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Carson IXO PORSCHE 917 KH 20 GULF Manual

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Table of Contents

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

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Table of Contents
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Summary of Contents for Carson IXO PORSCHE 917 KH 20 GULF

  • Page 1 Build the PORSCHE 917 KH #20 GULF FULL KIT DIFFICULTY Over LEVEL Parts Die-cast 158 in metal...
  • Page 2 Build the PORSCHE 917 KH #20 GULF 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 Porsche 917 Queen of the circuits! Launched in 1969 to compete in the World Brands Championship in the Sport category, the 917 will give Porsche its first victory at the 24 Hours of Le Mans. t the end of 1967, Porsche already models.
  • Page 4 Queen of the circuits! n March 1968, in order to stem the rise of cars competing in Endurance races, the International Sporting Commission decided to modify the regulations of this category for the following season. Thus, the competitors of Group 6 (Sport Prototypes) see their displacement limited to 3000 cc and those of Group 4 (Sport) to 5000 cc.
  • Page 5 Porsche 917 During the 24 Hours of Le Mans 1970, the team of David Hobbs and Mike Hailwood in their 917 KH beats the team David Piper and Gijs Van Lennep. of the tubular chassis, but this time in aluminum and no longer in steel.
  • Page 6 Queen of the circuits! An impressive track record During the three editions (1969 to 1971) of the World It was on this same circuit, in 1971, that the 917 won Sports Car Championship in which it participated, the its last World Championship victory with Pedro Rodri- Porsche 917 achieved no less than 15 wins in 31 rac- guez and Richard Attwood.
  • Page 7 Kits details 1-8 Porsche 917 KH Car 20 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 Screw M1,7 x4mm (x2) Big headlight bezel M1,7 x4x5mm (x2) Big headlight reflector Left front Headlight assembly...
  • 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 Front wheel inner rim Steering column Hub cover Steering wheel badge Screw M 1.7 x 3 mm (x 2) Front wheel Screw M 2.0 x 4 mm (x 4) Front wheel outer rim Steering wheel preassembly ssembly diAgrAm...
  • Page 14 Assembly guide steP Position the steering wheel 2A on the steering column 2B and secure it with a screw AM. Position the badge 2C in the center of the steering wheel 2A.
  • Page 15 Parts of the issue 2 steP Preassembled Steering wheel Put the 2D tire in hot water for 2 minutes, then position the outer rim 2E on the front 2D wheel.
  • Page 16 Assembly guide steP Position the inner rim 2F on the front wheel 2D and fix it to the outer rim 2E with three BM screws. Front wheel preassembly...

  • 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) Outer brake disc (note hole pattern orientation) Piston rod Inner brake disc (note hole pattern orientation) Suspension spring Inner rotor Suspension damper Outer rotor and hub Damper lower mount (marked 2) M2,0 x4mm (x4)
  • 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 from bigger hole direc- tion (red arrow) , forming moving joint.
  • Page 21 Parts of the issue 3 steP Fit together 3N Inner rotor and 3O Outer ro- tor and hub and fix with two CP screws. steP Peel away (red arrow) backing paper from 3L Outer brake disc (note hole pattern orientation blue arrows) and apply with its self adhesive side to 3O Outer rotor and hub , taking care to orient outermost holes opposite to 3O Rotor inner ribs (orange arrows).
  • Page 22 Assembly guide steP Peel away (red arrow) backing paper from 3M Inner brake disc (note hole pattern orientation blue arrows) and apply with its self adhesive side to 3N Inner rotor , taking care to orient ou- termost holes opposite to 30N Rotor inner ribs ( orange arrows).
  • Page 23 Assembly guide Arts of the issue Right gearbox housing External flector Right side mounting bracket Cardan shaft Transmission seal Screw M 2.0 x 4 mm (x 2) Cross Screw M 2.0 x 3 x 5 mm (x 2) Transmission seal Screw M 1.7 x 4 mm (x 6) Internal flector Screw M 1, 7 x 5 mm (x 5)
  • Page 24 Assembly guide steP Position the right-side mounting bracket 4B on the right-hand gearbox housing 4A and secure it with a BM screw. Position the 4D spider on the 4E transmission joint and secure it with two FM screws.
  • Page 25 Parts of the issue 4 steP Position the external flector 4G on the internal flector 4F and secure it with two GM screws. Position the inner flector 4F on the transmission seal 4E and secure it with an FM screw.
  • Page 26 Assembly guide steP Fit 4G Outer shock absorber to 4F Inner shock absorber and fix with two GM screws. Position the 4H cardan shaft on the external 4G flector and secure it with two GM screws.
  • Page 27 Parts of the issue 4 steP Position the shaft of the 4C transmission seal on the right crankcase of the 4A gearbox and se- cure it with a CM screw. enerAl view...
  • Page 28 Assembly guide Arts of the issue Gearbox casing bottom panel Exhaust pipe holder Inner connection bracket Starter drive side bracket Gearbox control support Starter motor Gearbox control joint Starter Stabilizing rod M2,0 x4mm (x4) Gearbox rear casing M2,0 x5mm (x5) Gearbox rear cover M1,7 x4x6 (x2) 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 panel and...
  • 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 illustra- tions ). enerAl view...
  • Page 33 Assembly guide Arts of the issue Left gearbox housing Cardan tulip Left side mounting bracket Screw M 1.7 x 3.5 mm (x 8) Transmission joint Screw M 1.7 x 4 mm (x 7) Cross Screw M 1.7 x 5 mm (x 5) Transmission joint Screw M 2.0 x 4 mm (x 4) Flector interior...
  • Page 34 Assembly guide steP Position the left side mounting bracket 6B on the left gearbox housing 6A and secure it with a BM screw. Position the crossbar 6D on the transmission joint 6E and secure it with two IM screws. steP Position the crossbar 6D on the transmission joint 6C and secure it...
  • Page 35 Parts of the issue 6 steP Position the exterior Flector 6G on the interior Flector 6F and secure it with two GM screws. Position the 6H cardan tulip on the 6G external Flector and secure it with two GM screws. steP Position the shaft of the 6C transmission seal on...
  • Page 36 Assembly guide steP Position the 5F gearbox rear casing on the end of the right and left ca- sings and secure it with three FM screws. Position the 5I exhaust pipe bracket on the 5F gearbox rear housing and secure it 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 M1,7 x3,5mm (x3) Cylinder upper part (x2) M2,0 x4mm (x4) Engine assembly ssembly diAgrAm...
  • Page 38 Assembly guide steP Fit together 7D Cylinder upper and 7E Cylinder lower parts forming two preassembled Cylin- ders. 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...
  • 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 Water pump housing Upper cylinder part (x 8) Oil pump Lower part of cylinder (x 8) Oil hose (x 2) Screw M 2.0 x 4 mm (x 4) Oil filter holder Screw M 2,0 x 3 x 5 mm (x 2) Oil filter cover Engine, and engine components...
  • Page 42 Assembly guide steP Assemble simul- taneously the upper parts 8F and the lower parts 8G to form eight cylinders as in the illus- tration below. steP Position the oil filter cover 8E on the support Connect the two oil hoses 8C to the oil pump 8B.
  • Page 43 Parts of the issue 8 steP Position the water pump housing 8A at the end of the right engine block 7A and secure it with a CM screw. Position the right en- gine block 7A on the internal support 5B of the assembled trans- mission and secure it with three BM screws.
  • Page 44 Assembly guide steP Right engine block mounted on transmission enerAl view...
  • Page 45 Assembly guide Arts of the issue Right cylinder head Bulkhead (x 2) Spark plugs (x 12 + 6 additional) Screw M 1.7 x 3.5 mm (x 3) Intake valve cover Screw M 1.7 x 5 mm (x 5) Exhaust valve cover Right Cylinder head assembly and installation...
  • Page 46 Assembly guide steP Position the exhaust valve cover 9D on the underside of the right cylinder head 9A and secure it with two EP screws. Position the intake valve cover 9C on the upper side of the right cylinder head 9A and secure it with two EP screws.
  • Page 47 Parts of the issue 9 steP 9C and 9D valve covers and 9B spark plugs installed on the right cylinder head. Position the first par- tition 9E, riveted face outward (red arrow), on the side at the left end of cylinder head 9A.
  • Page 48 Assembly guide steP Four preassembled cylinders installed on the rear wall of the right cylinder head 9A. Position the right cylinder head 9A, with its four cylinders and its two partitions 9E, on the right engine block 7A and its two lower cylinder parts 7E, then secure it with two IM screws.
  • Page 49 Parts of the issue 9 enerAl view...
  • Page 50 Assembly guide Arts of the issue Crankcase top Distributor base (x 2) Pulley Screw M 2.0 x 4 mm (x 3) O-ring Screw M 1.7 x 3 x 5 mm (x 2) Generator (x 2) Screw M 1.7 x 3 x 5 mm (x 3) Front cover and axle (x 2) Screw M 1.7 x 5 mm (x 5) Pulley (x 2)
  • Page 51 Parts of the issue 10 steP Successively position the O-ring 10G then the pulley 10F on the axis of the front cover 10E and secure them with a DP screw. Position the front cover and the 10E axle on the 10D generator and secure it with an EP screw.
  • Page 52 Assembly guide steP Position the 8D oil filter on top of the 10A crankcase and secure it with an AP screw. Position the engine casing top 10A on the linkage support 7F and secure it 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 Lower part of cylinder (x 2) Transmission box Screw M 1.7 x 3.5 mm (x 3) Transmission housing cover Screw M 2,0 x 5 mm (x 3) Upper part of cylinder (x 2) Left engine block assembly ssembly diAgrAm...
  • Page 55 Parts of the issue 11 steP Assemble simul- taneously the upper parts 11D and the lower parts 11E to form two cylinders. Position the two cy- linders assembled, through their lower parts 11E, on the outer face of the left engine block 11A and se- cure them with two IM screws.
  • Page 56 Assembly guide steP Preassembled left engine block Position the left engine block 11A on the right engine block 7A and secure it with two JM screws. enerAl view...
  • Page 57 Assembly guide Arts of the issue Intake valve cover Compressor outer body Main gear Connector Compressor Toothed belt Side cover (x 2) Injector nozzle (x 15) Compressor housing Housing cover Secondary pinion Screw M 1.7 x 4 mm (x 6) (note the four rivets on the side) Screw M 1.7 x 3 x 5 mm (x 3) Compressor base...
  • Page 58 Assembly guide steP Position the secondary gear 12F on the axis of the compressor 12C and secure it with a DP screw. Position connector 12J on compressor 12C and secure it with two AP screws.Position the side cover 12D on the compressor 12C.
  • Page 59 Parts of the issue 12 steP Position the compres- sor housing 12E on the outer body of the compressor 12I and secure it with two silver JP screws. Position the main gear 12B on the shaft of the intake valve cover 12A and secure it with a DP screw.
