustment lever Lower belt Tape (x5) Lock M1,7 x4mm (x5) Driver’s seat assembly and attachment ssembly diAgrAm...
  • Page 282 Assembly guide steP Pass 61C Lower belt in 61A Driver’s seat upholstery slot and fit 61D Lock to its buckle. Fit 61C Lower belt loop over 61A Upholstery peg (blue arrow) and fix it with two 61G Tapes. steP 61C Lower belt with 61D Lock is attached to 61A Driver’s seat upholstery.
  • Page 283 Parts of the issue 61 steP Position the middle of 61E Waist belt at middle of 61B Driver’s seat base width and secure with two 61G Tapes. Take care to bypass two attachment pegs by some 2mm as blue arrows indicate. Fit 61F Seat adjust- ment lever to 61B Driver’s seat base.
  • Page 284 Assembly guide enerAl view...
  • Page 285 Assembly guide Arts of the issue Passenger’s seat upholstery M1,7 x4mm (x5) Passenger’s seat Driver’s seat assembly and attachment ssembly diAgrAm...
  • Page 286 Assembly guide steP Fit 62A Upholstery to 62B Passenger’s seat and fix with two AP screws. Fit 62B Passenger’s seat to 25A Chassis frame. steP Fix 62B Passenger’s seat to 25A Chas- sis frame with two AP screws. steP Driver’s and Passen- ger’s seats are attached to Chassis...
  • Page 287 Parts of the issue 62 enerAl view...
  • Page 288 Assembly guide Arts of the issue Dashboard Dashboard decal (x2) Lever Oil gauge housing Ignition lock Oil gauge dial Ignition key M1,7 x4mm (x2) Dashboard assembly ssembly diAgrAm...
  • Page 289 Parts of the issue 63 steP Fit 63B Lever to 63A Dashboard. Nip 63C Ignition lock from its sprue. steP Fit 63C Ignition lock to 63A Dashboard. Separate two sets of 63E Dashboard decals to start using one of them. steP Put 63E-3 Decals in Rear Ignition (Zundung H) and Front...
  • Page 290 Assembly guide steP Put 63E-1 Decals in Fuel pump (Benzin P.) and water for 15 seconds, Light (Licht) 63E-1 Decals slide them off to apply are applied on 63A on 63A Dashboard as Dashboard. shown below. steP Put 63E-2 Decal in water for 15 seconds, slide them off to apply on 63A Dashboard as...
  • Page 291 Parts of the issue 63 steP Attach 63G Oil gauge dial to 63F Oil gauge housing. Attach 63F Oil gauge housing to 63A Dashboard, passing its two red wires through it, and fasten with AP screw from below. Cut excess red wires flush with surface.
  • Page 292 Assembly guide Arts of the issue Instrument panel hood Button Switch button Instrument panel Button Switch button Dials block Button (x5) M1,7 x4mm (x8) Reflector panel Button (x2) M2,0 x5mm (x5) Switch panel Fuel button Switch panel Switch button Instrument panel and dashboard assembly ssembly diAgrAm...
  • Page 293 Parts of the issue 64 steP Unplug 34E Horn sound switch cable (green), 35H Light switch cable (white), 34D Engine sound swit- ch cable (blue) and 35I Instrument light LED cable (red-white). Fit 34E Horn sound switch cable (green), 35H Light switch cable (white) and 34D Engine sound switch cable (blue) to 64E Switch...
  • Page 294 Assembly guide steP Fit 64D Reflector panel to 64B Instrument panel (with 64C Dials block in between) and fix with two AP screws. Fit 35I Instrument light LED into 64D Reflector panel. steP Fit 64B Instrument panel to 63A Dashboard, passing 35I Instrument light LED cable through its opening. Fit 64A Instrument panel hood over 64B Instrument panel to 63A Dashboard and fix with two AP screws.
  • Page 295 Parts of the issue 64 steP Fit 64L, M, N Switch buttons onto 63A Dashboard as indicated above. Fit 64E Switch panel to 63A Dashboard with switches aligning against respective 64L, M, N Switch buttons. steP Fit and fix 64E Switch panel to 63A Dashboard with two AP screws. Nip 64K Fuel button off its fret. steP Nip five 64I Buttons off the fret.
  • Page 296 Assembly guide steP Fit 64K Fuel button and five 64I Buttons to 63A Dashboard. steP Nip two 64J Buttons off the fret. Fit two 64J Buttons to 64F Switch panel. steP Nip 64H and 64G Buttons off their frets. Fit 64H and 64G Buttons to 64F Switch panel.
  • Page 297 Parts of the issue 64 steP Fit 64F Switch panel to 63A Dashboard and fix with AP screw. Twist together Blue, Green, White and Red- White cables to flow to left side of 63A Dashboard. enerAl view...
