Pack 03 - model-space.com

33

BUILD YOUR OWN

Pack 03

TM

TM

www.model-space.com

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., 915 Broadway, Suite 609, New York, NY 10010. All rights reserved © 2014Warning: 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.

CONTENTS

35Assembly Guide

Stage 8: The headlightStage 9: The brake caliperStage 10: The front fender

35

Honda CB750 FOUR: Assembly Guide

Stage 8

Headlight rim*Headlight retaining ring *Headlight reflector Headlight lensFront reflector bases × 2 Front reflector mounts × 2 Front reflectors × 2

*The headlight rim and headlight retaining ring come as one part but are not properly assembled.

Hold the black tube housing the LED cables and gently pull the headlight LED through, as shown, while holding the two indicator cables in place.

Hold the headlight LED as above, and carefully bend its wires around to a curve matching the one in the next step.Tools

Tweezers

PrepareFront fork (Stage 7)

The headlight

Your parts

1

2

36


Pull the other end of the headlight LED cable to bring the LED closer to the hole in the headlight case.

The wiring in the headlight case should now look like this. The headlight LED should be about 5mm above the hole, and there should be some slack in the indicator wires.

Hold the headlight reflector with the wide cutout at the top, and fit it into the headlight case, making sure the LED comes through the hole in the centre (circled).

Locate the cutouts at the top and bottom of the headlight reflector: one is wide and the other is narrow.

Pull the headlight LED cable

Top = wide

Bottom = narrow

Hold the black tube

Headlight LED

5

6

7

8

The headlight LED and its wiring should now look like this, with the LED itself at roughly a right angle to the red and grey wires. Pull the headlight LED wires out a bit

more (blue arrow), to make certain there is some slack. To ensure that the indicator cables don't move, hold them against the headlight case (red arrows).

3

4

37


The headlight rim (right) and headlight retaining ring (left) come as one part, but need to be assembled properly. There are projections at the top and bottom of the rim, and cutouts at the top and bottom of the ring.

Place the retaining ring into the headlight rim, aligning the cutouts and projections.

13

14

Gently push the reflector further into the case, aligning the cutout in the reflector with the corresponding projecting part of the headlight case. Like the reflector, the headlight lens has

cutouts at the top and bottom.

Place the lens onto the reflector, aligning its cutouts with the projections in the headlight case.

Hold the lens over the headlight case, with the wide cutout at the top.

Top = wide

Bottom = narrow

9

10

11

12

38


Align the projections on the headlight rim with the cutouts in the headlight case (all circled).

Push the projections into the cutouts. With tweezers, peel off the protective backing on the back of one of the front reflectors.

Hold the headlight rim in place and turn it clockwise a few millimetres to secure it. Apply pressure, but don’t force it.

17

18

19

20

Make sure the retaining ring is properly set into the rim.

15

16

Turn the retaining ring about 1cm in a clockwise direction to lock it into position.

39


Take one of the front reflector mounts and check that the recessed part is clear of any dust, then hold it and the reflector as shown.

Place the reflector into the centre of the reflector mount.

The pin projecting from the rear of one of the reflectors (circled) will fit into the hole in the left fork cover.

Insert the pin on the rear of the mount into the hole on the recessed side of one of the reflector bases. Repeat Steps 20-23 to assemble the second reflector.

Insert the reflector pin into the hole in the fork cover.

Insert the pin of the second reflector into the hole in the right fork cover.

The pin on the other reflector fits into the hole in the right fork cover.

21

22

23

24

25

26

27

Stage complete

40


Stage 9

Caliper ACaliper B Front brake disc Screws (type N) × 2 Screws (type U) × 2 Front wheel axle nut Front wheel axle Cross wrench

The brake caliper

PrepareFront forks (Stage 8)Front wheel (Stage 3)

The pins of caliper B fit into the holes of caliper A, as shown.

Push the pins of caliper B straight into the holes of caliper A.

Align the holes in the mounting bracket of caliper A with the projections on the left fork.

1

2

3

Your parts

41


Fit the holes in caliper A’s mounting bracket onto the projections on the fork.