  • Page 60 Assembly guide steP Position the toothed belt around the se- condary pinion 12F and the main pinion 12B. Carefully detach twelve 12L injector nozzles from the holder using the pliers (red arrows). steP Position one by one, in two rows, the twelve 12L injector nozzles on the outer body of the 12I compressor.
  • Page 61 Parts of the issue 12 enerAl view...
  • Page 62 Assembly guide Arts of the issue Left cylinder head Inner pulley Spark plugs (x 12 + 6 additional) Pulley shaft Exhaust valve cover Screw M 1.7 x 4 mm (x 2) Partition (x 2) Screw M 1.7 x 3 x 5 mm (x 2) Outer pulley Screw M 1.7 x 5 mm (x 5) Left cylinder head...
  • Page 63 Parts of the issue 13 steP Position the inner 13F and outer 13E pulleys on axis 13G and secure them with a DP screw. Position the pulley shaft 13G on the intake valve cover 12A and secure it with an AP screw. steP Detach twelve spark plugs 13B from the sup-...
  • Page 64 Assembly guide steP Preassembly of the left cylinder head enerAl view...
  • Page 65 Assembly guide Arts of the issue Top of the air cooling chamber Main generator belt Upper air flow guide Secondary generator belt Air intake bracket (x 12) Screw M 1.7 x 3.5 mm (x 7) Air cooling chamber top, generators belts and Left cylinder head installation on engine...
  • Page 66 Assembly guide steP Position the upper air flow guide 14B on top of the Crankcase top 10A. Position the secondary generator belt 14E on the pulleys 10F and 10B (illustrations above and opposite). steP Position the top of the air cooling chamber 14A on the top of the Crankcase top 10A and secure it with four IM...
  • Page 67 Parts of the issue 14 steP Position two 14C air intake brackets on the upper cylinder parts 11D on the left side of the engine. Position a 10H distribu- tor base on top of the 10A crankcase. steP Position another 10H Position six 14C air intake distributor base on top brackets on the upper cylinder...
  • Page 68 Assembly guide steP Position two upper cylinder parts 8F on the left engine block 11A by passing the two air intake supports 14C through the openings provided on the top of the air cooling chamber 14A, as indicated by the blue arrows. (illustrations above and opposite).
  • Page 69 Parts of the issue 14 steP Position the left cylinder head 13A on the lower part of cylinder 11E making sure that the two partitions 13D are correctly positioned on the left engine block 11A, then fix the assembly with two IM screws (illustrations opposite and below).
  • Page 70 Assembly guide steP Connect the free end of the 8C oil hose to the nozzle located at the end of the 13C exhaust valve cover. enerAl view...
  • Page 71 Assembly guide Arts of the issue Intake trumpet base top Intake trumpet flange (x6) Intake trumpet base bottom M1,7 x3x3mm (x4 , flat head) End cover (x2) M1,7 x4mm (x4) Intake trumpet (x6) Left side Intake trumpets installation on the engine ssembly diAgrAm...
  • Page 72 Assembly guide steP Position the six 15E in- let flanges on the top of the 15A intake trumpet support. Position the two 15C covers at the ends of the 15A intake trumpet support top. steP Position the inlet trum- pet support underside 15B on the support top 15A and secure with three CP screws.
  • Page 73 Parts of the issue 15 steP Position the 15B mission trumpet hol- der over the six 14C air intake brackets. Place three 15D inlet trumpets into the three corresponding 14C hol- ders by passing them through their respective three 15E flanges. 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 support top Inlet flange (x 6) Admission trumpet support underside Generator support arm End cover (x 2) Screw M 1.7 x 3 x 3 mm (x 4, flat head) Admission Trumpet (x 6) Screw M 1.7 x 4 mm (x 8) Right side Intake trumpets installation...
  • Page 76 Assembly guide steP Position the six 16E intake flanges on the top of the 16A intake trumpet support. Posi- tion the two 16C covers at the ends of the 16A inlet trumpet support top. steP Position the inlet trum- pet support underside 16B on the support top 16A and secure with three CP screws.
  • Page 77 Parts of the issue 16 steP Position the support arm 16F on the bracket of the generator 10D and at the corner of the top of the air cooling chamber 14A (illus- trations opposite and below). steP Position the 16B intake trumpet bracket over the six 14C air intake brackets.
  • Page 78 Assembly guide steP Secure the 16D intake trumpets to the 8G (x 4) and 7E (x 2) cylinder lower parts with six AP screws. Start with the 8G indicated by the red arrow (illustrations op- posite and below). enerAl view...
  • Page 79 Assembly guide Arts of the issue Return spring (x2) Rocker Generator strut (x 6) Bracket (x2) Control rod (x 2) Damper (x2) Rocker axle (x 2) Vis M 1,7 x 4 mm (x 4) Control lever Notice of cancelled parts Unfortunate parts shown below (with old coding) Throttle control were already produced and supplied before the eni-...
  • 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 illustrations).
  • Page 81 Parts of the issue 17 steP Fit 17H Damper to 17D Rocker axle. steP Start fitting 17D Roc- ker axle by passing its free end into 15A Intake trumpet base eye plate (green arrow) and 17H Damper into 16A Intake trumpet base (red arrow).
  • Page 82 Assembly guide steP Fit 17H Damper into 15A Intake trumpet base (blue arrow) and 17F Rocker to 17D Rocker axle (red arrow). 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 bottom 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 (x 6) Exhaust pipe Exhaust pipe Exhaust manifold Exhaust pipe Exhaust manifold Exhaust pipe Screw M 1.7 x 3 x 5 mm (x 7) Exhaust pipe Screw M 1.5 x 3 mm (x 10) Exhaust pipe Screw M 1.5 x 3 mm (x 5) Right exhaust mani-...
  • 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.
  • 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 Igni- tion wire plugs from the molded fret. steP Fit fourteen 22C Ignition wire plugs to 22B Distributor cover.
  • 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...
  • 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...
  • 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 (first illustra- tion), then lead and fit to 22C Ignition wire plug (second 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 (x12) 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 Igni- tion 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 (first illustration), then lead and fit to 23C Ignition wire plug (se- cond 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...

  • Page 119: General View

    Parts of the issue 23 enerAl view...
  • Page 120 Assembly guide Arts of the issue V-frame Windshield washer reservoir Collar link Windshield washer pump Brake fluid reservoir Clip Brake fluid reservoir Cap (x 2) Windshield washer fluid hose Support Screw M 1.7 x 4 mm (x 2) Brake Fluid Hose (x 2) Brake and Washer fluid reservoirs as- sembly...
  • Page 121 Parts of the issue 24 steP Position the Cap (24K) onto the Washer reservoir (24H). Position the Windshield washer pump (24I) on Washer reservoir (24H), then connect the Washer fluid hose (24L) to the Washer pump (24I) and Windshield washer reservoir (24H). Position the Windshield was- her reservoir (24H) on the V-frame (24A) and secure with an AP screw.
  • Page 122 Assembly guide steP Position the Cap (24E) on the Brake fluid tank (24D, then connect the Fluid hose (24G). Position Brake fluid re- servoir (24C) on Clamp (24B). Position Clamp (24B) on Support (24F). steP Position Support (24F) on the V-frame (24A) – illustrations below.
  • Page 123 Parts of the issue 24 enerAl view...
  • Page 124 Assembly guide Arts of the issue Lower frame Screw M 1.7 x 4 mm (x 3) Front engine mount Lower frame assembly ssembly diAgrAm...
  • Page 125 Parts of the issue 25 steP Position the front en- gine mount 25B on the lower frame 25A and fix it with two FM screws (illustration opposite).
  • Page 126 Assembly guide enerAl view...
  • Page 127 Assembly guide Arts of the issue Footrest Tappet (x 2) Clutch cable Bottom bracket Brake light switch cable Throttle pedal Screw M 1.7 x 4 mm (x 2) Clutch pedal Screw M 1.2 x 5 mm (x 2) Brake pedal Screw M 1.2 x 9.5 mm (x 2) Pedal bracket Screw M 1.7 x 3.5 mm (x 3)
  • Page 128 Assembly guide steP Position a KP screw in a 26I tappet by first pas- sing it through the 26E clutch pedal and then the 26G bracket. Position a GP screw in a 26I tappet by first pas- sing it through the 26D Throttle pedal.
  • Page 129 Parts of the issue 26 steP Fold the 26K brake light switch cable to the side (blue arrow) and position the switch into the slot provided under the 26C bottom bracket. Pedal assembly...
  • Page 130 Assembly guide steP Position the 26C bot- tom bracket on the 25A lower frame and secure it with two KM screws. Crankset installed on the frame steP Position the master cylinders 26H on the lower frame 25A and, at the same time, insert the two 26I tappets into their respective master cylinder housings 26H...
  • Page 131 Parts of the issue 26 steP Attach the master cylin- ders 26H to the lower frame 25A with an AP screw. Position the clutch cable 26J on the nozzle at the rear of the bot- tom bracket 26C. steP Position the footrest 26A on the lower frame 25A using the three lugs provided.
  • Page 132 Assembly guide steP Footrest 26A installed on the chassis Position the 24G brake fluid hose nozzles on the front of the 26H master cylinders (continued on the following illustration). steP Continue by positioning the 24A V frame on the lower frame 25A, then fix it from below with two IM screws (illustra- tions opposite).
  • Page 133 Parts of the issue 26 enerAl view...
  • Page 134 Assembly guide Arts of the issue Dashboard Frame Horn Bracket (x 2) Screw M 1.7 x 3.5 mm (x 2) Windscreen wiper control Screw M 2 x 4 mm (x 4) Dashboard frame and left front suspension assembly ssembly diAgrAm...
  • Page 135 Parts of the issue 27 steP Position the 27C wiper control and 27D horn on the 27A dashboard frame and secure the horn with an IM screw. Position the upper swing arm 3A on the dashboard frame 27A. steP Attach the upper swingarm 3A to the dashboard frame 27A using the brackets 27B...
  • Page 136 Assembly guide enerAl view View of the left front suspension in its future mounting position...
  • Page 137 Assembly guide Arts of the issue Attachment Fire extinguisher pull Support Screw M 1.7 x 4 mm (x 3) Support Screw M 1.7 x 3.5 mm (x 5) Attachment Installation of the steering wheel on the dashboard frame ssembly diAgrAm...
  • Page 138 Assembly guide steP Position the 28B support on the 27A dashboard frame and secure it with an IM screw. Position the 28C support on the 27A dashboard frame and se- cure it with an IM screw. steP Position the 28E fire extinguisher pull on the 27A dashboard frame.
  • Page 139 Parts of the issue 28 steP Position the end of 2B steering column on 28B sup- port (blue arrow) and secure it to support 28C using attachment 28D and two AP screws. Check the orientation of the axle at the end of steering column 2B (red arrow).
