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MOTORCYCLE
Pack 05

MOTORCYCLE

22 The transmission cover 56

23 The engine assembly 58

24 The oil filter 60

25 Fitting the oil filter 61

26 The distributor 63

27 The transmission cover 65

Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP.
Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE.
Published in the USA by De Agostini Publishing USA, Inc.,121 E. Calhoun Street, Woodstock, IL 60098.
All rights reserved © 2018

Warning: Not suitable for children under the age of 14.


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

YOUR PARTS
PARTS 22 PARTS 23
B
A A

A. Brake disc A. Drive chain


B. Sprocket

PARTS 24 PARTS 25
A
A

B
C
D B

A. Crankcase D. Washer screws A. Transmission case


B. Tappet guide B. Screws
C. Plug

PARTS 26 PARTS 27

B C B C D E
A A

A. Screws A. Screws D. Gasket


B. Oil filter top B. Transmission cover E. Distributor
C. Oil filter C. Distributor base

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MOTORCYCLE
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STAGE 22: THE TRANSMISSION COVER


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

STEP 1 STEP 2

STEP 1 Prepare the tappet guide and plug from STEP 2 Align the end of the plug with the hole in
Parts 24. the guide.

STEP 3 STEP 4

STEP 3 Insert the end of plug into the hole. STEP 4 Here is how the assembly should look.

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STEP-BY-STEP ASSEMBLY

STEP 5 STEP 6

STEP 5 Prepare the transmission case (Parts 25) and STEP 6 Take the guide and the transmission case,
the washer screw (Parts 24). and hold them as shown.

STEP 7 STEP 8

STEP 7 Place the hole at the end of the tab over the STEP 8 Tighten the washer screw into the hole in the
post, as shown. post to secure the pieces together.

Stage complete

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MOTORCYCLE
from

STAGE 23: THE ENGINE ASSEMBLY


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

STEP 1 STEP 2

STEP 1 Prepare the transmission case from the STEP 2 Take the crankcase and the transmission
previous stage, as well as the crankcase (Parts 24) case, and hold them as shown.
and the screws from Parts 25.

STEP 3 STEP 4

STEP 3 Align the corresponding posts and holes of STEP 4 Press the posts into the holes.
both parts.

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STEP-BY-STEP ASSEMBLY

STEP 5 STEP 6

STEP 5 Turn the assembly to the side and check that STEP 6 Tighten one of the screws into one of the
the holes are aligned, as shown. aligned holes.

STEP 7 STEP 8

STEP 7 Tighten a screw into each of the two STEP 8 Here you can see how the assembly should
remaining holes to secure the two parts together. look with the screws in place.

Stage complete

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MOTORCYCLE
from

STAGE 24: THE OIL FILTER


In this stage, you assemble the oil filter.

STEP 1 STEP 2

STEP 1 Prepare the oil filter and oil filter top from STEP 2 The posts of the oil filter top are two
Parts 26. different sizes, so make sure before fitting the parts
together that both are oriented correctly.

STEP 3 Stage complete

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

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STEP-BY-STEP ASSEMBLY

STAGE 25: FITTING THE OIL FILTER


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

STEP 1 STEP 2

STEP 1 Prepare the engine assembly (Stage 23), STEP 2 The oil filter has two pins and two holes
the oil filter (Stage 24) and the screws from Parts 26. around the centre post at one end, and these
correspond with only one point on the engine
(see following steps).

STEP 3 STEP 4

STEP 3 Insert the central post at the end of the oil STEP 4 Turn the oil filter so that the two pins
filter into hole in the mount on the engine assembly. engage with their corresponding holes. The filter
can only fit one way.

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STEP 5 STEP 6

STEP 5 Tighten a screw into one of the aligned STEP 6 Here you can see the screw in position.
holes from inside the mount.

STEP 7 STEP 8

STEP 7 Tighten a second screw into the hole on the STEP 8 Here is how the assembly should look with
other side of the post. the oil filter fixed in place.

Stage complete

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STEP-BY-STEP ASSEMBLY

STAGE 26: THE DISTRIBUTOR


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

STEP 1 STEP 2

STEP 1 Prepare the engine assembly (Stage 25) STEP 2 The central post on the reverse of the gasket
and the gasket (Parts 27). is D-shaped, so will only fit into the engine one way.

STEP 3 STEP 4

STEP 3 Hold the gasket so that the D-shaped post is STEP 4 Press the gasket into place.
aligned with the matching hole in the engine.

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STEP 5 STEP 6

STEP 5 The posts and holes of the distributor STEP 6 Press the two parts of the distributor
and distributor base (Parts 27) only fit together together, as shown.
in one orientation.

STEP 7 STEP 8

STEP 7 Align the post on the distributor with the STEP 8 Push the post into the hole.
hole in the gasket.

Stage complete

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STEP-BY-STEP ASSEMBLY

STAGE 27: THE TRANSMISSION COVER


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

STEP 1 STEP 2

STEP 1 Prepare the engine assembly (Stage 26), STEP 2 Align the edge of the transmission cover with
the transmission cover and screws (Parts 27). the raised edge of the transmission case.

STEP 3 STEP 4

STEP 3 Place the cover onto the case, keeping the STEP 4 Hold the two parts together, making sure
edges aligned. that the holes of both are aligned.

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STEP 5 STEP 6

STEP 5 Tighten one of the screws into the hole at the STEP 6 Working around the edge, tighten another
end, using a flat-head screwdriver. screw into the next hole.

STEP 7 STEP 8

STEP 7 Tighten a third screw into the next hole STEP 8 Tighten the rest of the screws into the
around the edge of the transmission cover. remaining holes to secure the cover to the case.

Stage complete

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