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Easy Rider Official Build Diary - Pack 11 Options
Levelord
#1 Posted : 18 July 2019 20:16:44

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Location: Celle, Germany
Stage 57


There is a lot to do in the build stage and to start with you will need the transmission case inner, brackets and two of the smallest screws from parts 58. Place one of the brackets over the recess at the front of the transmission case, secure the bracket with one of the small screws. Secure the other bracket in the same way.

Take the gearbox assembly from stage 53 and remove the pin linkage, Hold the gearbox as shown in step 7 of the instructions and place it into the space in the frame behind the engine. Position the gearbox centrally in the frame, aligning the corresponding holes of both parts. Tighten one of the screws supplied with parts 41 into the aligned holes on the left, then tighten the second screw from parts 41 into the holes on the right. Now tighten one of the longer screws from parts 51 into the lower hole in the gearbox, then tighten the second screw into the second lower hole. Finally, tighten the long screw from parts 51 into the hole in the underside.

Retrieve one self-tapping screw from parts 51, the rear fender and two of the screws from parts 40. Place the rear fender up against the back of the gearbox and the frame, aligning the corresponding holes of both. Secure the fender to the gearbox with the self-tapping screw, then secure the fender to the frame with the two screws from parts 40.

Retrieve the linkage lever, nuts and bolts from parts 55. Place the thin end of the lever into the end of the linkage, then insert one of the bolts through both parts and tighten with a nut. Pass the other end of the linkage through the frame under the gearbox and align the hole at the end of the linkage with the hole in the bracket, pass a bolt through and tighten with a nut.

Retrieve the drive chain supplied with parts 23 and place the chain around the sprocket on the gearbox. Retrieve the gearshift assembly from stage 19 and place the plate onto the side of the frame, aligning the holes of both. Tighten the short bolt from parts 19 into the forward hole. Now tighten the washer screw into the central hole.

You now need the transmission case inner, speaker, switch, three long screws and one washer screw from parts 58. Pass the speaker cable through the square hole in the transmission case, then place the speaker into the ring in the case. Lead the speaker cable up through the hole in the mounting plate. Now insert the D-shaped post at the end of the linkage into the hole at the top of the case. Place the case inner onto the side of the engine and gearbox and tighten one of the screws into the aligned holes of the case and engine. Tighten the other two screws into the other two holes.

The switch has a hole that matches the D-shaped post, place the switch onto the post, positioning the other end between the two black parts. Tighten the washer screw into the hole in the post to secure the switch. Test that when the gear lever is shifted the switch moves forward in the case.

You now need the screws and oil tank mounting plate from parts 50 and the circuit board from parts 49. Place the circuit board onto the corresponding posts of the plate and secure with the three screws. Retrieve the oil tank and three screws from parts 48, Insert the assembly into the oil tank, circuit board first and secure together with the screws. Pass the cable ends up through the hole in the oil tank and pull the ends through the top of the tank. Place the oil tank in the frame, on top of the mounting plate above the gearbox and secure from inside the rear fender with two screws from parts 48.

Secure the front of the oil tank with screws from parts 58. Retrieve linkage you removed earlier, pass the linkage through the frame, above the gearbox, aligning the hole with the post. Pas the bolt back through the linkage into the post and tighten in place.

Retrieve the clutch linkage from Stage 18 and the U-shaped clamp and nuts from parts 18. Place the linkage onto the left side of the frame as shown in step 57 of the instructions, then place the U-shaped clamp over the inside of the frame into the two holes on the inside of the linkage. Tighten the two nuts onto the end of the clamp. Place the end of the linkage rod into the end of the linkage and using pliers, press the parts together. Use glue to strengthen the connection.

You need the rear wheel from stage 54 and the parts from parts 54 and 22. Place the bushing from parts 54 into the centre of the wheel, the place the brake disc from parts 22 onto it. Now place the rear wheel between the sides of the frame, lifting the chain onto the sprocket. Pull the chain around all of the sprocket and placing the wheel into the ends of the frames. Place the bushing shaft between the centre of the wheel and the right side of the frame. Now pass the axle through the frame, bushing and wheel and out the other side. Fit the plate over the end of the axle then tighten the nut onto the end. Place the lever onto the post on the disc and tighten the bolt into the post to secure the lever. Tighten two nuts onto the tension bolt, then tighten two nuts onto the tension bolt on the other side of the wheel.

