BOX 14 - Kits 53-54-55-56

Kit 53

PARTS OF NUMBER 53

  • 53A Rear wheel outer rim
  • 53B Rear wheel inner rim
  • 53C Hub cap
  • 53D Washer
  • 53E Support stop
  • BM Screw M 2 x 4 mm (x 4)
  • MM Screw M 2 x 5 x 5mm (x 2)
Right rear wheel assembly and installation on chassis

STEP 1
Before starting to assemble the right rear wheel, locate the side of the tyre (52A) with the deepest bead as indicated by the red markings, in order to position the outer rim (53A).

The deepest bead (2 mm) is identified by the green arrow, while the shallowest bead (1 mm) is identified by the orange arrow.

STEP 2

To fit the tyre (52A) - the one on the side with the deepest bead, green arrows - to the outer rim 53A, you must  plunge it into hot water for two minutes so that the rubber becomes more flexible.

STEP 3

Position the inner rim (53B) on the other side of the tyre, aligning correctly the three fixing points

STEP 4

Fasten the inner rim (53B) and the outer rim (53A) together with three BM screws. The right rear wheel is ready to be mounted on the chassis.

STEP 5

Disconnect the support stop (5D) from the stabilization link (5E) (blue arrow) and remove it from the gearbox support lever (5C) (red arrow).

Replace the support stop 5D with the support stop 53E by carrying out the previous operations in reverse order (illustration below).

STEP 6

Locate the placement rib on the outer rim hub axle (53A) - red arrow.

STEP 7

Position the outer rim of the left rear wheel (53A) on the left rear pivot pin (42A) and rotate the wheel (blue arrow) until the locating rib engages the slot in the outer brake half disc (44G).

STEP 8

Secure the outer rim of the left rear wheel (53A) with an MM screw by first passing it through washer (53D).

STEP 9

Position the hub cap (53C) on the outer rim (53A).

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 54

PARTS OF NUMBER 54

  • 54A Cabin bulkhead
  • 54B Voltage regulator
  • 54C Electrical cable (blue)
  • 54D Electrical cable (red)
  • 54E Left tubular frame post
  • 54F Right tubular frame post

Separation of the cabin. Pre-assembly of the firewall

STEP 1

Position both electric cables, blue (54C) and red (54D), on the cabin bulkhead (54A) - grey side - by clamping them together.

STEP 2

Position the voltage regulator (54B) above the Blue 54C and Red 54D power cables on the cabin’s bulkhead (54A) - grey side.

STEP 3

The voltage regulator (54B) is positioned on the cabin’s partition wall (54A).

STEP 4

Cut the length of the electric blue (54C) and red (54D) cables (red arrows) that protrude from the cabin’s bulkhead 54A (silver side).

STEP 5

Position the left tubular frame post (54E) on the cabin’s bulkhead (54A) - silver side.

STEP 6

Position the right tubular frame post (54E) on the cabin’s bulkhead (54A) - silver side.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 55

PARTS OF NUMBER 55

  • 55A Plexiglass partition
  • 55B Seat belt support (x 2)
  • 55C Seat belt (x 2)
  • 55D Buckle, top (x 2)
  • 55E Buckle, bottom (x 2)
  • 55F Buckle lock (x 2)
  • 55G Double-sided tape (x 3)

Assembly of seat belts and cabin’s bulkhead

STEP 1

Position the plexiglass partition (55A) on the cabin’s bulkhead (54A) - grey side -  using the six pins provided.

STEP 2

Pass the seat belt (55C) through the top buckle (55D) as indicated by the red arrows. Repeat the operation with the second belt (55C). Check the installation as shown in the illustration.

STEP 3

After installing the top buckle (55D), continue in the same way by passing the seat belt (55C) through the bottom buckle (55E) as shown in the illustration. Repeat the operation with the second belt (55C).

STEP 4

Pass the seat belt (55C) through the buckle lock (55F). Apply double-sided adhesive (55G) to the end of the seat belt (55C). Remove the backing paper (red arrow) from the adhesive (55G), then fold the belt over and stick the free end (blue arrow) so that it holds the buckle (55F).

Refer to the illustrations opposite and above. Repeat with the second belt (55C).

STEP 5

Pass the belt support (55B) through the buckle at the upper end of the seat belt (55C) - see illustrations opposite. Repeat with the second belt (55C).

