Start with the bare frame.
Fit 108-Spacer Tube, 109-Spacer Bolt, 144-Cap
Spacer Tube (2x) and 1005F-Nut 7/16” BSF Hex (2x). Two
lock washers were used.
Put the frame upside down and fit 134-Shaft Foot Starter,
1005P-Nut, ½” BSF, Washers, 133-Segment, Foot Starter
with 132-Pedal, Foot Starter, and 135-Spring, Foot
Starter. Put the frame upright again, fit 600-Engine
and adjust the clearance between the teeth of 133-Segment, Foot
Starter and 621-Pinion, Foot Starter by rotating
134-Shaft Foot Starter and securing it with 1005P-Nut,
½” BSF. Remove 600-Engine again.
Put the frame upside down again, put the nut for the front bolt of 405-Fixed
Hanger in the recess of 105-Side Reinforcement, LH and
secure it with some glue or putty. I needed to shorten the front bolt for
405-Fixed Hanger to have sufficient room for 178-Distance Piece
Foot Starter, to be fitted later. It will not be possible to put
this nut in place after 178-Distance Piece Foot Starter has
Put 178-Distance Piece Foot Starter in place. (In my case this
is a replica). The Foot Starter Assembly and 178-Distance
Piece Foot Starter are now in place, as well as the front nut for
securing 405-Fixed Hanger. The sequence for all this is very
important as this recess in 105-Side Reinforcement, LH is a
crowded and extremely inaccessible place.
Contrary to the photographs, a flat headed bolt was
used, with the head at the inside and the nut at the outside, to give
sufficiently room for 406-Chain Guard.
See also Repair Starter Support.
Fit 203-Under Pan with 242-Latch, Front
Stand and 243-Back Plate, Latch, Front Stand; the
accessibility of the two screws for this Latch is very poor, as
SA900C-Flywheel runs closely over their nuts.
Make sure to fit 203-Under
Pan with 242-Latch, Front Stand and 243-Back Plate, Latch,
Front Stand before 6-Engine is put in place, otherwise the
attachment screws, especially at the RH side will be difficult to place.
Fit 221-Rear Stand Assembly with 218-Stud, Stand,
Fit 172-Gusset, Front Stand, RH and 173-Gusset,
Front Stand, LH. Keep the bolts and nuts loose in order to be able to
fit S800A-Exhaust Assy later. Fit 151-Stand, Front
with 149-Bolt, RH, Front Stand, 156-Bolt, LH, Front
Stand and 150-Spacer, Front Stand (2x).
Fit S800A-Exhaust Assy.
Fit SA500A-Change Gear Assy.
651-Cable to Sparking Plug;
it might be difficult to attach the HT Cable later, when the
engine is in place,
to 939-Bolt HT, Terminal Post. Temporarily fit 6a-Carburettor.
This is done because I had to make a replica of 656-Funnel.
Although the sequence, mentioned above is doable, in
it might have been better to execute item #10 and #11 after
for better accessibility of 517-517-Nipples, Long, Short (adjustment
and securing both parts with split pins) and attaching Spring
and Bowden Cable Friction Control to 419-Sliding Hanger.
In order to be able to fit 4-Cross Shaft Assy, first 437-Brake
Linings were fitted into 433-Brake Band. At the
same time 310-Brake Linings were fitted onto 308-Brake
Shoes of 3b-Rear Wheel. As 437-Brake Linings
are very thin and soft and not easy to rivet, besides riveting, adhesive was
also used. The same was done for 310-Brake Linings. The adhesive used
is Araldite 2000 2014-1 which could be applied cold. In order to
align the linings correctly in both cases the linings were placed and the
brake engaged unit the adhesive had hardened.
Assemble 4-Cross Shaft Assy.
Fit 514-Cable, Outer with 515-Cable, Inner and 529-Screwed
Stop and Nut for SA500L Twist Grip Assy for 5-Cross
Shaft. Guide 514-Cable, Outer and 515-Cable, Inner through the
LH part of 501-Handle Bar, stick 515-Cable, Inner through
589-590-Ball Cage with Circlip, degrease 515-Cable, Inner and
solder Cable Nipple. To create enough room to solder this joint,
514-Cable, Outer was shortened. 529-Screwed Stop and Nut gave
insufficient possibility to tighten 515-Cable, Inner. This problem
was solved by fitting a split washer between the Cable Nipple and
515-Cable, Inner, which was covered by the rubber grip.
Fit the two footboards, 110-111-Footboard LH, RH with the two
147-152-Mat, LH, RH, Footboard and the fit 540-Brake
Pedal with 542-Pad, Brake Pedal.
Connect 566-Cable Long to 540-Brake Pedal now
as it will be inaccessible after 110-Footboard LH has been put into place.
Connect the two footboards with 146-Cross Stay,
Fit 202-Fuel Tank Cradle to the frame and bolt 212-213-Brace,
LH, RH onto it; they are each other’s mirror image. Fit 252-Clip,
Small, Inflator and 259-Clip, Large, Inflator and fit the
air pump (“820-Inflator”)
Place 201-Rear Fender into 202-Fuel Tank
Cradle and fasten it with bolts. Connect Latch,
211-Rear Stand with the two Reinforcements to
Place 253-254-Stay, Long, LH,RH which have different PN’s, but
seem identical to me.