Insert the projection of the brake disc into the notch in the hub.

Press caliper A firmly into place, so that it is flush with the fork.

Hold the wheel flat, as shown, then press down on the centre of the disc so that it sits securely in place.

Locate the projection on the front brake disc (circled) and the corresponding notch in the front wheel hub.

Check that the caliper looks like this from the rear, with the circled holes aligned.

Put all the parts you didn’t use – screws (type N), screws (type U), front wheel axle nut and front wheel axle – into a plastic bag labelled with the stage number and store it safely until the parts are needed. Keep the cross wrench with your tools.

Gap

Stage complete

4

5

6

7

8

9

10

42


Front fender stays × 2 Front fender Caliper holder Screw (type L) Screws (type C) × 4 Screws (type K) × 4 Allen key (1.5mm)

ToolsPhillips screwdriver (No. 1) Cross wrench

Caution: handle the front fender with care, as the edges may be sharp.

PrepareFront forks (Stage 9)Front wheel (Stage 3)Front wheel axle (Stage 9)Front wheel axle nut (Stage 9)Screw (type N) × 1 (Stage 9)Screw (type U) × 1 (Stage 9)

The front fender The holes L3, L4, R3 and R4, circled in blue in these photos, should be tapped prior to assembly. You should use a type C screw to tap the holes, as it has the correct diameter, and use the cross wrench received with Stage 9 to screw it in.

Take a type C screw and insert the head into the smallest end of the cross wrench. Press the projecting end of the screw into one of the blue-circled holes (above) and then turn the cross wrench as you would a screwdriver. Tighten the screw only about two-thirds of the way into the hole, and then unscrew it.

Threading the holes

R1

R3

R4

R2

L2

L4

L3

L1

Stage 10

Your parts

43


Place the fender between the front forks, with the caliper holder next to the left fork.

Remove the brake caliper fitted in the previous stage.

Align the circled holes of the fender bracket with holes L1 and R1 in the forks (see page 42).

Take the caliper holder and place it over the two circled holes on the left side of the front fender’s mounting bracket.

Hold the caliper holder in position and place a type L screw into the left-hand hole.

Use the cross wrench to tighten the type L screw into place.

1

2

3

4

5

6

44


Tighten the final type K screw into hole R2, securing the fender to the forks.

Fit the brake caliper to the left fork, as in the previous stage.

Tighten a type N screw into the indicated hole in the caliper.

Tighten a type K screw into hole R1.

9

10

11

12

Use the Allen key to tighten a type K screw into the hole in the fender bracket aligned with hole L1 on the left fork.

Once you have secured hole L1, tighten a type K screw into hole L2. This will secure the left side of the fender to the left fork.

7

8

45


Place one of the front fender stays over the rear of the fender, aligning the two projections with the two holes (arrowed).

Push the projections of the stay into place in the holes in the fender. Then test-fit the other stay to the front of the fender in the same way.

Tighten a type U screw into the hole at the rear of the caliper, to secure it to the fork.

From the left side, the screw holes of the ends of the fender stays should align with the screw holes L3 and L4 of the fork. Check that they align on the right side as well.

Check that you can align the screw holes in the stays with those of the forks.

13

14

15

16

46


Insert the projections of the second stay into the holes near the front of the fender.

Tighten the screw into the holes, then tighten another type C screw into the aligned stay and fork holes on the other side.

Align one of the holes of the rear fender stay with the hole in the fork. Place a type C screw into the small end of the cross wrench and tighten it into the aligned holes.

Tighten another type C screw into the aligned stay and fork holes on the other side.

Place a type C screw into the cross wrench and insert the end into the aligned holes.

1718

19

20 21

47


Place the front wheel between the forks, carefully guiding the brake disc into the slot in the brake caliper (circled).

Align the holes at the ends of the forks with the hole at the centre of the wheel hub. Insert the front wheel axle through the aligned holes.

Tighten the wheel axle nut onto the end of the axle.

Stage complete

22

23

24

20

Honda CB750 FOUR:

TM

Documents

Pack 03 - model-space.com