PAPER CRAFT Assembly Instructions

Thank you for downloading the "SR400"paper craft model. By simply following this manual while referring to the names and numbers shown on the parts sheets, you can assemble an authentic-looking replica of the SR400.

Assembly instructions: Fifteen A4-sized sheets. Paper craft: Seventeen A4-sized sheets with 223 parts in all

These instructions apply only to the "SR400." These Paper Craft parts are easier to work with when printed out on strong, thick paper (like postcard stock).

In creating these Paper Craft models we use 135kg Kent paper stock (0.18mm).

2003.4.25 Note

TO BEGIN Basic working method and markings

Tools and materials needed Solid lines -Ruler -Scissors - Blade cutter or "Exacto-knife" - Awl or Fold along these lines. The printed other pointed tool (for making a folding crease) - Felt surface should be on the outside of pen - Pin set - Glue - Hand towel ( for cleaning your the folded shape. fingers) - Dictionary or other heavy book ( to press the papers flat) Broken lines Items of Caution Fold along these lines. The printed *Take care when using sharp or pointed objects or when surface should be on the inside of using bladed cutting tools. Place a heavy sheet of paper the folded shape. under the paper you want to cut. *Use glue and other adhesives only in well-ventilated areas. Dotted line *When printing, use a slightly reduced font size as there are many differences in dimensions depending on the Cut along these lines type of printer used.

HOW TO ASSEMBLE Do not fold or cut the parts *Follow the working method and markings carefully. marked . *Cut carefully along the outer line with a cutting blade, Exacto-knife or scissors.

One - point Advice Cut out parts marked with an as- terisk (*). *Cut carefully with a cutting blade, Exacto-knife or scissors.

*For folding parts, first use an awl or other pointed tool to make a light crease along the dotted or solid line. This will make the folds straight. Avoid making strong creases, as this will cause the paper to tear. Red dots are the reference positions for gluing surfaces. *As an adhesive, white wood glue is recommended. Avoid over-application as this will cause the paper to wrinkle.

*Before beginning assembly, test adhesive amounts on extra paper.

*Occasionally, white spots will be apparent on folds and cuts. Use a marker or pencil to fill-in these spots. It is recommended that this be done after each stage of assembly because coloring becomes more diffi- cult once parts are assembled.

- 2 - 1 Assembling the Fuel Tank & Seat

First, assemble each component by following the working method and markings. Then, refer to the il- Indication of Fold or Curve Glue lustration and photos below to glue the parts together. Working Methods

Fuel Tank Fold each relevant part according to the assembly symbols. Sheet A, 5 parts in total Please use the dots on each component as reference when gluing surfaces.

A-4

Fold and glue the corresponding tabs (dotted parts) so that they make good symmetrical pairs.

A-3 A-5

Reference photo

A-4 A-1 A-2

- 3 - 2 Assembling the Steering

Steering Fold each relevant part according to the assembly symbols. Sheet B, 39 parts in total Please use the dots on each component as reference when gluing surfaces.

[ Upper Steering Column ] B-38 Insert B-19 through B-5 and B-6, then fold B-19 as indicated with the arrows in the drawing. B-8 B-37 B-6 B-5 B-39 B-19 B-36

B-15 B-9 B-14 B-4 B-13 B-12 DO NOT glue the upper and the lower B-18 parts of the steering column at this B-16 stage. B-17

[ Lower Steering Column ] [ Telescopic Front Fork ] Assemble both forks. The diagram shows how the right front fork looks. The numbers within the parentheses indicate the parts B-32 B-11 for the left front fork. B-10 B-20 (24)

B-22 (26) B-2 B-31 B-1 B-33 B-3 B-21 (25)

B-34

B-30 Reference photo B-35

[ Front Fork ] B-23 (27)

B-28 (29)

- 4 - 3 Assembling the Frame -A

Frame Fold each relevant part according to the assembly symbols. Sheet C, 78 parts in total Please use the dots on each component as reference when gluing surfaces.

1 2 C-65

C-76 C-67 C-75

C-74

C-64

C-66

C-54 3 4 C-72

C-68 C-53 C-71 C-70 C-52 C-69 C-49

C-51 C-50 C-73

5 C-63

C-62 C-60 C-61 C-56 C-59

C-55

C-57

C-58

- 5 - 3 Assembling the Frame -B

Frame Fold each relevant part according to the assembly symbols. Sheet C, 78 parts in total Please use the dots on each component as reference when gluing surfaces.

C-28 4 C-25 C-15 C-29 C-11 C-1 C-6 C-7 C-13 C-78 C-12 C-14 C-10 C-26 C-4 C-77 C-17 C-5 C-47

3 C-19 C-48 C-2 C-22 C-9 C-24 C-8 C-45 C-16 C-44 C-3 C-18 C-39 C-21 2 C-43 C-27 C- C-40 C- 38 46 C-20 C-30 C-41 C-33 C-34 C-42 C-36 C-37 3 C-35 C-31 C-23 C-32 1 5 Reference photo

- 6 - 4 Assembling the Engine

Engine Fold each relevant part according to the assembly symbols. Sheet D, 24 parts in total Please use the dots on each component as reference when gluing surfaces.

D-3 D-2 D-1 D-4

D-5 D-6

D-7

D-17 D-16 D-10 D-8 D-12 D-14 D-9 D-18 D-13

D-19 D-23 D-20

D-21 D-11

D-15

D-22

D-24 Reference photo

- 7 - 5 Assembling the Exhaust Pipes & Rear Fender

Exhaust Pipes Fold each relevant part according to the assembly symbols. Sheet E, 9 parts in total Please use the dots on each component as reference when gluing surfaces.

