Instruction manual

Step 4: Installing the Fan Shroud and Switch Plate

Parts Required: Bag #

5 #0029 M2.2x13.0 Phillips self-tapping screws 7F

2 #0032 M2.9x9.5 Phillips self-tapping screws 7F

2 #0061 M3x8 Socket Head Bolts 7F

2 #0063 M3x10 Socket Head Bolts 7F

2 #0079 M3x35 Socket Head Bolts 7F

1 #0548-5 Left and right fan shroud 7A

4 #115-58 Fan shroud braces 7F

2 #115-60 M5.75x27.5 carbon tubes 7F

1 #123-34 Switch plate 7F

4 #3923-1 M4.0x14.6x4.9 round plastic spacers (black) 7F

2 #0065 M3x12 Socket Head Bolts 7F

2 #0060-1 M3x6 Socket Head Bolts 7F

Refer to Drawings #7D

and #7E

Please note the following before proceeding to install the fan shroud:

Some additional trimming of the fan shroud may be required depending on your choice of engine. It is assumed

you will trial fit the shroud prior to any modification. In general, trimming is for carburetor and/or cylinder head

clearance. If your carburetor inlet comes to within 8.8mm of the fan shroud, trimming is suggested. The

Atrimming@ can simply be to add about a 20.0mm diameter hole directly in-line with the carburetor inlet or making

a Au@ shaped cut-out extending downward into the cylinder head opening at the base of the shroud (the latter will

eliminate one #0029 M2.2x13 Phillips screw and the surrounding material B which is not a problem). Trimming

can easily be done by using a sharp modeler=s knife (scoring the surface deeply and bending the material to break it

away) or a Dremel tool with cutting wheel or abrasive drum.

A. Select two #0079 M3x35 Socket Head Bolts, one #115-58 Fan Shroud Brace, two #115-60 Carbon Tubes,

and one #123-34 Switch Plate. Examine the drawing and note the orientation of the switch plate and related

parts. Prepare each bolt with Blue Loctite. Insert each bolt through the switch plate followed by a carbon

tube and the fan shroud brace. Install this assembly onto the left main frame and into the threaded inserts of

the left side of the #115-24 Horizontal Channel. Leave each bolt just loose enough to allow adjustment in the

next steps.

B. Select two #0061 M3x8 Socket Head Bolts and one #115-58 Fan Shroud Brace. Prepare each bolt with Blue

Loctite and install (similar to the previous step) in the right main frame opposite the switch plate/fan shroud

brace of the left frame. Again, leave the bolts loose enough to allow adjustment.

C. Select two #0063 M3x10 Socket Head Bolts, the two remaining #115-58 Fan Shroud Braces, and two #3923-

1 Plastic Spacers. Examine the drawing and note that each frame has two holes for attachment of the rear fan

shroud braces. For this step, the forward hole (containing a threaded insert) in each frame is utilized. Prepare

each #0063 Socket Head Bolt with Blue Loctite and insert first into the fan shroud bracket hole (nearest the

bend) and then through one #3927-1 Plastic Spacer. Install each onto either side of the frame assembly,

noting that they should be horizontal and not so tight as to restrict adjustment. Keep in mind that the rear

holes will be utilized during later steps so the holes should remain aligned with the frame and vertical channel

holes. Select two #3923-1 Plastic Spacers and two #0065 M3x12 Socket Head Bolts. Prepare each bolt with

Blue Loctite. Slide a plastic spacer between the rear fan shroud brace on each side and install a #0065 Socket

Head Bolt in each threading into the vertical rear channel. As with the preceding hardware, leave just loose