  • Page 298 Assembly guide Arts of the issue Front bottom panel M2,0 x4mm (x5) Dashboard and front bottom panel attachment ssembly diAgrAm...
  • Page 299 Parts of the issue 65 steP Before attaching 63A Dashboard to 27A Dashboard subframe, pass four Dashboard wires (Blue, Green, White and Red-White) behind 31A Frame and 31C Junction panel as red arrow indicates (left and right illustrations). steP Plug 35I Red-White, 35H White, 34E Green and 34D Blue cables from Dashboard onto...
  • Page 300 Assembly guide steP From below car, fix 63A Dashboard to 27A Dashboard subframe with two MP screws. Fix 63A Dashboard to 27A Dashboard subframe (at left side front wheel) with MP screw. steP Fix 63A Dashboard to 27A Dashboard subframe (at right side front wheel) with MP screw. Fit back 28E Extinguisher lever to 27A Dashboard subframe.
  • Page 301 Parts of the issue 65 steP Unplug right and left side parts of 35F Headlight cables with LEDs. Store them until later assembly. Fit 65A Front bottom panel to 25A Chassis frame and fix with four PM screws. steP 65A Front bottom panel is attached to Chassis...
  • Page 302 Assembly guide enerAl view...
  • Page 303 Assembly guide Arts of the issue Radiator box Metal hose (x2) Radiator front panel Connector (x4) Radiator left end panel Oil hose Fitting (x4) M1,7 x4mm (x3) Radiator right end panel M2,0 x5mm (x3) Radiator assembly and attachment ssembly diAgrAm...
  • Page 304 Assembly guide steP Fit 66B Radiator front Attach two 66D Fittings and two panel to 66A Radiator 66G Connectors to both ends of box and fix with two MP 66F Metal hose. Make two such screws. Fit 66C Left and assemblies.
  • Page 305 Parts of the issue 66 steP Fit the first of two just cut 66H Oil hoses to 8A Engine front cover nozzle (instead of remo- ved 37B Hose) and pass under 54A Cockpit partition corner (upper and lower illustrations). steP Tuck 66H Oil hose un- der 31C Junction panel while passing it all the...
  • Page 306 Assembly guide steP Pass remaining 66H Oil hose under 54A Cock- pit partition lower left corner leading along the seat side (upper and lower illustrations). steP Pass 66H Oil hose behind 31C Junction panel while leading it all the way forward. Fit 66H Oil hose to up- per 66D Fitting.
  • Page 307 Parts of the issue 65 enerAl view...
  • Page 308 Assembly guide Arts of the issue Cockpit bottom panel M2,0 x4mm (x7) Cockpit bottom panel attachment ssembly diAgrAm...
  • Page 309 Parts of the issue 67 steP Attach 56P Fire extin- guisher with 56R Tape to 25A Chassis lower frame on the left side and in front of Passen- ger’s seat. Unscrew two CM screws from 25A Chassis frame. steP Align 67A Cockpit bottom panel to 25A Chassis frame and fix with two PM screws in...
  • Page 310 Assembly guide steP F=Finish fixing 67A Cockpit bottom panel to 25A Chassis frame with four more PM screws. enerAl view...
  • Page 311 Assembly guide Arts of the issue Left cockpit panel Hand brake cord Right cockpit panel M1,7 x3,5mm (x9) Hand brake lever Cockpit side panels and hand brake attachment ssembly diAgrAm...
  • Page 312 Assembly guide steP Fit 68B Right cockpit panel to 25A Chassis frame and 34B Frame, taking care to slide its rear edge under 54A Cockpit partition rein- forcement (blue arrow). steP Fix 68B Right cock- pit panel with two IM screws to 34B Frame (blue arrows) and with one IM screw to 25A...
  • Page 313 Parts of the issue 68 steP Fit 68D Hand brake cord to 68C Hand brake lever. Fit 68C Hand brake lever to 68B Right cockpit panel. Fit the free end of 68D Hand brake cord to connector pin on 54A Cockpit partition.
  • Page 314 Assembly guide steP Fix 68A Left cockpit panel with two IM screws to 31B Frame (blue arrows) and two IM screws to 25A Chassis frame (green arrows) Refer to upper and lower illustrations, and upper illustration on previous page. Tighten up two 66H water hoses passing over 68A Left cockpit panel flange.
  • Page 315 Assembly guide Arts of the issue Left sponson platform Pump fitting Fuel pump Connector Pump shield Braided fuel line Left sponson platform and fuel pump assembly ssembly diAgrAm...
  • Page 316 Assembly guide steP Fit 69B Fuel pump to 69C Fuel shield. Fit 69C Fuel shield with attached pump to 69A Left sponson platform. steP Fit 69F Braided fuel line to 69D Pump fitting through 69E connector. Fit 69D Pump fitting to 69B Fuel pump.