E-4

E-3 E-6

E-1 E-5 E-2 E-9

E-7 E-8 Reference photo

Rear Fender Fold each relevant part according to the assembly symbols. Sheet F, 4 parts in total Please use the dots on each component as reference when gluing surfaces.

F-1

F-2 F-3

F-4

Reference photo

- 8 - 6 Assembling the Rear Arm

Rear Arm Fold each relevant part according to the assembly symbols. Sheet G, 25 parts in total Please use the dots on each component as reference when gluing surfaces.

Glue G-24 (the grab bar) AFTER all parts are as- G-24 sembled and completed.

G-9

G-12 G-10 G-13

G-11 G-14 G-8 G- G-15 22 G-4 G-21 G-16 G-25 G-19 G-17

G-3 G-23 G-7 G-20 G-18

G-2 G-1 G-6 G-5 Reference photo

- 9 - 7 Assembling the Side Covers & Intake

Side Covers Fold each relevant part according to the assembly symbols. Sheet H, 2 parts in total Please use the dots on each component as reference when gluing surfaces.

Assemble both side covers.The diagram shows how the right side cover looks.The numbers within the parentheses indicate the parts for the left side cover.

H-9(10)

Reference photo

Intake Fold each relevant part according to the assembly symbols. Sheet H, 8 parts in total Please use the dots on each component as reference when gluing surfaces.

H-4 H-8 H-5

H-3 H-1

Reference photo

H-6

H-7 H-2

- 10 - 8 Assembling the Front Tire

Front Tire Fold each relevant part according to the assembly symbols. Sheet I, 15 parts in total Please use the dots on each component as reference when gluing surfaces.

*Glue the completed front wheel to the assembled front tire.

I-6 [Front tire]

I-15

I-14

I-11

I-12 [Front wheel]

I-4 I-13 I-7

I-8 I-5

I-1 I-2 I-9

I-10

I-3 Reference photo

- 11 - 9 Assembling the Rear Tire

Rear Tire Fold each relevant part according to the assembly symbols. Sheet J, 14 parts in total Please use the dots on each component as reference when gluing surfaces.

*Glue the completed rear wheel to the assembled rear tire.

J-4 [Rear tire]

J-12

J-11

J-10

J-13

J-14

[Rear wheel] J-6 J-5

J-7

J-1

J-2 J-9 J-3 J-8

Reference photo

- 12 - 10 Finish

Please use the dots on each component as reference when gluing surfaces.

Fuel Tank & Seat Assembly Instructions Grab Bar glue the assembled parts in numerical Rear Fender order 1 through 11 . Exhaust Pipe Upper Steering Column 1 Glue the engine to the frame. 2 Glue the rear arm to the engine and the frame. 3 Glue the air filter to the engine and the frame. 4 Glue the rear tire to the rear arm. 5 Glue the rear fender to the frame. 6 Glue the exhaust to the engine and the frame. 7 Insert the upper steering column in the frame and then glue this part to the lower steering column. 8 Glue the front tire to the lower steering column. 9 Glue the right and left side covers. Engine 10 Glue the fuel tank/seat to the frame. 11 Glue the grab bar to the rear arm. Rear Tire

Rear Arm

Intake Lower Steering Column Frame Side Cover

Front Tire

- 13 - 11 Assembled Model and the List of Parts

Please refer to the photo below when attaching each component.

RIGHT FRONT

Intake Side Cover Fuel Tank & Seat H-1 H-7 H-9 A-1 H-2 H-8 H-10 A-2 H-3 A-3 H-4 A-4 H-5 A-5 H-6

Rear Tire Exhaust Pipe Engine Front Tire Steering

J-1 J-7 J-13 E-1 E-7 D-1 D-7 D-13 D-19 I-1 I-7 I-13 B-1 B-7 B-13 B-19 B-25 B-31 B-37 J-2 J-8 J-14 E-2 E-8 D-2 D-8 D-14 D-20 I-2 I-8 I-14 B-2 B-8 B-14 B-20 B-26 B-32 B-38 J-3 J-9 E-3 E-9 D-3 D-9 D-15 D-21 I-3 I-9 I-15 B-3 B-9 B-15 B-21 B-27 B-33 B-39 J-4 J-10 E-4 D-4 D-10 D-16 D-22 I-4 I-10 B-4 B-10 B-16 B-22 B-28 B-34 J-5 J-11 E-5 D-5 D-11 D-17 D-23 I-5 I-11 B-5 B-11 B-17 B-23 B-29 B-35 J-6 J-12 E-6 D-6 D-12 D-18 D-24 I-6 I-12 B-6 B-12 B-18 B-24 B-30 B-36 - 14 - 12 Assembled Model and the List of Parts

Please refer to the photo below when attaching each component.

LEFT REAR Rear Arm G-1 G-6 G-11 G-16 G-21 G-2 G-7 G-12 G-17 G-22 G-3 G-8 G-13 G-18 G-23 G-4 G-9 G-14 G-19 G-24 G-5 G-10 G-15 G-20 G-25

Frame Rear Fender

C-1 C-7 C-13 C-19 C-25 C-31 C-37 C-43 C-49 C-55 C-61 C-67 C-73 F-1 C-2 C-8 C-14 C-20 C-26 C-32 C-38 C-44 C-50 C-56 C-62 C-68 C-74 F-2 C-3 C-9 C-15 C-21 C-27 C-33 C-39 C-45 C-51 C-57 C-63 C-69 C-75 F-3 C-4 C-10 C-16 C-22 C-28 C-34 C-40 C-46 C-52 C-58 C-64 C-70 C-76 F-4 C-5 C-11 C-17 C-23 C-29 C-35 C-41 C-47 C-53 C-59 C-65 C-71 C-77 C-6 C-12 C-18 C-24 C-30 C-36 C-42 C-48 C-54 C-60 C-66 C-72 C-78 - 15 -