  • Page 140 Assembly guide enerAl view...
  • Page 141 Assembly guide Arts of the issue Upper front wishbone Lower hub carrier Bracket (x 2) Lower front wishbone Shock absorber upper support (marked 1) Lower wishbone support (x2, marked 3) Shock piston Hub carrier joint (x 2) Shock spring Screw M 2.0 x 4 mm (x8) Shock cylinder Screw M 2.0 x 3 x 5 mm (x3) Lower shock absorber support (marked 2)
  • Page 142 Assembly guide steP Position 29L hub carrier joint on 29A front upper wishbone and fix with a DM screw through the widest hole (red arrow), maintain mobility. Position the top of 29H hub carrier on 29L hub carrier joint and fix with a CM screw, do not overtighten, allow the wheel to turn.
  • Page 143 Parts of the issue 29 steP Position the bottom of 29I hub carrier on 29L hub carrier joint and secure with a CM screw, do not overtighten – al- low the wheel to turn. Position the bottom of 29I hub carrier on the top of 29H hub carrier and secure with two BM screws.
  • Page 144 Assembly guide steP Position 29C upper shock absorber bracket (marked 1) on 27A dashboard frame and secure with a BM screw. steP Position 29A upper front wishbone on 27A dashboard frame and secure with 29B brackets and two BM screws (shown above and oppo- site).
  • Page 145 Assembly guide Arts of the issue Left brake caliper Right brake caliper Brake piston cover (x 2) Right brake scoop Left brake bailer / Brake force regulator Steering Rod Inner surface of right brake disc Steering Bar (note direction of ventilation holes) Screw M 2.0 x 4 mm (x 8) Outer surface of right brake disc Screw M 2.0 x 3 x 5 mm (x 3)
  • Page 146 Assembly guide steP Position 30J steering link on 27A dashboard frame while engaging the lever at the end of the steering column in the slot provided (red arrow), then secure with a KM screw. Position 30K steering bar on the upper hub carrier arms 29H and 3G, engaging it in the axis of the steering rod (red arrow) and se- cure with two CM screws.
  • Page 147 Parts of the issue 30 steP Position left brake disc 30-3N (note the direc- tion of the ventilation holes, red arrow) on 3G hub carrier while inserting it into 30C Left brake bailer (blue arrows). Illustrations opposite. steP Position 30A left brake caliper on 3G hub carrier and secure with two IM screws.
  • Page 148 Assembly guide steP Remove the backing paper (blue arrow) from the inner surface of 30D right brake disc and ap- ply the adhesive to 30F right outer brake half disc (note the direction of the ventilation holes, red arrow). Ensure that the outer holes face the disc ribs (orange arrows).
  • Page 149 Parts of the issue 30 steP Position 30B piston co- ver on 30H right brake caliper. Preassembly of front suspen- sion and steering steP Install the front suspen- sion by positioning the two lower swingarm brackets 3J /3I on 25A lower frame and fix them with two BM screws.
  • Page 150 Assembly guide steP Attach the frame arms of 27A instrument panel to the ends of 25A lower frame with two BM screws. Align the two 29K lower wishbone brackets with the slots on the upper right of the lower frame 25A. steP Attach the two 29K lower wishbone...
  • Page 151 Assembly guide Arts of the issue Chassis Screw M 2 x 4 mm (x 5) Chassis Screw M 1.7 x 3.5 mm (x 5) Wiring board Assembly of the cockpit tubular mesh assembly on the chassis ssembly diAgrAm...
  • Page 152 Assembly guide steP Position 31C wiring board on 31A chassis and secure it with two IM screws. Position 31B chassis on 31A chas- sis and fix it with an IM screw. steP Install 31A-31B preas- sembly (illustration opposite) on 25A lower chassis and 27A dashboard frame (red arrow and blue arrows...
  • Page 153 Parts of the issue 31 steP Secure 31A chassis to the 27A dashboard frame with two BM screws. Attach 31A chassis to 25A bottom chassis with two BM screws. steP Secure the 31B chassis to the 25A lower chas- sis with an IM screw. View of the tubular mesh assembly frame at cockpit level...
  • Page 154 Assembly guide enerAl view...
  • Page 155 Assembly guide Arts of the issue Top panel Spacer washers Left fuel tank Screw M 1.7 x 4 x 5 mm (x 5) Filling pipe/neck Screw M 2.0 x 3 x 5 mm (x 2) Printed circuit board with wires Installation of the left fuel tank and the printed circuit board...
  • Page 156 Assembly guide steP Position the 32D printed circuit board on the four pins located inside the 32B fuel tank, then place a washer above each of them (illustrations opposite). steP Attach the 32D PCB to the 32B fuel tank with four BP screws.
  • Page 157 Parts of the issue 32 steP Position 32B fuel tank on the lugs provided on 25A lower chassis and secure with a CM screw (illustra- tions opposite). Refer to the illustrations in the next step for the arrangement of the cables. steP 32D electrical wires must run between...
  • Page 158 Assembly guide Arts of the issue Top Panel Switch cable (double red) Right fuel tank Screw M 1.7x 3.5 mm (x 2) Filling neck Installation of the right fuel tank ssembly diAgrAm...
  • Page 159 Parts of the issue 33 steP Position the top panel (33A) on the right fuel tank (33B) using the three pins (red arrows). Position the filling neck (33C) on the top panel (33A) of the right fuel tank. steP Position the right fuel tank (33B) on the lugs provided on the lower frame (25A) and secure...
  • Page 160 Assembly guide steP Connect the red and black cable (33B) - note its passage through the chassis tubes - to the socket of the red and black cable (32D) from the battery com- partment (illustrations opposite). steP Guide the black double cable (26K) along the footrest (26A), then through the chassis...
  • Page 161 Assembly guide Arts of the issue Chassis Horn Switch (Green Cable) Chassis Screw M 2.0 x 4 mm (x 5) Speaker (yellow cable) Screw M 1.7 x 3.5 mm (x 3) Engine Sound Switch (Blue Cable) Assembly of the cockpit tubular mesh to the frame - Elements 34C, 34D and 34E will be used in future assemblies ssembly diAgrAm...
  • Page 162 Assembly guide steP Assembly of the cock- pit tubular mesh to the frame - Elements 34C, 34D and 34E will be used in future assemblies Preassembled 34A-34B chassis steP Position the preassembled chassis (34A-34B) - pre- vious illustration - on the lower chassis (25A) and the dashboard frame (27A) - red and blue arrows.
  • Page 163 Parts of the issue 34 steP Attach the chassis (34A) to the lower frame (25A) with two BM screws. Attach the chassis (34B) to the lower frame (25A) with two IM screws. steP The assembly of the preassembled frame (34A-34B) on the lower frame (25A) is completed.
  • Page 164 Assembly guide Arts of the issue Left mudguard LED Cable Taillights (Black-White) Right mudguard Light switch cable (white) Washer Instrument Backlight LED Cable (Red-White) Left brake hose Adhesive tape (x 6) Right Brake Hose Screw M 1.7 x 3.5 mm (x 5) LED Cable Headlight (White-Green) Screw M 2 x 4 x 5mm (x 2) Installation of electri-...
  • Page 165 Parts of the issue 35 steP The illustration on the right shows the instal- lation of the right (35E) and left (35D) brake hoses that will be carried out in the following four steps. steP Position the right brake hose (35E) on the nipple located under the brake piston cover (30B).
  • Page 166 Assembly guide steP Connect the tail light LED cable / black- white (35G) and the switch cable / red (33D) to the same colour cables on the circuit board (32D). Carefully identify the longest (blue arrow) and shortest (green arrow) of the tail light LED cables / black-white (35G) in the illustration above.
  • Page 167 Parts of the issue 35 steP The right fuel tank cable / black-red (33B), the switch cable / red (33D) and the tail light LED cable / black-white (35G) are installed on the chassis. Connect the headlight LED cable / white-green (35F) and the cable of the same colour from the circuit board (32D).
  • Page 168 Assembly guide Place two AAA batte- ries (not supplied) in the battery compartment / red arrows (33B). Turn switch 33D to the ‘on’ position (blue arrow). steP Turn on the horn swit- ch / green wire (34E) to hear it through the speaker (34C).
  • Page 169 Parts of the issue 35 steP Disconnect the yellow speaker cable (34C) from the yellow circuit board cable (32D) so as not to damage it during the following assembly steps. Position the left mud- guard (35A) on the chassis (31A) - hidden behind the 35F and 26K cables - and secure it with two IM screws.
  • Page 170 Assembly guide steP Attach the wheel rim (2E) with an MM screw by first passing it through the washer (35C). Position the hub cap (2G) on the wheel rim (2E). Position the right mudguard (35B) on the chassis (34A) and fix it with two screws IM.
  • Page 171 Assembly guide Arts of the issue Front tyre Washer Front wheel outer rim Screw M 2 x 5 x 5mm (x 2) Front wheel inner rim Screw M 2 x 34 mm (x 4) Hub Cover Assembly and installation of the right front wheel ssembly diAgrAm...
  • Page 172 Assembly guide steP Position the outer rim (36B) on the front tyre (36A). Position the inner rim (36C) on the front tyre (36A) and secure it to the outer rim (36B) with three BM screws.
  • Page 173 Parts of the issue 36 steP Position the rim of the left front wheel (36B) on the axle of the hub carrier (29H) by turning it gently until it engages the notch in the outer brake disc (30G). Attach the front outer wheel rim (36B) with an MM screw by first passing it through the washer (36E).
  • Page 174 Assembly guide enerAl view...
  • Page 175 Assembly guide Arts of the issue Cockpit partition frame Screwdriver Oil hose (x2) screw M 2,0 x4mm (x5) Cockpit Screwdriver partition frame and oil hoses installation on the engine ssembly diAgrAm...
  • Page 176 Assembly guide steP Fit 37A Cockpit par- tition frame to 25A Chassis lower frame sockets and 31A Left , 34A Right Side frames. Illustration below shows the attachment points on chassis in closer detail. steP Fix 37A Cockpit parti- tion 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 two 37B Oil hoses to 8A Front cover pins.
  • Page 178 Assembly guide enerAl view...
  • Page 179 Assembly guide Arts of the issue Left side frame Fuel hose Fuel filter screw M2,0 x4mm (x4) Connectors (x3) screw M2,0 x5mm (x2) Installation of the fuel filter on the side chassis and the engine on the chassis ssembly diAgrAm...
  • Page 180 Assembly guide steP Fit two Connectors (38D) to Fuel filter (38B) pins. Fit Fuel hose (38xc) into Connector (38D). steP Fit Fuel filter (38B) to Left side frame (38A). steP Fit 38A Left side frame (38A) to Cockpit par- tition frame (37A) and Chassis frame (25A).