Connect 230-Carrier Seat at the rear end with 253-254-Stay,
Long, LH,RH and at the front side to 212-213-Brace, LH, RH,
by sticking temporarily a long screwdriver through the four holes. Later
SA800A-Saddle Assy will be mounted here; see item # 24.
Connect 255-256-Stay, Short, LH, RH at one side to 201-Rear
Fender and at the other side to 253-254-Stay, Long, LH,RH
and 230-Carrier Seat.
Fit 246-Number Plate Assy, consisting 246-Number Plate
(which actually is the plate the licence plate is fitted onto), the
Licence Plate, 247-Bracket, Long, 248-Bracket,
Short (two different items, which are each others mirror image)
250-Clip Rear Generator, 810-Generator, Rear,
251-Wing Nut Rear Generator Clip and 809-Taillamp, complete.
Take 205-Front Fender and fit two transfers on each side. The
“NER-A-CAR Tank” transfer, # 7257LC, the one with the logo, is a vinyl
transfer. The other one, “NER-A-CAR Mudguard”, # 7097, the one with the
patent numbers, is a water slide transfer. Applying them is not difficult,
as long as you closely follow the instructions provided. All four transfers
are protected by waterborne Glitsa.
The transfers were supplied by
Classic Transfers, Robert Derrick LTD
PO Box 17, Wotton-Under-Edge
Gloucestershire, GL12 8YX
Place 204-Top Pan. It has to be bent here and there to make it
more or less fit. Fortunately it is secured by 647-Thumb Nut.
Off course, 204-Top Pan has to be removed later to get access to the
Fit SA800A Saddle Assy and support its ‘nose’ by a pillow or
hang it on a string (701-Fuel Tank has not yet been placed, as in my
case both 715-Anchor Plates were missing.
For reasons of accessibility, #24 can better be done after #
Replicas of 715-Anchor Plate were made, 715-Anchor Plates
and 701-Fuel Tank were fitted. NB! The inner radius of 715-Anchor
Plates was made such, that the radius matched the radius of
701-Fuel Tank. The outer radius of 715-Anchor Plates was
however much smaller than the inner radius of 202-Fuel Tank Cradle.
The result could be that 715-Anchor Plates are pulled loose from the
tank when tightening the nuts. I’m aware of 2 Fuel tanks where this
happened. Both had by the way only been soldered at the outer edges of
715-Anchor Plates. Therefore I used Adhesil Marine 2502 Black
from Innotech. The gap between 715-Anchor Plate and
202-Fuel Tank Cradle was filled up with the same adhesive, sticking only
to 715-Anchor Plates.
324-Front Axle Assy
has been assembled. In rotating 316-Lock Nut Inner, Front Axle
and 317-Lock Nut Outer, Front Axle (2x) care has to be taken
not to use the threaded hole, but the two plain holes instead. Make sure
that 315-Axle Bearing, Front is positioned in the centre of the
Fit 210-Steering Post Tube, into 142-Bracket
Steering Post, with two 154-Packing Washers
Bottom, two153-Packing Washers Top, two long vertical and
two short, horizontal Bolts for 142-Bracket, Steering Post.
Make sure 154-Packing Washer Bottom and 153-Packing
Washer Top are not commingled and that the right angles are facing the
nut and the head of the bolt respectively (pointing outward).
Orient them such that the angled faces are correctly rotated
to fit onto 141-Cross Member. Prevent vertical
Bolt for 142-Bracket, Steering Post and the Packing Washers to
rotate when fastening.
fitted (I could not resist the challenge).
3a- Front Wheel
with 324-Front Axle Assy and Suspension Assy
and 265-Stay, Front Fender placed.
If you use 229-Packing Front Fender Base, make sure it
isn’t too thick, otherwise 204-Top Pan will even be more difficult to
close than it already is.
520-Thrust Washer, Graphitic, 209-Brace, Steering
Post Tube, Steering Clamp, 224-Reinforcement,
Steering Tube Brace, 521-Lever, Steering Post with Key,
330-Drag Link, 327-Cup, Steering Ball,
391-Peg Spring and 331-Nut, Steering ball Cup with
Split Pins where applicable. 210-Steering Post Tube has
exactly the same length to contain 501-Handle Bars with 520-Thrust
Washer, Graphitic on top and 521-Lever, Steering Post ‘flush’ at
the bottom end. 501-handle Bars has to be vertically adjusted such,
that 521-Lever, Steering Post and 330-Drag Link just run free
from the parts at the bottom of the motorcycle; 210-Steering Post Tube
will move up and down with the vertical axle of 501-Handle Bars, as
the Tube is ‘squeezed’ between 520-Thrust Washer, Graphitic and
521-Lever, Steering Post.
C4-Throttle Lever, RH, C5-Air Lever, RH, 576-Clip,
Carburettor Cables, Carburettor Cables and 656-Funnel
fitted. Manual Brake Assy fitted.
Fit 3b-Rear Wheel Assy. While
manipulating 362-Sleeve, LH, Rear Wheel, make sure
that 361-Spacer, LH, Rear Wheel does not fall down into the brake
Fit 422-Driving Chain and adjust the tension. Apart from the lamps,
splash guards and some other miscellaneous things, the assembly has been
13, 2012, engine started. It ran after a single kick!
Miscellaneous things to follow, like Headlamps, Tail Lamp, Splashguard, etc.
January 12, 2012