  • Page 317 Parts of the issue 69 enerAl view...
  • Page 318 Assembly guide Arts of the issue Oil tank base frame Electrical cut-out switch Fuel collector pot Fuel hose Left sponson platform, fuel collector pot attachment and fittings preassembly ssembly diAgrAm...
  • Page 319 Parts of the issue 70 steP Fit 70C Cap to 70B Fuel collector pot. Fit 70B Fuel collector pot to 69A Left spon- son platform. steP Cut 70E-1 Fuel hose 210mm long, and 70E- 2 Fuel hose 80mm long from the supplied 70E Fuel hose.
  • Page 320 Assembly guide enerAl view...
  • Page 321 Assembly guide Arts of the issue Oil filler cap Strap M1,7 x4mm (x5) Handle Thermostat M2,0 x4mm (x3) Oil tank body Oil hose M1,7 x3,5mm (x3) Oil tank body Oil hose M2,0 x5mm (x3) Bracket Strut Oil tank assembly and attachment along with left sponson platform to chassis...
  • Page 322 Assembly guide steP Fit 71E Bracket to 71C Oil tank body and fix with two AP screws. Fit 71D Oil tank body to 71E Bracket and fix with two AP screws. steP Fit 70A Oil tank base to 71C Oil tank body and fix with two MP screws. Fit 71G Thermostat to 70A Oil tank base bar.
  • Page 323 Parts of the issue 71 steP Fit 70A Oil tank base to 69A Left sponson platform and fix with two IM screws. Cut from 71H Oil hose two segments: 71H-1 of 140mm long, and 71H-2 of 40mm long. steP Fit 71H-1 Oil hose and 71B Handle to 71A Oil filler cap.
  • Page 324 Assembly guide steP Fit 71I Oil hose between 71C Oil tank nozzle and 71G Ther- mostat. steP Fit 71J Strut (by its smaller peg) to 70A Oil tank base and along 71D Oil tank wall.
  • Page 325 Parts of the issue 71 steP Lead 37B and 66H Hoses upwards as shown in red and green highlighted colors. steP Fit 69A Left sponson platform to 25A Chas- sis frame, connecting 71J Strut to 47A Upper frame socket.
  • Page 326 Assembly guide steP Fix 69A Left sponson platform to 25A Chassis frame by two BM screws. steP Fit green highlighted 66H Hose to 71G Thermostat. Fit red highlighted 37B Hose to 71C Oil tank nozzle.
  • Page 327 Parts of the issue 71 steP Fit 69F Braided fuel line to 38D Connector of 38B Fuel filter. Please note that 69F Braided Fuel Line should assume natural, free style, larger curva- ture bends than you see on assembly guiding illustration, to alleviate load on plastic connec- ting pins.
  • Page 328 Assembly guide Arts of the issue Left rear wheel arc M2,0 x4mm (x4) Rear brake cooling duct M1,7 x3,5mm (x6) Fuel and oil lines attachment, left rear wheel arc attachment ssembly diAgrAm...
  • Page 329 Parts of the issue 72 steP Fit 71A Oil filler cap to 71C Oil tank body and lead 71H-1 Oil hose (highlighted in red co- lor) behind the engine cage bars to fit to 46C Engine oil catch tank upper nozzle. steP Attach one end of 70E-1 Fuel hose to...
  • Page 330 Assembly guide steP Fit 72B Rear brake cooling duct to 72A Left rear wheel arc. Fit 72A Left rear wheel arc to 47A Upper frame, with its front bracket under 69A Left sponson platform. Fix 72A Left rear wheel arc to 47A Upper frame with five IM screws.
  • Page 331 Parts of the issue 72 enerAl view...
  • Page 332 Assembly guide Arts of the issue Right sponson platform Connector Fuel pump Braided fuel line Pump shield Fuel line (shorter) Pump fitting Right sponson platform fuel pump, fuel filler neck assembly and attachment ssembly diAgrAm...
  • Page 333 Parts of the issue 73 steP Fit 73B Fuel pump to 73C Fuel shield, with 73G-1 Fuel line connec- ted to its lower nozzle. Fit 73C Fuel shield and 73G-1 Fuel line to 73A Right sponson platform socket and nozzle. steP 73B Fuel pump is attached to 73A Right...
  • Page 334 Assembly guide steP Fit 73D Pump fitting to 73B Fuel pump. enerAl view...
  • Page 335 Assembly guide Arts of the issue Battery box Strut Battery tray Pump shield Battery cover Fuel breather hose Contact clamps (x2) M1,2 x3,5mm (x3) Replacement battery assembly and attachment. Fuel breather hose attachment ssembly diAgrAm...