  • Page 181 Parts of the issue 38 steP Fix Left side frame (38A) to Chassis frame (25A) with BM screw. steP Fix Left side frame (38A) to Cockpit parti- tion frame (37A) with BM screw. steP Fit Engine assembly to Chassis, aligning two immediate attachment points (red arrows).
  • Page 182 Assembly guide steP Pass the upper Oil hose (37B) above and the lower Oil hose (37B) below Left side frame V-bars (38A). Upturn Chassis with Engine and fix Front Engine cover (8A) to Engine front (25A) mount with BM screw. steP Upturn Chassis with Engine and fix Front...

  • Page 183: General View

    Parts of the issue 38 enerAl view...
  • Page 184 Assembly guide Arts of the issue Right side frame Connectors ( x3 ) Hose manifold screw M2,0 x4mm ( x3 ) Right side frame and fuel hose attachment ssembly diAgrAm...
  • Page 185 Parts of the issue 39 steP Fit Right side frame (39A) to Chassis frame (25A) and cockpit parti- tion frame (37A) . steP Fix Right side frame (39A) to cockpit partition frame (37A) with BM screw. steP Fix Right side frame (39A) to Chassis frame (25A) with BM screw from under side of...
  • Page 186 Assembly guide steP Fit three Connectors (39C) to Hose manifold (39B). steP Fit Hose manifold (39B) by single Connector (39C) to 38C Fuel hose (38C) - pass Fuel hose (38C) below side frame bar - green arrow. Fit Hose manifold (39B) with attached Fuel hose (38C) to Right side frame (39A).
  • Page 187 Assembly guide Arts of the issue X- Frame Brake line ( x2 ) Ignition coils ( x2 ) Brake line ( x2 ) High tension cables ( x2 ) screw M1,7 x3,5mm ( x3 ) Connector ( x2 ) screw M2,0 x5mm ( x2 ) Installation of ignition coils and brake line ssembly diAgrAm...
  • Page 188 Assembly guide steP Fit High tension cables (40C) to both Ignition coils (40B) and fit them to X-frame (40A) - note notch orientation pointed by green arrows. steP Fit 40A X-Frame (40A) to Left (38A) and 3 Right (39A) side frames. steP Fix X-Frame (40A) to Left side frame (38A)
  • Page 189 Parts of the issue 40 steP Fix X-Frame (40A) to Right side frame (39A) with IM screw. Fix Mounting arm (4B) to Right side frame (39A) with JM screw. steP Fit both High tension cables ends (40C) on two Plugs (23C) . steP Fit and Brake lines (40E &...
  • Page 190 Assembly guide steP Fit Connector (40D) with attached Brake lines (40E & 40F) to 38A Left side frame bar (38A) - upper and lower illustrations. steP Fit Brake lines (40E & 40F) to Connector (40D). Fit Connector (40D) to 39A Right side frame bar (39A) - upper and two lower illustra- tions.
  • Page 191 Parts of the issue 40 enerAl view...
  • Page 192 Assembly guide Arts of the issue Rear left upright Suspension damper Radius arm with upper link Suspension spring Bottom wish bone Screw M 2.0 x 4 mm (x 2) Radius arm Screw M 2.0 x 3 x 5 mm (x 2) Bracket Screw M 2.0 x 8 mm (x 3) Piston rod...
  • Page 193 Parts of the issue 41 steP Fit Bottom wish bone (41C) to Rear left upright (41A) and fix with two DM screws. Fit Suspension damper (41H) to A Rear left upright (41A) and fix with CM screw. steP Fit Radius arm (41B) with upper link to Left rear upright (41A) and fix with NM screw (up-...
  • Page 194 Assembly guide steP Fit Radius arm (41D) to Bracket (41E) and fix with KM screw. Fit Bracket (41G) to Left side frame (38A) 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 Screw M 2.0 x 4 mm (x 2) Radius arm Screw M 2.0 x 3 x 5 mm (x 2) Bracket Screw M 2.0 x 8 mm (x 3) Piston rod...
  • Page 196 Assembly guide steP Fit Bottom wish bone (42C) to Rear right upright (42A) and fix with two DM screws. Fit Suspension dam- per (42H) to Rear left upright (42A) and fix with CM screw. steP Fit Radius arm (42B) with upper link to Right rear upright (42A) and fix with NM screw (up- per and lower illustra-...
  • Page 197 Parts of the issue 42 steP Fit Radius arm (42D) to Bracket (42E) and fix with KM screw. Fit Bracket (42G) to Right side frame (39A) and fix with BM screw. enerAl view...
  • Page 198 Assembly guide Arts of the issue Rear axle Universal joint ( x2 ) Drop links ( x2 ) Screw M 2.0 x 9 mm (x 3) Rear anti roll bar Screw M 1.7 x 3.5 mm (x 16) Tie down planks ( x2 ) MOUNTINGS LUGS Screw M 2.0 x 5 mm (x 6) Half shaft ( x2 ) Vis M 1.7 x 3 x 5 mm (x 5)
  • Page 199 Parts of the issue 43 steP Fit Drop link (43B) to Rear left upright (41A) and fix with KM screw. Fit Drop link (43B) to Rear right upright (42A) and fix with KM screw . steP Fit Bottom wish bone (41C) of Left upright (41A) to Rear axle (43A) and fix with EM screw .
  • Page 200 Assembly guide steP Assemble 2 sets of Half shafts following upper and lower illustrations : Fit Universal joint (43G) to Half shaft (43F) and fix with two IM screws. Fit Half shaft (43E) to Universal joint (43G) and fix with two IM screws. steP Fit Rear axle (43A) to Chassis frame (25A)
  • Page 201 Parts of the issue 43 steP Elevate Left upright (41A) to catch the stub of Half axle (43E) - blue arrow -, at the same time aligning Radius arm (41B) with upper link to Left side frame (38A) attachment points (orange and green arrows). Fix Radius arm (41B) with upper link to Left side frame (38A) with...
  • Page 202 Assembly guide steP Fix Rear axle (43A) to Chassis frame (25A) with two JM screws. Fix preassembled Radius arm (41D) with Bracket (41E) to Chas- sis frame (25A) by OM screw, and Left upright (41A) by IM screw res- pectively. steP Fix preassembled Radius arm (42D)
  • Page 203 Parts of the issue 43 steP Fix Rear anti roll bar (43C) to Left side frame (38A) via Tie down plank (43D) with two IM screws. Fix Rear anti roll bar (43C) to Right side frame (39A) via Tie down plank (43D) with two IM screws.
  • Page 204 Assembly guide enerAl view...
  • Page 205 Assembly guide Arts of the issue Left brake caliper Brake disc surface with ventilation holes to the left (x 2) Right brake caliper Inner brake half disc (x 2) Brake piston cover (x 2) Outer Brake half Disc (x 2) Brake disc surface with ventilation holes to the right (x 2) Screw M 1.7 x 3.5 mm (x 5)
  • Page 206 Assembly guide steP Remove the paper Right brake disc backing (green arrow) assembly from the surface of the Brake disc (44E) - note the direction of the ventilation holes, blue arrow - and apply the adhesive to the inner Brake half disc (44F). Ensure that the outer holes are in front of the ribs of the disc (44F) -...
  • Page 207 Parts of the issue 44 steP Remove the paper backing (green arrow) from the surface of the Brake disc (44E) - note the direction of the ventilation holes, blue arrow - and apply the adhesive to the outer Brake half disc (44G). Ensure that the outer holes are in front of the ribs of the disc (44G) -...
  • Page 208 Assembly guide steP Connect the Brake line (40E) to the nipple at the bottom of the Piston cover (44C) - blue arrow. Position the Left brake caliper (44A) on the left rear pivot (41A) and fix with two IM screws (illustrations opposite).
  • Page 209 Assembly guide Arts of the issue Reinforcement frame Pipe outlet Left-hand stand Support bracket Right-hand stand Screw M 1.7 x 4 mm (x 4) Transmission cooling line Screw M 1.7 x 3.5 mm (x 3) Transmission cooling line Screw M 1.7 x 3 x 5 mm (x 3) Installation of the reinforcement frame and assembly of the...
  • Page 210 Assembly guide steP Position the Pipe Outlet (45F) on the 45E-45D assembly. Position the Support bracket (45G) on the line (45E) and secure it with an AP screw. Connect the two Coo- ling line halves (45E and 45D) and secure with two AP screws.
  • Page 211 Parts of the issue 45 steP Position the Reinforce- ment frame (45A) on the Lower frame (25A) and on the left (38A) and right (39A) Side frames. Fix the Reinforcement Frame (45A) to the left (38A) and right (39A) Side frames with two IM screws as shown in the two illustrations below.
  • Page 212 Assembly guide steP Position the Sus- pension Spring (41I) on the Dam- per (41H) - red dotted arrows. Position the Sus- pension piston rod (41F) into the Damper cylinder (41H) by passing it through the spring (41I). Position the Sus- pension piston rod head (41F) on the end of the bracket...
  • Page 213 Parts of the issue 45 enerAl view...
  • Page 214 Assembly guide Arts of the issue Strut Support bracket Engine oil recovery tank Bonnet - Arm Support Tank cover Bonnet - Lift arm Engine oil recovery hose Bonnet - Lift arm Transmission cooling line Screw M 1.7 x 4 mm (x 9) Transmission cooling line Screw M 1.7 x 3 x 5 mm (x 3) Line outlet...
  • Page 215 Parts of the issue 46 steP Position the Cover (46C) on the Engine oil recovery tank (46B) and secure with two AP screws. Position the Strut (46A) on the Engine oil recovery tank (46B) and secure with two AP screws. steP Position the Engine oil recovery hose (46D) on...
  • Page 216 Assembly guide steP Connect the two Cooling line halves (46F and 46E) and secure them with two AP screws. Position the Line outlet (46G) on the 46E-46F assembly. steP Position the Lift arm (46J) on the Lift arm (46K) - note the orientation of the free end indicated by the red arrow - and secure it with a KM screw.
  • Page 217 Parts of the issue 46 enerAl view...
  • Page 218 Assembly guide Arts of the issue Upper frame Screw M 1.7 x 3 mm (x 8) Front lower strut (x 2) Screw M 2.0 x 3 x 5 mm (x 3) Bracket (x 2) Screw M 2.0 x 9 mm (x 3) Bracket (x 2) Screw M 1.7 x 3 x 5 mm (x 2) Preassembly of...
  • Page 219 Parts of the issue 47 steP Position the left stand (45B) and right stand (45C) on the Upper frame (47A) and secure each with an AM screw (see illustrations opposite and below). steP Position the Bonnet lift arm (46K-46J) on the Upper frame (47A) via the bracket 46I and secure with a KM screw.
