Project JAWA-ČZ KÝVAČKA 250/353.02 - PART No.5 - Under seat covers + tank

Here you are the 5th part of my Jawa-ČZ 250/353.02 build. 

Hope the 4th part was fun for you :)

Project JAWA-ČZ KÝVAČKA 250/353.02 - PART No.4 od autora jawarmaniak | Stáhněte si zdarma STL model | Printables.com

The 5h part consist a big parts but the very small also so pay attention to the description and attached pictures. As usual be extremely careful during the assembly itself and work slowly and cautiously.
If you manage to damage or break some part despite being extra careful you should "weld" it with a soldering gun rather than gluing it with super glue.

at first we started with the biggest part today - the tank

Printing instruction:

• fuel_tank_middle_part - 1 piece, red PLA, 70% infill, 0.2 layer.
• filler_neck - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

Now you have to choice variants of the side parts you will print. 

If you have MMU unit and you can print in different colors you can print fuel_tank_left_part.stl and left_tank_logo.stl together as a one part. Also fuel_tank_right_part.stl and right_tank_logo.stl. 

If you cannot print in different colors you have to print only fuel_tank_left_part.stl and fuel_tank_right_part.stl. Both stls with logo you do not print separately. They are not possible to install into side parts afterwards. After printing the parts you can color the logos red. 

• fuel_tank_left_part - 1 piece, chrome PLA, 60% infill, 0.15 layer.
• left_tank_logo - 1 piece, red PLA, 100% infill, 0.15 layer.
• fuel_tank_right_part - 1 piece, chrome PLA, 60% infill, 0.15 layer.
• right_tank_logo - 1 piece, red PLA, 100% infill, 0.15 layer.

Assembly instruction:

• Put all the parts together and glue them with super glue.
• For now, set the complete tank aside.

at second we can continue with the cylinder for the engine

Printing instruction:

• cylinder_insert - 1 piece, grey PLA, 50% infill, 0.15-0.2 layer.
• cylinder_part_1 - 1 piece, black PLA, 50% infill, 0.15-0.2 layer.
• cylinder_part_1 - 1 piece, black PLA, 50% infill, 0.15-0.2 layer.

Assembly instruction:

• All 3 parts glue together into one part. The insert has a shape lock, so wrong orientation should not be possible. See pictures below.

• Insert the crankshaft, piston and connecting rod into the crankcases if you printed them.
• Screw both crankcases together by screws M2 according picture below.

• Cut the M3 threads in the crankcases and screw on the threaded rods with a length of 38 mm. You can secure them with glue and slide the cylinder onto the piston (if you printed it)

• Recalibrate the 4 holes in the cylinder head by 3.5mm with a drill.
• Install the cylinder head and secure it with 4 M3 nuts.

• Install the carburetor cover and by pen mark through the hole for the air filter the position for the retaining pin.

• Drill a 1.5mm hole and screw in the M2-7 screw into the hole, do not tighten. It has to stay cranked out far enough to slide the carburetor cover on.

at third we can continue with the under seat covers

Printing instruction:

• left_cover - 1 piece, red PLA, 100% infill, 0.15 layer.
• right_cover or right_cover_sidecar - 1 piece, red PLA, 100% infill, 0.15 layer.
• ledge_1 - 1 piece, red PLA, 100% infill, 0.15 layer.
• ledge_2 - 1 piece, red PLA, 100% infill, 0.15 layer.
• middle_cover - 1 piece, silver/sand/chrome PLA, 100% infill, 0.15 layer.

Assembly instruction:

• If you want to print the solo motorcycle, you have to print right_cover.stl. For bike with sidecar you will need right_cover_sidecar.stl
• After print screw together 3 main parts (right, left, middle cover) into one assembly

• Install it into frame and only for now, hold them with a screw M2-5 on both sides

• The small ledge_2 save for now. It will only be needed in future steps.
• Install the engine into the frame and fix it by 4 screws M2.5-14 with nuts.
• Install tank on its place and for fixation use 2 screws M2-3 for the front holders and 1 screw M2.5-25 with nut for fix the under seat covers and rear of the tank.

at fourth we can complete the top headlight cover

Printing instruction:

• headlight_cover - 1 piece, red PLA, 100% infill, 0.2-0.15 layer.
• setup_screw - 1 piece, grey PLA, 100% infill, 0.15 layer.
• setup_screw_bottom_shim - 1 piece, grey PLA, 100% infill, 0.15 layer.
• adjustment_cam - 1 piece, grey PLA, 100% infill, 0.15 layer.
• right_handlebars_grommet - 1 piece, black PLA of TPU, 0.2-0.15 layer.
• left_handlebars_grommet - 1 piece, black PLA of TPU, 0.2-0.15 layer.