Now take the chain cover from stage 56, the bolt from parts 58 and the bracket from parts 48. Take the bracket and locate the corresponding holes in the transmission case and the oil tank. Push the pins into the holes in the tank, then tighten the bolt into the aligned holes of the bracket and case. Place the hole in the chain cover plate over the post in the frame

Place the sissy bar from stage 16 on either side of the frame. Align the end of the sissy bar with the post in the frame that the chain cover plate is on and align the other end with the hole in the frame, as shown in step 81 of the instructions. Slide the sissy bar forward, making sure the strut is inside the rear fender, then secure it in place with the screws from parts 47.

Now take the rear lights and bolts from parts 46 and 47. Place the left rear lights onto the end of the frame, aligning the corresponding holes of both. Tighten the shorter bolt into the upper hole and the longer bolt into the lower hole. Place the right rear lights onto the frame, aligning the holes. Tighten the short bolt into the upper hole and the long bolt into the lower hole.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.








































































































































































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Levelord
#2 Posted : 18 July 2019 20:18:51

Rank: Pro
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Joined: 20/01/2013
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Points: 339
Location: Celle, Germany
Stage 58


You need the cover and cap from parts 56 and the transmission case outer and screws from parts 59. Place the transmission case outer onto the case inner, aligning the holes around the edges of both. take one of the flathead screws and tighten it into the aligned holes at the back. Tighten the two other flathead screws into the hole in the top and at the front. Now tighten the long screw into the hole at the bottom of the transmission case.

Align the posts of the cover with the holes in the transmission case and press the cover into place. Fit the cap to the two holes in the middle of the transmission case.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.















Der gesamte Baubericht und alle Fotos unterliegen dem Urheberrecht. Verwendung außerhalb dieses Forums bedürfen schriftlicher Genehmigung. © Levelord




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Levelord
#3 Posted : 18 July 2019 20:21:23

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Location: Celle, Germany
Stage 59



You will need the contents of parts 60. Take the box and mount and fit the two parts together, the two pins on the box fit into two corresponding holes in the mount. The two pins on the bottom of the mount fit into two holes at the front of the engine, as shown in step 6 of the instructions.

Now take the parts shown in step 7 of the instructions. Place the hollow screw up through the hole at the top of the clutch linkage and tighten the nut onto the screw. Place the bolt into the hole in the linkage, then place the U-shaped bracket between the two holes and turn the bolt through the bracket to hold it in place. Fully tighten the bolt through the bracket, into the hole on the other side.

Take the parts shown in step 14 of the instructions. Place the hinge over the lever, aligning the holes. Pass the bolt through the aligned holes and tighten the nut onto the other side of the bolt. Insert the post into the hole in the lever.

Take the headlight from stage 3, screws from parts 58 and the front fork assembly from stage 9. Align the pins and holes of the headlight bracket with the corresponding holes in the lower triple trees, secure in place with two screws. Lead the cable back between the forks.

Now take the throttle parts shown in step 24 of the instructions. Place the handlebar clamp with the cable on the underside of the right end of the handlebar. Place the handlebar clamp upper over the bar, onto the lower part and secure the clamp halves together with the two screws. Place the spring onto the handlebar, up against the clamp and insert the end of the spring into the hole in the clamp. Slide the throttle sleeve over the handle, engaging it with the spring. Tighten a screw into the end of the handlebar to secure the sleeve, making sure you can still twist the throttle. If not, looses the screw slightly. Slide the grip onto the sleeve, pushing the grip all the way up to the clamp. Slide the complete grip onto the left end of the handlebars.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.




































































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Levelord
#4 Posted : 18 July 2019 20:23:18

Rank: Pro
Build-Diary Medal: Build-Diary Medal of HonourPublisher Medal: Article published MedalRed Medal: Red Medal
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Joined: 20/01/2013
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Points: 339
Location: Celle, Germany
Stage 60



You will need the contents of parts 61, Take the kickstand and four smaller bolts. Place the kickstand onto the mount in front of the transmission, aligning the holes of both parts. Tighten a bolt into the top left holes of the kickstand then, tighten a second bolt into the lower right hole. Tighten two more bolts into the remaining holes. Test that the kickstand can swing in and out.

Now take the parts shown in step 8 of the instructions. Place the post into the pillion footrest, aligning the holes of both. Pass the bolt through the holes and tighten the nut onto the end of the bolt. Take the bracket, spacer and bolt shown in step 12 of the instructions. Place the bracket around the frame, on the left side, then place the spacer between the two ends of the bracket. Insert the end of the pillion footrest through the bracket and spacer. Now turn the bracket to access the inner hole and insert the bolt into it, tightening the bolt by hand. Turn the bracket back to the correct position and fully tighten the bolt with pliers.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.


Stage 61



Take the first footrest and bolt. Insert the cylindrical end of the footrest into the hole in the side of the frame. Hold the footrest in place and secure from the inside with the bolt. Fit the second footrest and bolt in the same way.