  • Page 220 Assembly guide Preassembled upper frame steP Position a Bracket (47C) on each Front lower strut (47B) and secure with an AM screw. steP Unscrew the DM screw from the left upright joint 3I & 3K (red arrow) and secure it on the other side with an EM screw by attaching the Bracket (47D) - blue arrow.
  • Page 221 Parts of the issue 47 steP Unscrew the DM screw from the Left upright joint (3J-3L) - red arrow - and se- cure it on the other side with an EM screw by attaching the Bracket (47D) - blue arrow. Position the free end of the Front lower strut (47B) on the Bracket (47D) and the Bracket (47C) of the other end on the Lower frame (25A).
  • Page 222 Assembly guide enerAl view...
  • Page 223 Assembly guide Arts of the issue Left tripod bar Left tail light Left tail light housing Screw M 1.7 x 3 mm (x 6) Left tail light reflector Screw M 1.7 x 4 mm (x 2) Preassembly of the upper chassis and installation of the left tail light ssembly diAgrAm...
  • Page 224 Assembly guide steP Position the Left Tripod Bar (48A) on the Top frame (47A) and secure with three AM screws (shown opposite and below). steP Position the Left tail light (48D) in the housing (48B). Position the Reflector (48C) on the Left tail light housing (48B) and secure it with an AP screw.
  • Page 225 Parts of the issue 48 steP Position the left tail light housing (48B) on the right rear end of the Upper frame (47A) and secure with two AM screws (shown opposite). enerAl view...
  • Page 226 Assembly guide Arts of the issue Right tripod bar Adhesive tape (x 6) Right tail light housing Screw M 1.7 x 3 mm (x 15) Right tail light reflector Screw M 1.7 x 4 mm (x 4) Right tail light Screw M 2.0 x 4 mm (x 3) Preassembly of the upper frame and installation of...
  • Page 227 Parts of the issue 49 steP Position the right tripod bar (49A) on the upper frame (47A) and secure it with three screws AM. Position the right rear light (49D) into the hou- sing (49B). steP Position the reflector (49C) onto the right rear light housing (49B) and secure with one AP screw.
  • Page 228 Assembly guide steP The upper frame (47A) is ready to be installed on the main frame. steP Position the engine oil recovery tank (46C) on the lower frame (25A) via the strut (46A). steP Position the engine oil recovery hose (46D) onto the nipple of the right gearbox housing (4A).
  • Page 229 Parts of the issue 49 steP Align and position (by engaging the studs in the corres- ponding sockets as indicated by the red dotted arrows) the upper frame (47A) and the right-hand stand (45C) on the lower frame (25A), the right side frame (39A) and the cockpit partition frame (37A).
  • Page 230 Assembly guide steP Attach the upper frame (47A) to the right side frame (39A) with two AM screws. Fix the upper frame (47A) to the left side frame (38A) with two AM screws. steP Attach the upper frame (47A) to the reinforce- ment frame (45A) with two AM screws.
  • Page 231 Parts of the issue 49 steP Attach the rear ends of the lower frame (25A) to the left (48A) and right (49A) tripod bars with two BM screws. steP Run the tail light LED cable (35G) - black-white - behind the right side frame (39A), attach it to the top right bar of the upper frame (47A) with two adhesive tapes (49E), then engage the lamp in the right tail light reflector (49C).
  • Page 232 Assembly guide steP Run the tail light LED cable (35G) - black- white - behind the left side frame (38A), attach it to the top left bar of the upper frame (47A) with two pieces of tape (49E), and then engage the lamp in the left tail light reflector (48C).
  • 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 Rear wheel outer rim Washer Rear wheel inner rim Screw M 2 x 4 mm (x 4) Hub cover Screw M 2 x 5 x 5mm (x 2) Assembly of the left rear wheel and installation on the framework ssembly diAgrAm...
  • Page 237 Parts of the issue 51 steP Before starting the assembly of the left rear wheel, locate the side of the tyre (50A) with the deepest bead by the red markings in order to position the outer rim (51A). The deepest bead (2 mm) is indicated by the green arrow, while the shallowest...
  • Page 238 Assembly guide steP Fix the inner rim (51B) and the outer rim (51A) together with three BM screws. The left rear wheel is ready to be mounted on the chas- sis. steP Identify the locking groove on the outer rim hub axle (51A) - red arrow.
  • Page 239 Parts of the issue 51 steP Fix the outer rim of the left rear wheel (51A) with a MM screw by first pas- sing it through the washer (51D). Position the hub cover (51C) on the outer rim (51A). Left rear wheel 51A installed on the frame...
  • Page 240 Assembly guide enerAl view...
  • Page 241 Assembly guide Arts of the issue Rear left tyre Screw M 1.7 x 3.5 mm (x 3) Reinforcement bar Mounting the reinforcement bar on the upper frame ssembly diAgrAm...
  • Page 242 Assembly guide steP Position the reinforce- ment bar (52B) on the upper frame supports (47A) and secure it with two IM screws (shown opposite). 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 Please note the deeper (2mm Rear left wheel assem- deep) highlighted red recess bly begins with identifi- pointed by green arrow, versus cation of 52A narrow (1mm deep) highlighted red Tire side having a recess pointed by orange arrow. deeper recess for 53A Outer wheel rim.
  • Page 245 Parts of the issue 53 steP Fix 53B Inner and 53A Outer rear wheel rims with three BM screws. Rear right wheel is preassembled for mounting on Chassis. steP Note the positioning rib on 53A Outer rear wheel rim hub axle (red arrow).
  • 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 Cabin bulkhead Electrical cable (red) Voltage regulator Left tubular frame post Electrical cable (blue) Right tubular frame post Separation of the cabin. Preassembly of the firewall ssembly diAgrAm...
  • Page 249 Parts of the issue 54 steP Position both electric cables, blue (54C) and red (54D), on the cabin bulkhead (54A) - grey side - by clamping them together. steP Position the voltage regulator (54B) above the Blue 54C and Red 54D power cables on the cabin’s bulkhead (54A) - grey side.
  • Page 250 Assembly guide steP Cut the length of the electric blue (54C) and red (54D) cables (red arrows) that protrude from the cabin’s bulk- head 54A (silver side). steP Position the left tubular frame post (54E) on the cabin’s bulkhead (54A) - silver side.
  • Page 251 Parts of the issue 54 enerAl view...
  • Page 252 Assembly guide Arts of the issue Plexiglass partition Buckle, bottom (x 2) Seat belt support (x 2) Buckle lock (x 2) Seat belt (x 2) Double-sided tape (x 3) Buckle, top (x 2) Assembly of seat belts and cabin’s bulkhead ssembly diAgrAm...
  • Page 253 Parts of the issue 55 steP Position the plexiglass partition (55A) on the cabin’s bulkhead (54A) - grey side - using the six pins provided. steP Pass the seat belt (55C) through the top buckle (55D) as indicated by the red arrows. Repeat the operation with the second belt (55C).
  • Page 254 Assembly guide steP Pass the seat belt (55C) through the buckle lock (55F). Apply double-sided adhesive (55G) to the end of the seat belt (55C). Remove the backing paper (red arrow) from the adhesive (55G), then fold the belt over and stick the free end (blue arrow) so that it holds the buckle (55F).
  • Page 255 Parts of the issue 55 enerAl view...
  • Page 256 Assembly guide Arts of the issue Ignition coil (x 2) Blue cable Fire extinguisher Black cable Brown cable Fire extinguisher Red cable Black cable Branch connector Black cable sheath Ignition box Fire extinguisher hose White cable Ignition box Adhesive tape (x 6) Red cable Rev limiter relay Regulator housing...
  • Page 257 Parts of the issue 56 steP Position the ignition box (56L) on the cabin’s partition (54A). Cut the quantities and lengths of the coloured cables as shown opposite. steP Insert the white (56E); red (56F); yellow (56G); blue (56H) and brown (56I) wires previously cut into the two lower openings of the cabin bulkhead (54A), then connect their ends to the slots above the ignition box (56L), as shown below.
  • Page 258 Assembly guide steP Insert the remaining white (56E), red (56F), yel- low (56G) cables previously cut, as well as the black cable (56J), into the black jacket. Pass the sheath (56D) - with the coloured cables inside - through the opening in the cock- pit bulkhead (54A) as shown above.
  • Page 259 Parts of the issue 56 steP Cut two lengths of 30 mm of the red cable (56C). Cut the quanti- ties and lengths of the black cable (56B) as detailed opposite. steP Connect the two red Connect the two black cables (56B-2), pre- cables (56C) and the viously cut, to the nipples, centrally positioned, two black wires (56B-...
  • Page 260 Assembly guide steP Cut two lengths of 250 mm from the fire extinguisher hose (56R). Connect the two fire extinguisher hoses (56R), cut previously, to the sides of the branch connector (56Q). steP The two fire extingui- sher hoses (56R) are attached to the bypass connector (56Q).
  • Page 261 Parts of the issue 56 steP Start by aligning the cabin’s bulkhead (54A) above the location it is to be integrated into the chassis. steP Before attaching the cabin’s bulkhead (54A) to the chassis, connect the two brake lines (40F) to the two nipples at the bottom of the partition (red arrows).
  • Page 262 Assembly guide steP The two black wires (56B-2) are connected to the two free ignition wire connectors (22C). Attach the cabin’s partition (54A) to the lower frame (25A) with two BM screws. As- semble the two fire extinguisher halves (56O and 56P). steP Position the fire extinguisher (56O)
  • Page 263 Parts of the issue 56 steP Attach the fire extinguisher hoses (56R), along the two upper lateral tubes of the en- gine cradle, with four pieces of tape (56S) - illustra- tions opposite and below. Leave both ends of the fire extinguisher hoses (56R) free at the rear and top of the engine.
  • Page 264 Assembly guide Arts of the issue Trumpet panel right Fuel line Trumpet cap (x 6) Guide to Fuel line Trumpet collar (x 6) M Screw 1.7 x 3.5 mm (x 3) Intake nozzle Assembly and mounting of the right intake trumpet panel and fuel lines to the engine ssembly diAgrAm...
  • Page 265 Parts of the issue 57 steP Detach the six intake nozzles (57D) from the sprue and position them on the right-hand trum- pet panel (57A) - illus- trations opposite. steP Cut the fuel line (57E) into three lengths: 57E-1 (125 mm), 57E-2 (135 mm), 57E-3 (155 mm) and 57E-4 (160 mm).
  • Page 266 Assembly guide steP Undo the two IM screws and remove the rein- forcement bar (50B). Carefully lift the igniter head (22B) to facilitate the passage of the three fuel lines 57E-1 through the two guide lines (18D). Follow the flow sequence as indi- cated by the red, blue and green...
  • Page 267 Parts of the issue 57 steP Replace the reinforcement bar (50B) by passing it under the fuel line (57E-2) - the highest one - and reattach it with two IM screws to the engine cradle. Check that no fuel lines run over the inlet trumpets (16D) - red arrow - and attach the right-hand panel...
