BOX 11 - Kits 41-42-43-44

Kit 41

PARTS OF NUMBER 41

  • 41A Rear left upright 
  • 41B Radius arm with upper link 
  • 41C Bottom wish bone 
  • 41D Radius arm 
  • 41E Bracket 
  • 41F Piston rod 
  • 41G Bracket 
  • 41H Suspension damper 
  • 41I Suspension spring
  • BM Screw M 2.0 x 4 mm (x 2) 
  • CM Screw M 2.0 x 3 x 5 mm (x 2) 
  • DM Screw M 2.0 x 8 mm (x 3) 
  • KM Vis M 1.7 x 3 x 5 mm (x 2) 
  • NM Screw M 2.0 x 7 mm (x 2)
Pre-assembly of the left rear suspension

STEP 1
Fit Bottom wish bone (41C) to  Rear left upright (41A) and fix with two DM screws .

Fit Suspension damper (41H) to A Rear left upright (41A) and fix with CM screw.

STEP 2

Fit Radius arm (41B) with upper link to Left rear upright (41A) and fix with NM screw (upper and lower illustrations)

STEP 3

Fit Radius arm (41D) to Bracket (41E) and fix with KM screw .

Fit Bracket (41G) to Left side frame (38A) and fix with BM screw.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 42

PARTS OF NUMBER 42

  • 42A Rear right upright 
  • 42B Radius arm with upper link 
  • 42C Bottom wish bone 
  • 42D Radius arm 
  • 42E Bracket 
  • 42F Piston rod 
  • 42G Bracket 
  • 42H Suspension damper 
  • 42I Suspension spring
  • BM Screw M 2.0 x 4 mm (x 2) 
  • CM Screw M 2.0 x 3 x 5 mm (x 2) 
  • DM Screw M 2.0 x 8 mm (x 3) 
  • KM Vis M 1.7 x 3 x 5 mm (x 2) 
  • NM Screw M 2.0 x 7 mm (x 2)

Pre-assembly of the right rear suspension

STEP 1

Fit Bottom wish bone (42C) to Rear right upright (42A) and fix with two DM screws .

Fit Suspension damper (42H) to Rear left upright (42A) and fix with CM screw.

STEP 2

Fit Radius arm (42B) with upper link to Right rear upright (42A) and fix with NM screw (upper and lower illustrations).

STEP 3

Fit Radius arm (42D) to Bracket (42E) and fix with KM screw.

Fit Bracket (42G) to Right side frame (39A) and fix with BM screw .

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 43

PARTS OF NUMBER 43

  • 43A Rear axle 
  • 43B Drop links ( x2 ) 
  • 43C Rear anti roll bar 
  • 43D Tie down planks ( x2 )  MOUNTINGS LUGS
  • 43E Half shaft ( x2 ) 
  • 43F Half shaft ( x2 ) 
  • 43G Universal joint ( x2 )
  • EM Screw M 2.0 x 9 mm (x 3) 
  • IM Screw M 1.7 x 3.5 mm (x 16) 
  • JM Screw M 2.0 x 5 mm (x 6) 
  • KM Vis M 1.7 x 3 x 5 mm (x 5) 
  • OM Screw M 2.0 x 4 x 5 mm (x 5)

Installation of the rear axle and suspension

STEP 1

Fit Drop link (43B) to Rear left upright (41A) and fix with KM screw . 

Fit Drop link (43B) to Rear right upright (42A) and fix with KM screw 

STEP 2

Fit Bottom wish bone (41C) of Left upright (41A) to Rear axle (43A) and fix with EM screw .

Fit the lower wishbone 42C (attached to the right rear pivot 42A) to the rear axle 43A and secure it with an EM screw.

STEP 3

Assemble 2 sets of Half shafts following upper and lower illustrations :

Fit Universal joint (43G) to Half shaft (43F) and fix with two IM screws.

Fit Half shaft (43E) to Universal joint (43G) and fix with two IM screws.

STEP 4

Fit Rear axle (43A) to Chassis frame (25A) and Casing (5A) with JM screw. Take note to place the end of Radius arm (42B) above Right fuel tank (33A) top panel ( lower illustration )

Fit two preassembled universal jointed Half shafts (43F) to Drive shaft compensation sleeves (6H & 4H).

