BOX 24 - Kits 93-94-95-96

Kit 93 - Assembly and fitting of the left headlight

Parts of number 93

  • 93A Fairing, left headlight 
  • 93B Lens, left headlight 
  • 93C Housing, left headlight 
  • Screw NP M 1.2 x 4 mm  (x 2) 
  • Screw MM M 1.2 x 3 mm (x 3) 
  • Screw QM M 1.4 x 3 mm (x 2)
Step 1
Place the left headlight lens (93B) on the left headlight housing (93C).

Step 2

Position the left headlamp housing (93C) on the body (66A).

Step 3

Secure the housing of the left headlamp (93C), from the rear,  to the body (66A) using an NP screw.

Step 4

Position the fairing of the left headlight (93A) on the body (66A).

Step 5

Affix the bottom of the fairing of the left headlight (93A) to the body (66A) using a QM screw. Be careful not to overtighten the screw, as this will split the headlight fairing. Fix the top of the left headlamp fairing (93A) to the body (66A) using two MM screws, making sure not to overtighten them to avoid splitting the headlamp bubble.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 94 - Assembly and fitting of the right headlight

Parts of number 94

  • 94A Fairing, right headlight 
  • 94B Lens, right headlight 
  • 94C Housing, right headlight 
  • Screw NP M 1.2 x 4 mm (x 2) 
  • Screw MM M 1.2 x 3 mm (x 3) 
  • Screw QM M 1.4 x 3 mm (x 2)
Step 1

Place the right headlight lens (94B) on the right headlight housing (94C).

Step 2

Position the right headlamp housing (94C) on the body (66A).

Step 3

Secure the housing of the right headlamp (94C), from the rear,  to the body (66A) using an NP screw.

Step 4

Position the fairing of the right headlight (94A) on the body (66A).

Step 5

Affix the bottom of the fairing of the right headlight (94A) to the body (66A) using a QM screw. Be careful not to overtighten the screw, as this will split the headlight fairing. Fix the top of the right headlamp fairing (94A) to the body (66A) using two MM screws, making sure not to overtighten them to avoid splitting the headlamp fairing.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 95 - Mounting of the long-range headlights

Parts of number 95

  • 95A Left long-range headlight 
  • 95B Right long-range headlight 
  • 95C Decal left long-range headlight 
  • 95D Decal, right long-range headlight
  • Screw NP M 1.2 x 4 mm (x 3)
Step 1

First, cut out the decal for the left long-range headlamp (95C). Soak it in water for 30 seconds, then place it in the recess provided for the left long-range headlamp on the body (66A). Remove excess water with a cotton pad and leave to dry for 5 minutes.

Step 2

Position the left long-range headlamp (95A) in the housing provided on the body (66A). Secure the long-range headlamp (95A) from behind to the body (66A) using an NP screw.

Step 3

First, cut out the decal for the right long-range headlamp (95D). Soak it in water for 30 seconds, then place it in the recess provided for the right long-range headlamp on the body (66A). Remove excess water with a cotton pad and leave to dry for 5 minutes.

Step 4

Position the right long-range headlamp (95B) in the housing provided on the body (66A). Secure the long-range headlamp (95B) from behind to the body (66A) using an NP screw.

ASSEMBLY DIAGRAM
GENERAL VIEW

Kit 96 - Assembly of the front rocker panel, blinking lights and cable extension

Parts of number 96

  • 96A Front rocker panel 
  • 96B Blinker cap (x 2) 
  • 96C Grille protector 
  • 96D Grille 
  • 96E Cable extension H 
  • 96F Adhesive tape (x2) 
  • Screw QM M 1.4 x 3 mm (x 5) 
  • Screw MP M 1.2 x 3 mm (x 5)
Step 1

Position the blinker cap (96B) in the housing on the right front of the body (66A) and secure with two MP screws. 

Position the blinker cap (96B) in the housing on the front left of the body (66A) and secure it with two MP screws.

Step 2

Position the grille protector (96C) on the front rocker panel (96A) and secure with two QM screws. Bend the grille (96D) to match the curve of the inner wall of the front rocker panel (96A).

Step 3

Fix the grille (96D) to the inner wall of the front rocker panel (96A) using two QM screws.

ASSEMBLY DIAGRAM
GENERAL VIEW
ASSEMBLY TIPS

To simplify final assembly, add the cable extension H (96E) to the existing H cable (47J).

Step 1

Start by removing the fuel line (61G) from the fuel tank (46A).

Step 2

Release, remove and set aside for use at a later stage the two CM screws located on the side tabs of the fuel tank (46A).

Step 3

Peel off the adhesive tape (47B) from the PCB (47A). Identify the connector marked H on the circuit board (47A) and disconnect cable H (47J) (red-black). Connect one end of cable extension H (96E) to the previously disconnected cable H (47J), then the other end to the PCB (47A). Reassemble the PCB (47A) and fuel tank (46A), following instructions 3 and 2 in reverse order, indicated by a red arrow.

Step 4

Remove the steering wheel emblem (67C) by applying some pressure, then unscrew the AM screw and put it aside for later use. Remove the steering wheel (67B or 3K) and keep the front wheels straight.

Step 5

Turn the chassis over and unscrew the four SM screws ( save them to use at a later date), then remove the left (64A) and right (65A) rocker panels.

Step 6

Unscrew and save the four EP screws, then detach the cabin floor (52A) from the chassis floor (39A).

Step 7

Lift, retract and tilt the chassis floor (39A) to access and remove the two adhesive tapes (57F) holding the cable H (47J) (red-black). Gently pull back the cable H (47J) (red/black) so as to tension it as much as possible. Refit the chassis, cabin floor and steering wheel, following instructions 7, 6, 5, 4 and 1 in reverse order, indicated by a red arrow. Use adhesive tape (96F) if necessary.

GENERAL VIEW