  • 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 trum- pets 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 intake cover Engine cover Right air intake cover M Screw 1.2 x 3.5 mm (x 13) Mounting of engine and air intake covers ssembly diAgrAm...
  • Page 275 Parts of the issue 59 steP Fit the engine cover (59C) over the left (58A) and right (57A) intake trumpet panels and secure with five LP screws (see illus- trations). steP Position the left air intake cover (59A) on the left trumpet panel (58A) and secure it with two LP screws.
  • Page 276 Assembly guide steP All covers are mounted on the engine. enerAl view...
  • Page 277 Assembly guide Arts of the issue Battery Strap Battery cover Battery holder Battery terminal (x 2) Gear lever with gear rod Battery cable Gearbox rod Battery cable M Screw 1.2 x 3.5 mm (x 3) Assembly and mounting of the battery and gear lever ssembly diAgrAm...
  • Page 278 Assembly guide steP Position the cables (60D and 60E) on the two battery terminals (60C). Position the terminals (60C) onto the battery (60A) and secure with two LP screws. Position the battery (60A) on the holder (60G). steP Place the strap (60F) on top of the cover (60B) and battery (60A), and underneath the holder...
  • Page 279 Parts of the issue 60 steP Connect the gear lever (60H) and the gearbox rod (60I), then pass the latter through the ope- ning in the cockpit bulk- head (54A) - see illustra- tions opposite. steP Guide the gearbox rod (60I) to the gearbox sup- port (53E) and connect it to it (see illustrations).
  • Page 280 Assembly guide steP Position the gear lever (60H) on the right side of the chassis (34A) in the cockpit. enerAl view...
  • Page 281 Assembly guide Arts of the issue Driver’s seat upholstery Upper safety belt Driver’s seat Seat adjustment lever Lower safety belt Adhesive tape (x5) Buckle lock screw M 1.7 x 4 mm screw (x 5) Driver’s seat assembly and installation ssembly diAgrAm...
  • Page 282 Assembly guide steP Pass the lower safety belt (61C) through the slot in the driver’s seat upholstery (61A) and fit the lock (61D) in its buckle. Route the opposite end of the lower safety belt (61C) around the pin on the driver’s seat uphols- tery (61A) - blue arrow - and secure with two...
  • Page 283 Parts of the issue 61 steP Position the midpoint of the upper safety belt (61E) halfway across the base of the driver’s seat (61B) - red arrow - and secure with two pieces of tape (61G). Ensure the tapes are a minimum of 2 mm from the moun- ting holes (blue arrows).
  • Page 284 Assembly guide enerAl view...
  • Page 285 Assembly guide Arts of the issue Passenger seat upholstery Screw M 1.7 x 4 mm (x 5) Passenger seat Passenger seat assembly and installation ssembly diAgrAm...
  • Page 286 Assembly guide steP Mount the passenger seat upholstery (62A) to the passenger seat (62B) and secure with two AP screws. Position the passenger seat (62B) on the lower chassis (25A). steP Secure the passenger seat (62B) to the lower chassis (25A) with two AP screws.
  • Page 287 Parts of the issue 62 enerAl view...
  • Page 288 Assembly guide Arts of the issue Dashboard Ignition key Lever Dashboard decal (x2) Starter switch Assembly of the dashboard ssembly diAgrAm...
  • Page 289 Parts of the issue 63 steP Fit the lever (63B) to the dashboard (63A). Detach the starter switch (63C) from its support. steP Install the starter switch (63C) on the dashboard (63A). Separate two sets of the dashboard decals (63E) and start using one of them.
  • Page 290 Assembly guide steP Dip decals (63E-1) in Fuel pump» (Benzin P.) and water for 15 seconds «Light» (Licht) decals to be and then peel off the applied to the dashboard decals and apply them (63A). to the dashboard (63A) as shown. steP Dip decal (63-E-2) in water for 15 seconds,...
  • Page 291 Parts of the issue 63 enerAl view...
  • Page 292 Assembly guide Arts of the issue Instrument panel cover Switch panel Fuel pump contactor Instrument panel Interrupters Switch (x 2) Dials Interrupters Switch Reflector panel Interrupters (x 6) screw M 1,7 x4mm (x8) Switch panel Interrupters (x 2) screw M 2,0 x5mm (x5) Instrument panel and dashboard assembly ssembly diAgrAm...
  • Page 293 Parts of the issue 64 steP Disconnect the cable from the horn sound switch (34E / green), the cable from the light switch (35H / white), the cable from the en- gine sound switch (34D / blue) and the cable from the instrument light LED (35I / red- white).
  • Page 294 Assembly guide steP Position the reflector panel (64D) on the instrument panel (64B), with the dial block (64C) in the middle and fix with two AP screws. Mount the instrument LED light (35I) on the reflector panel (64D). steP Position the instrument panel (64B) on the dashboard (63A) by passing the instrument backlight LED cable (35I) through the opening provided.
  • Page 295 Parts of the issue 64 steP Position switches (64L & 64M) on the instrument panel (63A) as shown below. Position the switch panel (64E) on the instrument panel (63A), ensuring that the contactors can be pressed with their respective swit- ches(64L &...
  • Page 296 Assembly guide steP Install the fuel pump contactor (64K) and the five interrupters (64I) on the dashboard (63A). steP Detach two interrupters (64J) from the sprue. Install the two interrupters (64J) into the switch panel (64F). steP Detach the Interrupters (64H & 64G) from the sprue. Install the Interrupters (64H & 64G) into the switch panel (64F).
  • Page 297 Parts of the issue 64 steP Mount the switch panel (64F) on the dashboard (63A) and secure with an AP screw. Bundle the blue, green, white and red-white cables and route them towards the left-hand side of the dashboard (63A). enerAl view...
  • Page 298 Assembly guide Arts of the issue Flat front floor Screw M 2,0 x 4 mm (x 5) Installation of the dashboard and front flat base ssembly diAgrAm...
  • Page 299 Parts of the issue 65 steP Before installing the dashboard (63A) onto the dashboard frame (27A), route the four dashboard cables (blue, green, white and red-white) between the frame (31A) and the connection panel (31C) as indicated by the red arrow (illustrations below). steP Connect the wires (35I - red-white), (35H - white),...
  • Page 300 Assembly guide steP Attach the dashboard (63A) to the dashboard frame (27A) from un- derneath the car with two MP screws. Attach the instrument panel (63A) to the instrument panel frame (27A) - at the front left wheel - with a PM screw. steP Attach the dashboard (63A) to the dashboard frame (27A) at the right front wheel with an MP screw.
  • Page 301 Parts of the issue 65 steP Disconnect the headlight LED cables (35F) on the right and left. Put them aside for future use. Position the front flat bottom (65A) onto the lower frame (25A) and secure with four PM screws. steP The front flat base (65A) is installed on the...
  • Page 302 Assembly guide enerAl view...
  • Page 303 Assembly guide Arts of the issue Water radiator Metal hose (x 2) Radiator front panel Connector (x 4) Radiator left side Water pipe Coupling (x 4) Screw M 1,7 x 4 mm (x 3) Radiator right side Screw M 2,0 x 5 mm (x 3) Assembly and installation of the water radiator...
  • Page 304 Assembly guide steP Position the radiator Attach a coupling (66D) and a front panel (66B) on the connector (66G) to each end of the water radiator (66A) metal hose (66F). Make a second and secure it with two identical assembly. MP screws.
  • Page 305 Parts of the issue 66 steP Position one of the two cutted lengths of water hose (66H) over the nozzle of the water pump housing (8A) - from which the oil hose (37B) has just been removed - and then run it under the edge of the cockpit bulkhead (54A) - illustrations opposite...
  • Page 306 Assembly guide steP Run the second cut length of the water hose (66H) under the left lower side of the cockpit bulkhead (54A). Leave the end hanging loose, as this will be connected in a later stage. There should be two free water pipes (66H and 37B) as shown.
  • Page 307 Parts of the issue 65 enerAl view...
  • Page 308 Assembly guide Arts of the issue Flat cockpit floor Screw M 2,0 x 4 mm (x 7) Installation of the flat cockpit floor ssembly diAgrAm...
  • Page 309 Parts of the issue 67 steP Unscrew the two mar- ked CM screws from lower frame (25A). steP Align and position the flat floor of the cock- pit (67A) on the lower frame (25A) and secure it with two PM screws replacing the two CM screws that were just removed.
  • Page 310 Assembly guide steP Complete the fixation of the flat cockpit floor (67A) to the lower frame (25A) with four additional PM screws. enerAl view...
  • Page 311 Assembly guide Arts of the issue Left cockpit housing Handbrake cable Right cockpit housing Screw M 1,7 x 3,5 mm (x 9) Handbrake Installation of the lateral cockpit housings and hand brake ssembly diAgrAm...
  • Page 312 Assembly guide steP Position the right cock- pit housing (68B) on the lower frame (25A) and onto the chassis (34B) ensuring that the rear edge slides under the reinforcement of the cockpit bulkhead (54A) - blue arrow. steP Attach the right cockpit housing (68B) to the chassis (34B) with two IM screws (blue ar-...
  • Page 313 Parts of the issue 68 steP Position the handbrake cable (68D) onto the handbrake (68C), then position the assembly onto the right-hand cockpit housing (68B). Position the free end of the handbrake cable on the pin situated on the cockpit bulkhead (54A). steP Before installing the left cockpit housing...
  • Page 314 Assembly guide steP Attach the left cockpit housing (68A) onto the chassis (31B) with two IM screws (blue arrows) and onto the lower frame (25A) with one IM screw (green arrows). Consult the illustrations below and in the previous step. Replace the two water hoses (66H) against the left cockpit housing (68A).
  • Page 315 Assembly guide Arts of the issue Platform left side Pump coupling Fuel pump Connector Protective shield Shielded/Protected fuel line Assembly of the left side platform and fuel pump ssembly diAgrAm...
  • Page 316 Assembly guide steP Position the fuel pump (69B) on the protective shield (69C). Position the shield (69C) and pump onto the left side platform (69A). steP Position the shielded fuel line (69F) onto the pump coupling (69D) via the connector (69E). Position the pump connector (69D) onto the fuel pump (69B).
  • Page 317 Parts of the issue 69 enerAl view...
  • Page 318 Assembly guide Arts of the issue Oil tank support frame Fitting (x 2) Fuel manifold Fuel hose Shielded fuel line (x 2) Electrical switch Installation of the fuel manifold on the left side platform, assembly of the fuel lines ssembly diAgrAm...
  • Page 319 Parts of the issue 70 steP Position the fuel hose (70F) onto the fuel cap (70C). Position the cap (70C) onto the fuel ma- nifold (70B). Position the fuel manifold (70B) on the left side platform (69A). Connect the fuel hose (70F) to the pin positioned on the left side platform (69A).