Assembly instruction:

• insert M1.2-8 screw into setup_screw and fit it by superglue and the setup_screw_bottom_shim.
• Whole subassembly install into headlight_cover and from bottom side slide the adjustment_cam on the screw. Fix it by the M1.2 nut and with super glue if it is necessary.

• Set the parts aside for the time being. Do not install the handlebars grommet yet.

at fifth we can complete the handlebars

Printing instruction:

• switch - 1 piece, black PLA, 100% infill, 0.2-0.15 layer.
• pushbutton - 1 piece, black PLA, 100% infill, 0.2-0.15 layer.
• throttle_control - 1 piece, grey PLA, 100% infill, 0.2-0.15 layer.
• left_lever - 1 piece, grey PLA, 100% infill, 0.15 layer.
• bowden_rest - 2 pieces, grey PLA, 100% infill, 0.15 layer.
• right_plug - 1 piece, grey PLA, 100% infill,0.2-0.15 layer.
• left_plug - 1 piece,  grey PLA, 100% infill,0.2-0.15 layer.
• switch_body - 1 piece,  chrome PLA, 50% infill, 0.15 layer.
• right_handlebar - 1 piece,  chrome PLA, 40% infill, 0.15 layer.
• left_handlebar - 1 piece,  chrome PLA, 40% infill, 0.15 layer.
• right_lever - 1 piece, grey PLA, 100% infill, 0.15 layer.
• right_handle - 1 piece,  black PLA or TPU, 0.2 layer.
• left_handle - 1 piece,  black PLA or TPU, 0.2 layer.

Assembly instruction:

• Glue together switch, pushbutton and the switch_body.

• Assembly all parts according the picture below. Both plugs should be fixed by super glue.
• Both levers fix by M1.4-6 screws with nuts ant the light switch by M1.2-10 screw with nut.

• Slide the grommets of the headlight cover onto the handlebars.
• Loosen the handlebar clamps on the front fork upper bracket. Slide the handlebars and tighten.

• Install the headlight cover and carefully insert the handlebar grommets. be careful and proceed with caution. It's not easy.
• from rear side fix the headlight cover by screw M1.2-6.

at the last today step we will complete the horn

Printing instruction:

• horn_holder_sheet_metal - 3 pcs, grey PLA, 100% infill, 0.2 layer.
• membrane - 1 piece, grey PLA, 100% infill, 0.2-0.15 layer.
• horn_body - 1 piece, red PLA, 100% infill, 0.2-0.15 layer.
• horn_cover - 1 piece, chrome PLA, 100% infill, 0.15 layer.
• horn_conector -  2 pcs, brass/gold PLA, 100% infill, 0.2 layer.
• pertinax_shim_1 -  2 pcs, dark brown PLA, 100% infill, 0.2 layer.
• pertinax_shim_2 -  1 piece, dark brown PLA, 100% infill, 0.2 layer.

Assembly instruction:

• Install all horn_holder_sheet_metals on the horn_body by M1.2-5screw and M2.5-5 screw with nut
• Both horn_conectors glue on the pertinax_shim_2 and all subassembly glue on horn_body.
• Install screw M2-5 into membrane and fix them by nut from outer side. See attached picture below.
• Fix left pertinax_shim_1 by M1.2-3 screw from outside on the horn_body.
• Fix right pertinax_shim_1 by M1.2-5 screw from inside on the horn_body. From outside install nut M1.2
• Assembly horn_body, membrane and horn_cover. You will need 6 pcs M1.6-4 screws and 6 pcs M1.6 nuts.
• Complete horn install on its holder on front fork by M2.5-5 screw with nut.

Bill of material:

• 4x nut M1.2
• 8x nut M1.4
• 6x nut M1.6
• 4x nut M1.2
• 1x nut M2
• 7x nut M2.5
• 4x nut M3

• 2x screw M1.2-3mm
• 2x screw M1.2-5mm
• 1x screw M1.2-6mm
• 1x screw M1.2-8mm
• 1x screw M1.2-10mm
• 6x screw M1.4-4mm
• 2x screw M1.4-6mm
• 6x screw M1.6-4mm
• 2x screw M2-3mm
• 4x screw M2-5mm
• 2x screw M2-7mm
• 5x screw M2-8mm
• 1x screw M2-10mm
• 2x screw M2.5-5mm
• 4x screw M2.5-14mm
• 1x screw M2.5-25mm
• 4x threaded rod M3-38mm

• superglue

I hope you had fun during building and everything went smoothly.

You can look forward to the next part. The 6th part is under progress right now ;)

6th part is avaliable here: https://www.printables.com/cs/model/802455-project-jawa-cz-kyvacka-25035302-part-no6-rear-mud