Take the upper exhaust from stage 12, as well as the pieces from parts 11. Place the bracket around the frame, as shown in step 8 of the instructions. Place the spacer between the ends of the brackets, then pass the bolt through the aligned holes. Remove the bolt and nut from the bracket at the front of the exhaust pipe, push the exhaust pipe onto the ball-end on the rear cylinder. Place the rear exhaust bracket in the bracket, next to the spacer. Push the bolt through the brackets and spacer, then tighten the nut onto the end of the bolt. Use the longer bolt from parts 61 to replace the one your removed from the bracket. Pass it through the bracket at the front of the pipe and tighten the same nut onto the end.

Take the second set of pillion footrest parts. Place the post into the pillion footrest, aligning the holes of both. Pass the bolt through the holes and tighten the nut onto the end of the bolt. Place another bracket around the frame, then place the second spacer between the ends of the bracket and pass the bolt through them, tightening the bolt by hand. Turn the footrest bracket up and fully tighten the bolt into the footrest.

Remove the front part of the lower exhaust and take the nuts and bolts from part 12. Pass the exhaust through the frame, under the engine, then place the end of the middle bracket over the hole at the end of the frame. Tighten the bolt into the aligned holes. Place the second bolt through the hole in the last bracket of the exhausts and tighten the nut onto the end of the bolt. Remove the nut and bolt from the end of the front exhaust, then press the exhaust onto the ball-end on the front cylinder. Push the two parts of the exhaust together again and tighten the nut and bolt back through the bracket.

Take the engine guard and align the holes in it with those in the frame. Tighten one of the two short screws from parts 62 into one of the holes in the rear of the guard, then tighten the second short screw into the other rear hole. Tighten the two long screws into the two holes in the front of the guard.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.

















































































Der gesamte Baubericht und alle Fotos unterliegen dem Urheberrecht. Verwendung außerhalb dieses Forums bedürfen schriftlicher Genehmigung. © Levelord




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Levelord
#5 Posted : 18 July 2019 20:35:05

Rank: Pro
Build-Diary Medal: Build-Diary Medal of HonourPublisher Medal: Article published MedalRed Medal: Red Medal
Groups: Global Forum Support Team, Administrator, Moderator, Official Builds, Forum Support Team Germany, Registered, Forum Support Team

Joined: 20/01/2013
Posts: 112
Points: 339
Location: Celle, Germany
Stage 62



You need the clutch cable, sleeve and tube from parts 60. Pass the cable up through the U-shaped bracket, fitted in stage 60 then up through the hollow screw above the bracket. Pass the end of the cable through the tube, slide the tube over the hollow screw then insert the cable though the sleeve, sliding the sleeve down the cable into the tube. Remove the screws as shown in steps 8 through 13 of the instructions.

Take the horn and mounting plate from stage 15. Insert the posts on the rear of the horn into the holes in the mounting plate. Carefully pull the frame apart at the front and place the sides of the mounting plate into the corresponding slots in the frame. Lead the horn cable back through the frame to the oil tank. Now tighten the screws removed in steps 8 - 13 back into the frame. Take the frame cover from parts 63 and align the three posts with the holes in the corresponding area of the frame, press the frame cover into place.

Now take the rest of the parts from parts 63. take the front assembly and place it onto the front of the main assembly, aligning the holes of both. Pass the axle up through the lower triple trees, the front of the frame, then through the upper triple trees. Place the washer over the axle, with the smaller hole over the pin on the frame. Tighten the nut onto the end of the axle. Now take the cover and place it over the nut, then tighten the cap onto the end of the axle.

Pass the throttle and brake cables between the upper triple trees and the handlebar. Insert the post into the hole in the lever, both from parts 60. Take the clutch cable and insert it into the hole in the post just fitted, use tweezers to adjust the placement of the cable to match the one shown in step 33 of the instructions. Tighten the washer screw from parts 60 into the top of the post to lock the cable in position. Place the lever clamp into the front of the groove around the left side of the handlebar. Place the rear clamp from parts 60 into the groove and secure to the other half of the clamp with the two screws.

Apply super glue to the end of the throttle cable. Insert the cable into the hole in the rear of the forward cylinder, pushing the cable in as far as it will go.

This Stage is now complete. Carefully store any remaining parts in a stage labelled bag for future use.


Pack 11 Complete.



















































































Der gesamte Baubericht und alle Fotos unterliegen dem Urheberrecht. Verwendung außerhalb dieses Forums bedürfen schriftlicher Genehmigung. © Levelord




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@work: Rossi Bike, X-Wing, VW Käfer 1303, VW T1 Samba Bus, McLaren MP4/23

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