  • Page 320 Assembly guide enerAl view...
  • Page 321 Assembly guide Arts of the issue Oil filler cap Strap Screw M 1.7 x 4 mm (x 5) Handle Thermostat Screw M 2.0 x 5 mm (x 3) Oil tank body Oil hose Screw M 1.7 x 3.5 mm (x 3) Oil tank body Oil hose Screw M 2.0 x 4 mm (x 3)
  • Page 322 Assembly guide steP Position the bracket (71E) on the oil tank body (71C) and secure it with two AP screws. Po- sition the oil tank body (71D) on the bracket (71E) and secure with two AP screws. steP Position the oil tank support frame (70A) on the oil tank body (71C) and secure with two MP screws. Position the thermostat (71G) on the tubular bar of the oil tank support frame (70A).
  • Page 323 Parts of the issue 71 steP Position the oil tank support frame (70A) on the left side platform (69A) and fix with two IM screws. Cut two sections of oil hose 71H: 71H-1 = 140 mm and 71H-2 = 40 mm. steP Position the oil hose (71H-1) and handle...
  • Page 324 Assembly guide steP Position the oil hose (71I) between the oil tank nozzle (71C) and the thermostat (71G). steP Position the arm (71J) - the end with the smallest peg - over the oil tank support frame (70A) and along the oil tank (71D).
  • Page 325 Parts of the issue 71 steP Point the oil line (37B) - highlighted in red - and the water line (66H) - highlighted in green - upwards as shown. steP Position the left side platform (69A) on the lower frame (25A), pla- cing the end of the arm (71J) in the slot located on the upper frame...
  • Page 326 Assembly guide steP Attach the left side platform (69A) to the lower frame (25A) with two screws BM. steP Position the water hose (66H) - highlighted in green - on the thermostat (71G) and the oil hose (37B) - highlighted in red - on the oil tank nozzle.
  • Page 327 Parts of the issue 71 steP Position the shielded fuel line (69F) onto the connector (38D) of the fuel filter (38B). enerAl view...
  • Page 328 Assembly guide N°18 Arts of the issue Left rear wheel arch Screw M 1.7 x 3.5 mm (x 6) Rear brake cooling valve Screw M 2.0 x 4 mm (x 4) Installation of fuel and oil lines, instal- lation of left rear wheel arch ssembly diAgrAm...
  • Page 329 Parts of the issue 72 steP Position the oil filler cap (71A) on the oil tank (71C) and guide the oil hose (71H-1) - highlighted in red - through the engine tube frame to secure it above the engine oil tank cover (46C).
  • Page 330 Assembly guide steP Position the rear brake cooling valve (72B) on the left rear wheel arch (72A). Position the left rear wheel arch (72A) on the upper frame (47A), placing its front bracket under the left lateral platform (69A). Secure the left rear wheel arch (72A) to the upper frame (47A) with five IM screws.
  • Page 331 Parts of the issue 72 enerAl view...
  • Page 332 Assembly guide Arts of the issue Platform right side Connector Fuel pump Shielded fuel line Protective shield Fuel line Pump coupling Assembly of the right side platform and fuel pump ssembly diAgrAm...
  • Page 333 Parts of the issue 73 steP Cut two sections from the fuel line (73G): 73G- 2 90 mm and 73G-1 50 mm. Connect the fuel line (73G-2) onto the nipples of the right side platform (73A). steP Position the fuel pump (73B) on the protective shield (73C) after connecting the fuel line (73G-1) to the nipple located at the bottom of the pump.
  • Page 334 Assembly guide steP Position the pump cou- pling (73D) on the fuel pump (73B). enerAl view...
  • Page 335 Assembly guide Arts of the issue Battery Battery holder Protective shield Battery cover Screw M 1.2 x 3.5 mm (x 3) Battery terminal (x 2) Assembly and mounting of the emergency battery ssembly diAgrAm...
  • Page 336 Assembly guide steP Position the two battery terminals (74D) on top of the battery (74A) and secure with two LP screws. Place the cover (74C) on the battery (74A). steP Position the battery hol- der (74B) on the right side platform (73A). Position the battery (74A) on the battery holder (74B).
  • Page 337 Parts of the issue 74 enerAl view...
  • Page 338 Assembly guide Arts of the issue Fuel filler neck Discharge pipe Fuel line Fuel filler neck Discharge pipe Shielded fuel line Fuel filler cap Fuel pump Screw M 2.0 x 4 mm (x 3) Handle Connector (x 3) Screw M 1.7 x 4 mm (x 4) Tray Pump connector Assembly and mounting...
  • Page 339 Parts of the issue 75 steP Assemble the two filler neck halves (75A & 75B) and secure with two AP screws. Position the filler neck (75B) on the right side platform (73A), inserting the tray (75E), and secure with an AP screw. Connect the discharge hoses (75F &...
  • Page 340 Assembly guide steP Position the oil hose (71H-1) and handle (71B) on the filler cap (71A). Position the oil hose (71H-2) between the nozzle of the oil tank (71C) and the thermos- tat (71G). steP Connect the two shielded fuel lines (70G) to the nipples at the filler neck (75B) via the connectors (75I).
  • Page 341 Parts of the issue 75 steP Detach the oil hose (39B) from the frame (39A) - red arrow - to facilitate connection of the shielded fuel lines (73F & 75L) to the two connectors (39C). Position the pump connector (75J) onto the fuel pump (75H). Re- place the hose (39B) on the frame bar (39A) - green arrow, illustrations above.
  • Page 342 Assembly guide Arts of the issue Right rear wheel arch Screw M 1.7 x 3.5 mm (x 6) Rear brake cooling bailer Screw M 2.0 x 4 mm (x 4) Installation of the right rear wheel arch ssembly diAgrAm...
  • Page 343 Parts of the issue 76 steP Position the rear brake cooling bailer (76B) on the right rear wheel arch (76A). Position the right rear wheel arch (76A) on the upper frame (47A), placing its front support under the right side platform (73A). Se- cure the right rear wheel arch (76A) to the upper frame (47A) with five IM...
  • Page 344 Assembly guide enerAl view...
  • Page 345 Assembly guide Arts of the issue Spare tyre Spare wheel strap Outer rim Screw M 2.0 x 4 mm (x 4) Inner rim Spare wheel assembly and installation ssembly diAgrAm...
  • Page 346 Assembly guide steP Position the outer wheel rim (77B) into the spare tyre (77A). Position the inner wheel rim (77C) into the spare tyre (77A), aligning it with the outer rim (77B) and secure it with three BM screws. steP Check that the quick release lever is poin- ting upwards when the...
  • Page 347 Parts of the issue 77 steP Position the spare wheel on the reinforce- ment frame (45A) and between the two upper frame bars (47A). Tilt the spare wheel strap (77D) over the spare tyre (77A), with the quick release lever now pointing upwards - red arrow.
  • Page 348 Assembly guide enerAl view...
  • Page 349 Assembly guide Arts of the issue Front left brake cooling jacket Brake Support (x 4) Front right brake cooling jacket Fitting of front brake cooling jackets ssembly diAgrAm...
  • Page 350 Assembly guide steP Locate the air intake on the right brake bailer (30I) - seen here from below - located in the right front wheel. Position the right brake cooling jacket (78B) over the air intake on the right brake bailer (30I) - seen here from above.
  • Page 351 Parts of the issue 78 steP Adjust the right (78B) and left (78A) brake cooling jackets so that they rest in the right (green arrow) and left (red arrow) slots respec- tively at the front of the flat front floor (65A). enerAl view...
  • Page 352 Assembly guide Arts of the issue Wheel arch, left Screw M 1.7 x 3.5 mm (x 8) Wheel arch, right Installation of front right and front left wheel arches ssembly diAgrAm...
  • Page 353 Parts of the issue 79 steP Position the left wheel arch (79A) on the front flat floor (65A) and fix it with three IM screws. Position the right wheel arch (79B) on the front flat floor (65A) and secure with three IM screws.
  • 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 Bo- dywork.
  • Page 357 Parts of the issue 80 enerAl view...
  • Page 358 Assembly guide Arts of the issue Right headlight plexiglass nacelle Left headlight protection (x2) Right headlight housing Right headlight protection (x2) Big headlight bezel Big headlight reflector Big headlight lens M1,7 x4mm (x3) Small headlight housing (R) M1,7 x4x5mm (x3) Small headlight lens M1,7 x4x6mm (x5) Headlights assembly and...
  • 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, we 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 new 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 (blue, x6) Left air scoop Hood cover lock (orange) Right air scoop Hood cover lock (white) Left air build up release grid Decal (x2) Right air build up release grid M1,7 x3,5mm (x9) Bodywork fittings and decal attachment...
  • 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 (upper 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 IM...
  • Page 366 Assembly guide steP 82A Air intake mesh is attached to the Bodywork Nip off 82F, 82G and 82H Hood cover locks off the sprues. steP Attach temporarily 1B Hood cover on four 82F Hood cover locks (blue ) to 80A Bodywork. Cut off one set of 82I Decal, put in water for about 60 seconds, and slide carefully on 80A Bodywork...
  • Page 367 Parts of the issue 82 steP While 82I Decal is well wet, move it to adjust to the number 20 image below, allowing its lower edge to overlap on 1B Hood cover (dotted red line). Once aligned, remove four 82F Hood cover locks, and lift away 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 Bodywork with four more IM screws.
  • Page 374 Assembly guide enerAl view...
  • Page 375 Assembly guide Arts of the issue Air scoop Rear view mirror Windscreen wiper Left door lock Rear view mirror housing Right door lock Rear view mirror bracket M1,7 x3,5mm (x3) Bodywork fittings attachment and rear mirror assembly ssembly diAgrAm...
  • Page 376 Assembly guide steP Attach 85A Air scoop to the underside of 80A Bodywork. 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...
  • 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 mir- ror bracket to 85C Rear view mirror housing. steP Sore safely the preas- sembled Rear view mir- ror until further assem-...
  • Page 378 Assembly guide enerAl view...
  • Page 379 Assembly guide Arts of the issue Lower hinge Pin (short) Top hinge Latch Door light Release button Lock Spring Pin (long) Screw M 1.7 x 3.5 mm (x 2) Assembly and installation of the left door lock and door light ssembly diAgrAm...
  • Page 380 Assembly guide steP Insert the long pin (86E) into the locking body (86D). Position the spring (86I) and latch (86G) on the long pin (86E). steP Align the latch pin (86G) with the locks (86D), then insert the short pin (86F). Position the release button (86H) on the long pin (86E).
  • Page 381 Parts of the issue 86 steP Press the release button (86H) to ensure that the latch (86G) swings out. Position the lock assembly (86D) at the rear of the left door (1A) and secure with an IM.
  • Page 382 Assembly guide steP Press the release button (86H) again to ensure that the latch (86G) still swings out correctly. Position the door light (86C) on the left door (1A) ensuring that the light is pointing forward.