STEP 6

Position the two seat belt supports (55B) on the cabin’s bulkhead  (54A) - grey side.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 56

PARTS OF NUMBER 56

  • 56A Ignition coil (x 2) 
  • 56B Black cable 
  • 56C Red cable 
  • 56D Black cable sheath
  • 56E White cable 
  • 56F Red cable 
  • 56G Yellow cable 
  • 56H Blue cable 
  • 56I Brown cable 
  • 56J Black cable 
  • 56K Ignition box 
  • 56L Ignition box 
  • 56M Rev limiter relay 
  • 56N Regulator housing 
  • 56O Fire extinguisher 
  • 56P Fire extinguisher 
  • 56Q Branch connector 
  • 56R Fire extinguisher hose 
  • 56S Adhesive tape  (x 6) 
  • 56T Regulator housing
  • BM Screw M 2 x 4 mm (x 3)

Assembly of the cockpit partition, ignition and fire extinguisher system and mounting on the chassis

STEP 1

Position the ignition box (56L) on the cabin’s  partition (54A). Cut the quantities and lengths of the coloured cables as shown opposite.

STEP 2

Insert the white (56E); red (56F); yellow (56G); blue (56H) and brown (56I) wires previously cut into the two lower openings of the cabin bulkhead (54A), then connect their ends to the slots above the ignition box (56L), as shown below. 

STEP 3

Position the rev limiter relay (56M) on the cabin’s partition (54A). Position the ignition box (56K) on the cabin’s partition (54A).

STEP 4

Insert the remaining white (56E), red (56F), yellow (56G) cables previously cut, as well as the black cable (56J), into the black jacket.

Pass the sheath (56D) - with the coloured cables inside - through the opening in the cockpit bulkhead (54A) as shown above.

STEP 5

Connect the ends of the yellow, white, red and black cables to the slots above the ignition box (56K) as shown below.

Flush cut the wires (red arrows) protruding from the other side of the cabin’s partition (54A) - silver side.

STEP 6

Position the regulator housing (56N and 56T) on the cabin’s bulkhead (54A). Position the two ignition coils (56A) on the cabin’s bulkhead (54A).

STEP 7

Cut two lengths of 30 mm of the red cable (56C). Cut the quantities and lengths of the black cable (56B) as detailed opposite.

STEP 8

Connect the two red cables (56C) and the two black wires (56B-1), previously cut, to the nipples on the sides above the ignition coils (56A) as shown, then feed the ends through the left opening in the cockpit partition (54A).

Connect the two black cables (56B-2), previously cut, to the nipples, centrally positioned, above the ignition coils (56A), then feed the ends through the openings (middle and right) in the cockpit partition (54A) as shown below.

STEP 9

Leave the two black cable lengths (56B-2) free for future use. Flush cut the red and black cables (red arrows) protruding from the other side of the cabin’s bulkhead (54A). 

Connect the black cable (56B-3), cut previously, to the underside of the branch connector (56Q), then position it on the cabin’s bulkhead (54A).

STEP 10

Cut two lengths of 250 mm from the fire extinguisher hose (56R).

Connect the two fire extinguisher hoses (56R), cut previously, to the sides of the branch connector (56Q).

STEP 11

The two fire extinguisher hoses (56R) are attached to the bypass connector (56Q). Pass the two fire extinguisher hoses (56R) through the two large openings at the bottom of the cabin’s partition (54A) so that they exit on the other side.

STEP 12

The cabin’s bulkhead (54A) is ready to be installed on the chassis.

STEP 13

Start by aligning the cabin’s bulkhead (54A) above the location it is to be integrated into the chassis.

STEP 14

Before attaching the cabin’s bulkhead (54A) to the chassis, connect the two brake lines (40F) to the two nipples at the bottom of the partition (red arrows). Then run the two fire extinguisher hoses (56R) along the upper side tubes of the engine cradle, as indicated by the green arrows in the illustrations opposite. Finally, connect the ends of the two black cables (56B-2) to the two loose ignition wire connectors (22C) on the igniter head as shown by the blue arrows in the illustration above.

STEP 15

The two black wires (56B-2) are connected to the two free ignition wire connectors (22C). Attach the cabin’s partition (54A) to the lower frame (25A) with two BM screws. Assemble the two fire extinguisher halves (56O and 56P).

STEP 16

Position the fire extinguisher (56O) on the cabin’s bulkhead (54A) and connect the end of the black cable (56B-3) to the fire extinguisher head (56O). Attach the clutch cable (26J) to the bottom of the cabin’s bulkhead (54A).

The cabin’s bulkhead is attached to the chassis.

STEP 17

Attach the fire extinguisher hoses (56R), along the two upper lateral tubes of the engine cradle, with four pieces of tape (56S) - illustrations opposite and below.

Leave both ends of the fire extinguisher hoses (56R) free at the rear and top of the engine.

ASSEMBLY DIAGRAM
GENERAL VIEW