  • Page 336 Assembly guide steP Fit two 74D contact clamps to 74A Battery box top and fix with two LP screws. steP Fit 74B Battery tray to 73A Right sponson plat- form. Fit 74A Battery box to 74B Battery tray. steP Attach 74G Fuel breather hose to 70C Cap of fuel collector on the left side of car, and pass it to the right side of car (upper illustrations).
  • Page 337 Parts of the issue 74 enerAl view...
  • Page 338 Assembly guide Arts of the issue Fuel filler neck Fuel pipe Fuel line Fuel filler neck Fuel pipe Braided fuel line Fuel filler cap Fuel pump M1,7 x4mm (x4) Handle Connector (x3) M2,0 x4mm (x3) Flange Pump fitting Right sponson platform fuel pump and fuel filler neck assembly and attachment...
  • Page 339 Parts of the issue 75 steP Fit together 75A and 75B Fuel filler neck halves and fix with two AP screws. Fit 75B Fuel filler neck to 73A Right sponson platform, with 75E Flange in between, and fix with AP screw. Fit 75F and 75G Fuel pipes to 75A Fuel filler neck and 73A Right sponson platform sockets.
  • Page 340 Assembly guide steP From the underside fix 73A Right sponson platform to 25A Chassis frame bars and through 33B Right fuel tank with two BM screws. Attach 74G Fuel breather hose to 75B Fuel filler neck nozzle (right side of car). steP Fit 75L Braided fuel line to 75J Pump fitting...
  • Page 341 Parts of the issue 75 steP Pull and attach 38C Fuel hose to 73A Right sponson platform remai- ning vacant nozzle. Fit 74E Strut between 47A Upper frame bar socket and 73A Right sponson platform corner socket. enerAl view...
  • Page 342 Assembly guide Arts of the issue Right rear wheel arc M2,0 x4mm (x4) Rear brake cooling duct M1,7 x3,5mm (x6) Right rear wheel arc assembly and attachment ssembly diAgrAm...
  • Page 343 Parts of the issue 76 steP Fit 76B Rear brake coo- ling duct to 76A Right rear wheel arc. Fit 76A Right rear wheel arc to 47A Upper frame, with its front bracket under 73A Right sponson plat- form. Fix 76A Right rear wheel arc to 47A Upper frame with five IM screws.
  • Page 344 Assembly guide enerAl view...
  • Page 345 Assembly guide Arts of the issue Spare wheel tire Spare wheel strap Outer wheel rim M2,0 x4mm (x4) Inner wheel rim Spare wheel assembly and attachment ssembly diAgrAm...
  • Page 346 Assembly guide steP Fit 77B Outer wheel rim into 77A Spare wheel tire. Fit 77C Inner wheel rim into 77A Spare wheel tire, align it to 77B Outer wheel rim and fix together with three BM screws. steP Take note of the Quick Release lever which should face up when 77D Spare wheel strap...
  • Page 347 Parts of the issue 77 steP Place 77A Spare wheel tire on 45A Support frame shelf and between two 47A Upper frame bars. Place 77D Spare wheel strap over 77A Spare wheel tire, with Quick release lever now facing up (red arrow). Adjust and tighten the knot on 47A Upper frame bar (green arrow).
  • Page 348 Assembly guide enerAl view...
  • Page 349 Assembly guide Arts of the issue Left brake cooling duct Jack stands (x4) Right brake cooling duct Front brakes cooling ducts attachment ssembly diAgrAm...
  • Page 350 Assembly guide steP Identify 30I Right air blower support nozzle (view from below) on the front right wheel. Fit 78B Right brake cooling duct to 30I Right air blower sup- port nozzle (view from above). steP Identify 30C Left air blower support nozzle (view from below) on the front left wheel.
  • Page 351 Parts of the issue 78 steP Adjust 78B Right and 78A Left brake cooling ducts to rest on 65A Right and 65A Left Front bottom panel cradles. enerAl view...
  • Page 352 Assembly guide Arts of the issue Left wheel arc M1,7 x3,5mm (x8) Right wheel arc Left and right front wheel arcs attachment ssembly diAgrAm...
  • Page 353 Parts of the issue 79 steP Fit 79A Left wheel arc to 65A Front bottom panel and fix with three IM screws. Fit 79B Right wheel arc to 65A Front bottom panel and fix with three IM screws. steP 79B Right and 79A Left wheel arcs are attached to Chassis...
  • Page 354 Assembly guide enerAl view...
  • Page 355 Assembly guide Arts of the issue Bodywork Bodywork preparation ssembly diAgrAm...
  • Page 356 Assembly guide steP Upturn 80A Bodywork and undo screws on right and left sides of Protection plank (upper and lower illustrations). steP Remove Protection plank from 80A Body- work.
  • Page 357 Parts of the issue 80 enerAl view...
