De Agostini MODEL SPACE Honda CB750 FOUR User manual

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 © 2014
Warning: Not suitable for children under the age of 14. is product is not a toy
and is not designed or intended for use in play. Items may vary from those shown.
CONTENTS
35
Assembly Guide
Stage 8: The headlight
Stage 9: The brake caliper
Stage 10: The front fender

35
Honda CB750 FOUR: Assembly Guide
Stage 8
Headlight rim*
Headlight retaining ring *
Headlight reector
Headlight lens
Front reector bases × 2
Front reector mounts × 2
Front reectors × 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
Prepare
Front fork (Stage 7)
The headlight
Your parts
1
2

36
Honda CB750 FOUR: Assembly Guide
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 reector with the
wide cutout at the top, and t 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 reector: 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
Honda CB750 FOUR: Assembly Guide
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 reector further into the
case, aligning the cutout in the reector
with the corresponding projecting part of
the headlight case. Like the reector, the headlight lens has
cutouts at the top and bottom.
Place the lens onto the reector, 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
Honda CB750 FOUR: Assembly Guide
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 o the protective
backing on the back of one of the front
reectors.
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
Honda CB750 FOUR: Assembly Guide
Take one of the front reector mounts
and check that the recessed part is clear
of any dust, then hold it and the reector
as shown.
Place the reector into the centre of the
reector mount.
The pin projecting from the rear of one
of the reectors (circled) will t 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 reector bases. Repeat Steps 20-23 to
assemble the second reector.
Insert the reector pin into the hole in the
fork cover.
Insert the pin of the second reector into
the hole in the right fork cover.
The pin on the other reector ts into the
hole in the right fork cover.
21
22
23
24
25
26
27
Stage complete

40
Honda CB750 FOUR: Assembly Guide
Stage 9
Caliper A
Caliper B
Front brake disc
Screws (type N) × 2
Screws (type U) × 2
Front wheel axle nut
Front wheel axle
Cross wrench
The brake caliper
Prepare
Front forks (Stage 8)
Front wheel (Stage 3)
The pins of caliper B t 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
Honda CB750 FOUR: Assembly Guide
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 rmly into place, so that it is
ush with the fork.
Hold the wheel at, 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
Honda CB750 FOUR: Assembly Guide
Front fender stays × 2
Front fender
Caliper holder
Screw (type L)
Screws (type C) × 4
Screws (type K) × 4
Allen key (1.5mm)
Tools
Phillips screwdriver (No. 1)
Cross wrench
Caution: handle the front
fender with care, as the edges
may be sharp.
Prepare
Front 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
Honda CB750 FOUR: Assembly Guide
Place the fender between the front forks,
with the caliper holder next to the left fork.
Remove the brake caliper tted 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
Honda CB750 FOUR: Assembly Guide
Tighten the nal 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
Honda CB750 FOUR: Assembly Guide
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-t 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
Honda CB750 FOUR: Assembly Guide
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.
17
18
19
20 21

47
Honda CB750 FOUR: Assembly Guide
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