STEP 5

Elevate Left upright (41A) to catch the stub of Half axle (43E) - blue arrow -, at the same time aligning Radius arm (41B) with upper link to Left side frame (38A) attachment points (orange and green arrows) 

Fix Radius arm (41B) with upper link to Left side frame (38A) with JM and OM screws

STEP 6

Elevate Right upright (42A) to catch the stub of Half axle (43E) -  blue arrow - , at the same time aligning Radius arm (42B) with upper link to Right side frame (39A) attachment points (orange and green arrows) .

Fix Radius arm (42B) with upper link to Right side frame (39A) with JM and OM screws.

STEP 7

Fix Rear axle (43A) to Chassis frame (25A) with two JM screws.

Fix preassembled Radius arm (41D) with Bracket (41E) to Chassis frame (25A) by OM screw, and Left upright (41A) by IM screw respectively.

STEP 8

Fix preassembled Radius arm (42D) with Bracket (42E) to Chassis frame (25A) by OM screw, and  Right upright (42A) by IM screw respectively.

Fit Rear anti roll bar (43C) to Left (38A), Right (39A) side frames - blue arrows - and two Drop links (43B) - green arrows .

STEP 9

Fix Rear anti roll bar (43C) to  Left side frame (38A) via Tie down plank (43D) with two IM screws.

Fix Rear anti roll bar (43C) to Right side frame (39A) via Tie down plank (43D) with two IM screws

STEP 10

Fix Rear anti roll bar (43C) to Left and Right side drop links (43B) with two KM screws (upper and lower illustrations).

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 44

PARTS OF NUMBER 44

  • 44A Left brake caliper 
  • 44B Right brake caliper 
  • 44C Brake piston cover (x 2) 
  • 44D Brake disc surface with ventilation holes to the right (x 2) 
  • 44E Brake disc surface with ventilation holes to the left (x 2) 
  • 44F Inner brake half disc (x 2) 
  • 44G Outer Brake half Disc (x 2) 
  • IM Screw M 1.7 x 3.5 mm (x 5) 
  • CP Screw M 1.7 x 3 x 3 mm (x 5)

Installation of rear brake discs and calipers

STEP 1

Right brake disc assembly

Remove the paper backing (green arrow) from the surface of the Brake disc (44E) - note the direction of the ventilation holes, blue arrow - and apply the adhesive to the inner Brake half disc (44F). Ensure that the outer holes are in front of the ribs of the disc (44F) - orange arrows.

Peel off the paper backing (green arrow) from the surface of the Brake disc (44E) - note the direction of the ventilation holes, red arrow - and apply the adhesive to the outer Brake half disc (44G). Ensure that the outer holes are in front of the ribs of the disc (44G) - orange arrows.

STEP 2

Position the Outer brake half discs (44G & 44F) together and attach them with two CP screws

Assembled right brake disc

STEP 3

Left brake disc assembly

Remove the paper backing (green arrow) from the surface of the Brake disc (44D) - note the direction of the ventilation holes, red arrow - and apply the adhesive to the inner Brake half disc (44F). Ensure that the outer holes are in front of the ribs of the 44F disc (44F) - orange arrows.

Remove the paper backing (green arrow) from the surface of the Brake disc (44E) - note the direction of the ventilation holes, blue arrow - and apply the adhesive to the outer Brake half disc (44G). Ensure that the outer holes are in front of the ribs of the disc (44G) - orange arrows.

STEP 4

Position the outer Brake half discs (44G & 44F) together and secure them with two CP screws.

Assembled left and right brake discs

STEP 5

Position the Brake piston covers (44C) on the left Brake calipers (44A & 44B)

STEP 6

Connect the Brake line (40E) to the nipple at the bottom of the Piston cover (44C) -  blue arrow. Position the Left brake caliper (44A) on the left rear pivot (41A) and fix with two IM screws (illustrations opposite).

STEP 7

Connect the Brake line (40E) to the nipple at the bottom of the Piston cover (44C) - blue arrow. Position the Right brake caliper (44B) on the Right rear pivot (42A) and fix it with two IM screws (illustrations opposite).

ASSEMBLY DIAGRAM
GENERAL VIEW