  • Page 358 Assembly guide Arts of the issue Right headlight plexiglass nacelle Small headlight lens Right headlight housing Left headlight protection (x2) Big headlight bezel Right headlight protection (x2) Big headlight reflector M1,7 x4mm (x3) Big headlight lens M1,7 x4x5mm (x3) Small headlight housing (R) M1,7 x4x6mm (x5) Headlights assembly and attachment...
  • Page 359 Parts of the issue 81 steP Attach 81G Small head- light lens to 81F Small headlight housing (R). Take one of two 35F Headlight LED cables, pass its endmost LED through 81B Right headlight housing, and plug it into 81F Small headlight housing (R). steP Attach 81F Small headlight housing (R)
  • Page 360 Assembly guide steP Right side Headlight is preassembled In order to attach LED Cable to Left side Headlight, you need to partially disassemble it first. Disassembly order is marked by yellow digits on the above diagram. steP Take remaining 35F Headlight LED cable, pass its endmost LED through 1D Left headlight housing, and plug it into 1H Small headlight housing.
  • Page 361 Parts of the issue 81 steP Attach 1H Small headlight housing to new 1D Left headlight housing and fasten with BP screw. Fit 1E Big headlight bezel to 1D Left headlight housing. Attach 1G Big headlight reflector (with 1F Big headlight lens on it) to 1D Left headlight housing and fasten with AP screw.
  • Page 362 Assembly guide steP Place 81B Right and 81J Left headlight hou- sings over Plexiglass nacelles and fasten to 80A Bodywork with four HM screws (upper and lower illustrations). steP Raise 81H Left head- light protection sticker off the backing paper, orient it over black left Headlight perimeter and apply.
  • Page 363 Parts of the issue 81 enerAl view...
  • Page 364 Assembly guide Arts of the issue Air intake mesh Hood cover lock (x7) Left air scoop Decal (x2) Right air scoop Ring (x7) Left air build up release grid M1,7 x3,5mm (x9) Right air build up release grid Bodywork fittings and decal attachment ssembly diAgrAm...
  • Page 365 Parts of the issue 82 steP Attach 82C Right and 82B Left air scoops to the front inner side of 80A Bodywork and fasten with three IM screws (left and right illustrations). steP Attach 82E Right and 82D Left air build up re- lease grids to the inner side of 80A Bodywork and fasten with four...
  • Page 366 Assembly guide steP 82A Air intake mesh is attached to the Bodywork Nip off seven 82F Hood cover locks off the sprues. Attach seven 82H Rings to seven 82F Hood cover locks. steP Attach temporarily 1B Hood cover on four 82F Hood cover locks (blue) to 80A Bodywork.
  • Page 367 Parts of the issue 82 steP While 82G Decal is well wet, move it to align to the number 23 on 1B Hood cover below, al- lowing its lower edge to overlap on 1B Hood cover (dashed red line). Once aligned, remove four 82F Hood cover locks, and lift off 1B Hood cover.
  • Page 368 Assembly guide enerAl view...
  • Page 369 Assembly guide Arts of the issue Windscreen M1,7 x3x5mm (x3) Windscreen attachment ssembly diAgrAm...
  • Page 370 Assembly guide steP Attach 83A Windscreen to 80A Bodywork. steP Make sure that two tabs of 83A Windscreen enter into respective slots on 80A Bodywork (red arrows), and fasten it with two KM screws.
  • Page 371 Parts of the issue 83 enerAl view...
  • Page 372 Assembly guide Arts of the issue Top roll cage M1,7 x3,5mm (x8) Top roll cage attachment ssembly diAgrAm...
  • Page 373 Parts of the issue 84 steP Attach 84A Top roll cage to 80A Bodywork and fasten with two IM screws. steP Fasten 84A Top roll cage to 80A Body- work with four more IM screws.
  • Page 374 Assembly guide enerAl view...
  • Page 375 Assembly guide Arts of the issue Lever Left door lock Windscreen wiper Right door lock Rear view mirror housing Windscreen sprinkler Rear view mirror bracket M1,7 x3,5mm (x3) Rear view mirror Bodywork fittings attachment and rear mirror assembly ssembly diAgrAm...
  • Page 376 Assembly guide steP Attach 85G Right and 85F Left door locks to 80A Bodywork and fasten them with two IM screws. steP 85G Right and 85F Left door locks are attached to 80A Bodywork Attach 85B Windscreen wiper to 80A Bodywork. Attach 85H Windscreen sprinkler and 85A Lever to 80A Bodywork.
  • Page 377 Parts of the issue 85 steP Peel away (blue arrow) backing paper from 85E Rear view mirror and stick it to 85C Rear view mirror housing. Fit 85D Rear view mirror bracket to 85C Rear view mirror housing. steP Sore safely the preas- sembled Rear view mir- ror until further assem- bly in next issues.
  • Page 378 Assembly guide enerAl view...