  • 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) Clamp M1,2 x3mm (x9) Spring 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 opening 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 Top hinge Lower hinge Decal (x 2) Position of the decal with the car’s race number on the right door ssembly diAgrAm...
  • Page 390 Assembly guide steP Immerse the decal (88D) into water for 60 seconds, then carefully slide it onto the outside of the right door (88A). steP Align and position the decal according to the following illustration. Wait 3 minutes for it to set, then gently smooth it with a soft cotton pad.
  • Page 391 Parts of the issue 88 enerAl view...
  • Page 392 Assembly guide Arts of the issue Window Latch M2,0 x4mm (x5) Vent window Lock release M1,7 x3,5mm (x2) Clamp Pin (longer) M2,0 x7mm (x2) Clamp Pin (shorter) M1,2 x3mm (x9) Door light Spring (smaller) M2,0 x3mm (x2) Lock Spring (larger) M2,0 x5mm (x3) Right door assembly and attachment...
  • 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 Place 88C Upper hinge axle into 80A Bodywork cradle and fasten with 89D Clamp and JM screw. 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.
  • Page 397 Parts of the issue 89 steP Push 89H Lock release to test opening of 88A Right door as shown further. steP Check opening and clo- sing 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 Bodywork 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 Double-sided circular tape Right air duct Screw M 1.7 x 3.5 mm (x 5) Clear cap Mounting the air ducts and transparent cap to the rear bonnet ssembly diAgrAm...
  • Page 404 Assembly guide steP Position the left air duct (91A) on the inside of the rear bonnet (90A) and secure with two IM screws. Position the right air duct (91B) on the inside of the rear bonnet (90A) and secure with two IM screws. steP Remove the circular double-sided tape (91D)

  • Page 405: General View

    Parts of the issue 91 steP Left (91A) and right (91B) air ducts as well as the clear cap (91C) are attached to the rear bonnet (90A). enerAl view...
  • Page 406 Assembly guide Arts of the issue Top centre spoiler Screw M 1.7 x 3 x 5 mm (x 3) Bottom centre spoiler Assembly of the rear centre spoiler and installation to the rear bonnet ssembly diAgrAm...
  • Page 407 Parts of the issue 92 steP Assemble the top (92A) and bottom (92B) of the centre spoiler. Place the centre spoiler as- sembly - top (92A) and bottom (92B) - onto the rear bonnet (90A). steP Attach the centre spoi- ler assembly - top (92A) and bottom (92B) - to the rear bonnet (90A)
  • Page 408 Assembly guide enerAl view...
  • Page 409 Assembly guide Arts of the issue Rear bonnet panel Fuel hose (short) Lock support (x 2) Fuel vent hose Screw AP Lock (x 2) M 1.7 x 4 mm (x 3) Fuel hose (long) Rear bonnet panel assembly and fuel line adjustment ssembly diAgrAm...
  • Page 410 Assembly guide steP Position the two locks (93C) on the two lock supports (93B). Position the two lock supports (93B) on the rear bonnet panel (93A) and secure them with two AP screws. steP On the left side of the chassis, detach the fuel hose (70F) - highlighted in red.
  • Page 411 Parts of the issue 93 steP After reconnecting the shielded fuel line (70G) as described in the previous step, fit the fuel hose - long (93D) to the nozzle located on the right side platform (73A), then point the free end towards the other side of the chassis, sliding it along the front of the engine.
  • Page 412 Assembly guide steP General layout of fuel hoses enerAl view...
  • Page 413 Assembly guide Arts of the issue Left side spoiler (L) Screw NP M 1.2 x 2.5 mm (x 10) Right side spoiler (R) Screw IM M 1.7 x 3.5 mm (x 5) Rear bonnet light Assembly of spoilers and installation of rear bonnet panel ssembly diAgrAm...
  • Page 414 Assembly guide steP Position the left spoiler (94A) on the rear bonnet panel (93A) and secure with four NP screws. Position the right spoiler (94B) on the rear bonnet panel (93A) and secure with four NP screws. steP Position the rear bon- net panel (93A) on the rear bonnet (90A) and secure with four IM...
  • Page 415 Parts of the issue 94 enerAl view...
  • Page 416 Assembly guide Arts of the issue Left half ventilation duct Right half ventilation duct Left half ventilation duct Screw EP M 1.7 x 5 mm (x 4) Screw IM Right half ventilation duct M 1.7 x 3.5 mm (x 3) Screw JM Right half ventilation duct M 2.0 x 5 mm (x 8)
  • Page 417 Parts of the issue 95 steP Assemble the half-duct units (95A&95B) and secure them together with an EP screw to form the left ven- tilation duct (95AB) - top illustration. Assemble the half-duct units (95C&95D) and secure them together with an EP screw to form the right ventilation duct (95CD) - illustration above left. Assemble the half-duct units (95E&95F) and secure them together with an EP screw to form the right vent duct (95EF) - illustration above right.
  • Page 418 Assembly guide steP At the front end of the chassis, place the connectors for the headlight LED cables (35F) into the position indicated opposite. steP Position the body (80A) on the lower frame (25A) and on the flat front floor (65A). At the same time, guide the right duct (95CD) through the tubular trel-...
  • Page 419 Parts of the issue 95 steP Join the connectors for the headlight LED cables (35F), then move them sideways to conceal them (red arrows). steP Attach the screw threaded end of the right duct (95EF) to the nozzle of the right air intake (82C).
  • Page 420 Assembly guide steP Attach the screw- threaded end of the left duct (95AB) to the nozzle of the left air in- take (82B) with the help of a tweezer. Secure the body from below, to the front flat floor (65A), the lower frame (25A) and the left (35A) and right (35B) mudguards, using six...
  • Page 421 Parts of the issue 95 enerAl view...
  • Page 422 Assembly guide Arts of the issue Left rocker panel Bracket #3 Upper bracket Front panel Screw IM Bracket #1 (x 2) M 1.7 x 3.5 mm (x 14) Bracket #2 Assembly and installation of the left rocker panel ssembly diAgrAm...
  • Page 423 Parts of the issue 96 steP Position the brackets (96D #2, 96E #3) and the two brackets (96C #1) on the left rocker panel (96A), then secure them with four IM screws. Position the upper bracket (96B) and the front panel (96F) on the left rocker panel (96A), then secure them with three IM screws.
  • Page 424 Assembly guide steP Open the left door and secure the left rocker panel (96A) - via the upper bracket 96B - to the chassis (31B) using an IM screw, through an opening in the rear of the left cockpit housing (68A). steP Remove the CM screw from under the lower...
  • Page 425 Parts of the issue 96 enerAl view...
  • Page 426 Assembly guide Arts of the issue Rocker panel, right Bracket #3 Upper support Front panel Screw IM Bracket #1 (x 2) M 1.7 x 3.5 mm (x 14) Screw SM Bracket #2 M 1.7 x 3.5 mm (x 3) Assembly and fitting of the right side rocker panel ssembly diAgrAm...
  • Page 427 Parts of the issue 97 steP Place the brackets (97D#2 & 96E#3) and brackets (97C#1) on the right rocker panel (97A) and secure these with four IM screws. Place the upper support (97B) and the front panel (97F) onto to the right rocker panel (97A) and secure these with 3 IM screws.
  • Page 428 Assembly guide steP Open the right door and attach the right rocker panel (97A) – with the help of the upper sup- port (97B) – onto the chassis (34B) with an IM screw, through the opening in the back of the right cockpit hou- sing (68B).
  • Page 429 Assembly guide Arts of the issue Left trim panel Left trim strip Right trim panel Right trim strip Attaching trim panels and trim strips to the cockpit ssembly diAgrAm...
  • Page 430 Assembly guide steP Open the right door and secure the right trim panel (98B) with its four lugs to the right cockpit housing (68B). Attach the right trim strip (98D) along the edge of the right trim panel (98B) to the right cockpit housing (68B).
  • Page 431 Parts of the issue 98 steP Fit the left trim strip (98C) along the edge of the left trim panel (98A) to the left cockpit housing (68A). With the left trim strip (98C) and left trim panel (98A) attached, proceed to close the left door. enerAl view...
  • Page 432 Assembly guide Arts of the issue Flat floor panel Screw PM M 2.0 x 4 mm (x 6) Fixing bracket Screw MP M 2.0 x 4 mm (x 3) Screw OP Decal (x 2) M 1.7 x 3 mm (x 3) Screw BM M 2.0 x 4 mm (x 8) Assembly of switch,...
  • Page 433 Parts of the issue 99 steP Position the loudspeaker (34C) in the round recess provided in the flat floor panel (99A), and secure it with the mounting bracket (99B) and two MP screws - see illustrations above. steP Position the flat floor panel (99A) against the bottom of the upside-down car and...
  • Page 434 Assembly guide steP The previously connec- ted cables are now hidden underneath the flat floor panel (99A). Align the flat floor panel (99A) with the bottom of the car and secure it to the lower frame (25A) using five PM screws.
  • Page 435 Parts of the issue 99 steP Position the rear bon- net (90A) onto the body (80A) at a 45 degree angle (red arrow), then close the bonnet (blue arrow). Take care not to scratch the edge of the bodywork when clo- sing the bonnet (green arrow).
  • Page 436 Assembly guide enerAl view...
  • Page 437 Assembly guide Arts of the issue 100A Battery compartment cover 100C Decal door number (x 4) 100B Decal emblem (x 2) 100D Decal rear bonnet number (x 2) Position of Porsche emblem and race number decals on the sides and top of the rear bonnet ssembly diAgrAm...
  • Page 438 Assembly guide steP Immerse the emblem decal (100B) in water for 30 seconds to soften it. Position the decal (100B) on the bum- per at the front of the body (80A), then carefully slide it off its paper backing. While it is still wet, you are able to adjust the decal (100B), if necessary.
  • Page 439 Parts of the issue 100 steP Immerse the number decal for the rear bonnet (100D) in water for 30 seconds to soften it. Position the decal (100D) above and to the rear right of the rear bonnet (90A), then carefully slide it from its backing paper. Adjust the decal (100D) while it is still wet and remove any excess water with a soft cotton pad.
  • Page 440 Assembly guide steP Rear lights 48D et 49D Open the left door and press the switch (64L) to check that the lights are working as shown in the following three illustrations. steP The four front lights Dashboard backlights steP Press the brake pedal (26F) - the one in the middle - by using the tip of a pencil to check that the brake lights (48D &...
  • Page 441 Parts of the issue 100 steP Press the switch (64M) to activate the horn. Press the switch (64L) to activate the engine running sound. steP Place two supports (78C) underneath the left and right side of the car to keep the wheels raised and check that the steering wheel ro- tates correctly.
  • Page 442 Assembly guide enerAl view...

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