  • Page 379 Assembly guide Arts of the issue Lower hinge Pin (shorter) Upper hinge Latch Spring Lock release Lock M1,7 x3,5mm (x2) Pin (longer) Left door lock and light assembly and attachment ssembly diAgrAm...
  • Page 380 Assembly guide steP Insert longer 86E Pin into 86D Lock body. Fit 86C Spring and 86G Latch on 86E Pin. steP Align 86G Latch axis to 86D Lock and insert 86F Pin. Fit 86H Lock release on 86E Pin.
  • Page 381 Parts of the issue 86 steP Push 86H Lock release to check 86G Latch rocking motion. Attach preassembled 86D Lock to the backside of 1A Left door and fasten with IM screw.
  • Page 382 Assembly guide steP Press 86H Lock release to check once more 86G Latch rocking motion in response.
  • Page 383 Parts of the issue 86 enerAl view...
  • Page 384 Assembly guide Arts of the issue Window M2,0 x4mm (x5) Vent window M2,0 x5mm (x3) Clamp M2,0 x7mm (x2) Spring M1,2 x3mm (x9) Clamp M2,0 x3mm (x2) Left door assembly and attachment. Rear view mirror attachment ssembly diAgrAm...
  • Page 385 Parts of the issue 87 steP Attach 87B Vent win- dow to 87A Window on its three pins. Attach 87A Window to 1A Left door and fasten with seven QM screws. steP Place 86A Lower hinge axle into 80A Bodywork cradle and fasten with 87C Clamp and RM screw from one side.
  • Page 386 Assembly guide steP Place 86B Upper hinge axle into 80A Bodywork cradle and fasten with 87E Clamp and JM screw. steP Attach 1A Left door to 80A Bodywork, engaging 86G Latch into 85F Left door lock loop. Fasten 86A Lower and 86B Upper hinges to 1A Left door with four BM screws.
  • Page 387 Parts of the issue 87 steP Fit Rear Mirror by its 85D Bracket to 80A Bodywork inner ceiling socket. Push 86H Lock release to test ope- ning of 1A Left door as shown further. steP Check opening and clo- sing of 1A Left door...
  • Page 388 Assembly guide enerAl view...
  • Page 389 Assembly guide Arts of the issue Right door Upper hinge Lower hinge Decal (x2) Right side door decoration with the car number decal ssembly diAgrAm...
  • Page 390 Assembly guide steP Put 88D Decal in water for about 60 seconds, then slide on 88A Right door outer surface. steP Align, referring to next illustration, allow to set for some 3 minutes and smooth on with soft cotton tissue.
  • Page 391 Parts of the issue 88 enerAl view...
  • Page 392 Assembly guide Arts of the issue Window Lock release M2,0 x4mm (x5) Vent window Pin (longer) M1,7 x3x5mm (x2) Clamp Pin (shorter) M1,7 x3,5mm (x2) Clamp Spring (smaller) M2,0 x5mm (x3) Glass Spring (larger) M2,0 x7mm (x2) Lock Lamp housing M1,2 x3mm (x9) Latch Lamp base...
  • Page 393 Parts of the issue 89 steP Insert longer 89I Pin into 89F Lock body. Fit 89K Spring and 89G Latch on 89I Pin. steP Align 89G Latch axis to 89F Lock and insert 89J Pin. Fit 89H Lock release on 89I Pin.
  • Page 394 Assembly guide steP Push 89H Lock release to check 89G Latch rocking motion. Attach preassembled 89F Lock to the backside of 88A Right door and fasten with IM screw. steP Press 89H Lock release to check once more 89G Latch rocking mo- tion in response.
  • Page 395 Parts of the issue 89 steP Attach 89B Vent win- dow to 89A Window on its three pins. Attach 89A Window to 88A Right door and fasten with seven QM screws. Place 88B Lower hinge axle into 80A Bodywork cradle and fasten with 89C Clamp and RM screw from one side.
  • Page 396 Assembly guide steP From the other side, fasten 89C Clamp to 80A Bodywork with NM screw passing it through 89L Spring. Don’t tighten NM screw, leave space for 89L Spring compression. steP Place 88C Upper hinge axle into 80A Bodywork cradle and fasten with 89D Clamp and JM screw.
  • Page 397 Parts of the issue 89 steP Attach 88A Right door to 80A Bodywork, engaging 89G Latch into 85G Right door lock loop. Fasten 88B Lower and 88C Upper hinges to 88A Right door with four BM screws. steP Push 89H Lock release to test opening of 88A Right door.
  • Page 398 Assembly guide enerAl view...
  • Page 399 Assembly guide Arts of the issue Rear hood Transparent tape (x2) Hinge clamp (x2) M2,0 x4mm (x5) Bodywork hinge clamps attachment, rear hood attachment test ssembly diAgrAm...
  • Page 400 Assembly guide steP Attach two 90B Hinge clamps to the underside edge area of 80A Body- work and fasten with four PM screws. steP Raise 90C Transparent tape off its backing paper and wrap around 80A Bodywork edge. This 90C Transparent tape will serve to safeguard the edge painting from scratching during the following 90A Rear hood attachment test.
  • Page 401 Parts of the issue 90 steP Raise 90A Rear hood to 45 degrees angle and keeping that way move forward (red arrow) to insert its two hinges into 80A Bodywork hinge sockets. Once inserted, turn 90A Rear hood to horizontal posi- tion (green arrow, upper and lower illustrations).
  • Page 402 Assembly guide enerAl view...
  • Page 403 Assembly guide Arts of the issue Left air duct Side lamp Right air duct M1,7 x3,5mm (x5) Air ducts and transparent plug attachment to rear hood ssembly diAgrAm...
  • Page 404 Assembly guide steP Attach 91A Left air duct to the underside of 90A Rear hood and fasten with two IM screws. Attach 91B Right air duct to the underside of 90A Rear hood and fasten with two IM screws. steP Attach 91C Side lamp to 90A Rear hood right side, with its slanted...

  • Page 405: General View

    Parts of the issue 91 enerAl view...
  • Page 406 Assembly guide Arts of the issue Rear hood panel Lock (x2) Lock base (x2) M1,7 x4mm (x3) Rear hood panel assembly ssembly diAgrAm...
  • Page 407 Parts of the issue 92 steP Attach 92C Lock to 92B Lock base. Attach 92B Lock base to one side of 92A Rear hood panel and fasten with AP screw. steP Attach 92C Lock to 92B Lock base. Attach 92B Lock base to the other side of 92A Rear hood panel and fasten with AP screw.
  • Page 408 Assembly guide enerAl view...
  • Page 409 Assembly guide Arts of the issue Left spoiler Right lamp base (twin mark) Right spoiler Lamp glass (x2) Left lamp housing (single mark inside) M1,7 x4mm (x3) Right lamp housing (twin mark inside) M1,7 x3,5mm (x5) Left lamp base (single mark) M1,2 x3,5mm (x10) Rear hood assembly ssembly diAgrAm...
  • Page 410 Assembly guide steP Attach 93C Left and 93D Right lamp housings to 93E Left and 93F Right lamp bases respectively. Attach 93G Lamp glasses to 93C Left and 93D Right lamp housings. Keep assembled Lamps and AP screws for later on use. steP Attach 92A Rear hood panel to 90A Rear hood with four IM screws.
  • Page 411 Parts of the issue 93 steP Attach 93B Right and 93A Left spoilers to 92A Rear hood panel and fasten each one with four LP screws (upper and lower illustrations).
  • Page 412 Assembly guide enerAl view...
  • Page 413 Assembly guide Arts of the issue Left half pipe Right half pipe Left half pipe M1,7 x5mm (x4) Right half pipe M1,7 x3,5mm (x3) Right half pipe M2,0 x5mm (x8) Right half pipe Cockpit ventilation pipes assembly and attachment with front bodywork and chassis ssembly diAgrAm...
  • Page 414 Assembly guide steP Fit together 94A and 94B Left half pipes and fasten with EP screw, forming 94AB Left pipe (picture above). Fit together 94C and 94D Right half pipes and fasten with EP screw, forming 94CD Right pipe (picture above).
  • Page 415 Parts of the issue 94 steP On the Chassis front end, move 35F Front lamp cables plugs to the position shown above. steP Attach 80A Bodywork to 25A Lower chassis frame and 65A Front bottom panel, at the same time guiding 94CD.
  • Page 416 Assembly guide steP Join both sides 35F Front lamp cables plugs, and tuck away from the view to sides (red arrows). steP Attach 94EF Right pipe by its screw joint end to 82C Right air scoop nozzle. Pass 94AB Left pipe through the framework, helping with finger tip through the open Left...
  • Page 417 Parts of the issue 94 steP Fit the screw joint end of 94AB Left pipe (helping with tweezers) to 82B Left air scoop cross shape connector. Fasten the upper Bo- dywork to 65A Front bottom panel, 25A Lower chassis frame and 35A Left, 35B Right mud guards with six JM screws.
  • Page 418 Assembly guide enerAl view...
  • Page 419 Assembly guide Arts of the issue Left side fairing Bracket #3 Upper bracket Front plate Bracket #1 (x2) M1,7 x3,5mm (x14) Bracket #2 Left side fairing assembly and attachment ssembly diAgrAm...
  • Page 420 Assembly guide steP Attach 95D Bracket #2, 95E Bracket #3, two 95C Brackets #1 to 95A Left side fairing and fasten with four IM screws. Attach 95B Upper bracket and 95F Front plate to 95A Left side fairing and fasten with three IM screws. steP Attach 95A Left side fairing to 25A Lower...

  • Page 421: General View

    Parts of the issue 95 steP Open left door and fasten 95A Left side fairing by its 95B Upper bracket to 31B Frame, through the hole in 68A Left cockpit panel with IM screw. Remove as no longer needed CM screw from 25A Lower chassis frame. enerAl view...
  • Page 422 Assembly guide Arts of the issue Right side fairing Bracket #3 Upper bracket Front plate Bracket #1 (x2) M1,7 x3,5mm (x14) Bracket #2 M1,7 x3,5mm (x3) Right side fairing assembly and attachment ssembly diAgrAm...
  • Page 423 Parts of the issue 96 steP Attach 96D Bracket #2, 96E Bracket #3, two 96C Brackets #1 to 96A Right side fairing and fasten with four IM screws. Attach 96B Upper bracket and 96F Front plate to 96A Right side fairing and fasten with three IM screws.
  • Page 424 Assembly guide steP Open right door and fasten 96A Right side fairing by its 96B Upper bracket to 34B Frame, through the hole in 68B Right cockpit panel with IM screw. steP Replace two IM screws with two newly supplied SM screws.
  • Page 425 Parts of the issue 96 enerAl view...
  • Page 426 Assembly guide Arts of the issue Left deco panel Left trim plank Cockpit left deco panel and trim plank attachment ssembly diAgrAm...
  • Page 427 Parts of the issue 97 steP Open left door and attach 97A Left deco panel, tucking it under 56L Spark boxes (green arrow), and then to 68A Left cockpit panel (blue arrow). Attach 97B Left trim plank along 97A Left deco panel edge to 68A Left cockpit panel.
  • Page 428 Assembly guide enerAl view...
  • Page 429 Assembly guide Arts of the issue Right deco panel Right trim plank Cockpit right deco panel and trim plank attachment ssembly diAgrAm...
  • Page 430 Assembly guide steP Open right door and attach 98A Right deco panel on its four pins to 68B Right cockpit panel. steP Attach 98B Right trim plank along 98A Right deco panel edge to 68B Right cockpit panel.
  • Page 431 Parts of the issue 98 steP 98B Right trim plank and 98A Right deco panel are attached. Close right door. enerAl view...
  • Page 432 Assembly guide Arts of the issue Bottom panel M2,0 x4mm (x3) Clamp M1,7 x3mm (x3) M2,0 x4mm (x8) M2,0 x4mm (x6) Switch, speaker and bottom plate attachment ssembly diAgrAm...
  • Page 433 Parts of the issue 99 steP Place 34C Speaker into the round nest on 99A Bottom panel and secure it with 99B Clamp and two MP screws (upper and lower illustrations).
  • Page 434 Assembly guide steP Place 99A Bottom pa- nel on the upturned car and attach 33D Switch, securing it with two OP screws. steP Plug together 34C Speaker yellow cable and 32D Circuit board yellow cable. Upturn 99A Bottom panel.
  • Page 435 Parts of the issue 99 steP Hide previously connec- ted cables from view under 99A Bottom pa- nel. Align 99A Bottom panel on car bottom and fix with five PM screws to 25A Chassis lower frame. steP Fix left and right sides of 99A Bottom pa- nel to 25A Chassis lower frame with six...
  • Page 436 Assembly guide enerAl view...
  • Page 437 Assembly guide Arts of the issue 100A Battery cover 100B Top number decal (x2) Car number decal application, rear hood and bonnet assembly and attachment, battery compartment loading and functions test ssembly diAgrAm...
  • Page 438 Assembly guide steP Put 100B Top number decal for 30 seconds in water to soften it. Posi- tion 100B Top number decal on right rear area of 90A Rear hood and carefully slide away the backing paper from un- der it. Adjust 100D Top number decal while it is wet, aligning decal holes with those on 90A Rear...
  • Page 439 Parts of the issue 100 steP Attach 1B Hood cover to 80A Bodywork front compartment and fasten it with seven 82F Hood cover locks. Attach 90A Rear hood at 45 degrees angle to 80A Bodywork (red arrow) and close it on car (blue arrow). Take care to keep 80A Bodywork edge from being scratched at the joint (green arrow).
  • Page 440 Assembly guide steP 48D and 49D Rear lights Open Left side door, and push 64N Switch button to check lights go up as shown on the next three illustra- tions. steP Four front Headlights Instrument panel dials back light steP Push 26F Brake pedal (middle pedal) with help of pen tip, and check 48D Left and 49D Right brake lights go up (upper and lower illustrations).
  • Page 441 Parts of the issue 100 steP Push 64M Switch but- ton to hear Horn sound. Push 64L Swith button to hear Engine work sound. steP Place two 78C Jack stands under left and two more under right sides of car to lift up front wheels facilitating testing steering wheel turn function.
  • Page 442 Assembly guide enerAl view...

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