Assembling the Cyclone RX3

The first thing to do is view the CSC tutorial on assembling the bike. The comments I make here are in addition to that tutorial, not a replacement for it.

My Cyclone RX3 arrived in three boxes. The big box contains the bike, the other two boxes contain various hardware items and the top and side cases. If you order it fully assembled from CSC I presume you just get one big box!

The first thing to do is remove all the plastic wrap and separate the boxes, then cut the cardboard away from the large box containing the bike. The bike is supported by a steel frame, which is the next thing you'll need to remove. It's held together with nuts and bolts.

Note the frame is what is holding the bike upright, so I attached a ratcheting strap between each side of the bike (orange webbing in photograph) and the pallet to hold it upright when the supports were removed.

Once you have the frame remove, the bike supported upright and all the plastic wrapping taken off, the next thing to do is install the handlebar and clutch assembly. Before you do that make sure the bolts holding the handlebar holder to the bike are tight. One you've installed the handlebar you can't get at them to check.

Now comes the fun part, installing the front wheel. With enough strong help around I guess you can lift the bike off the pallet, hold up the front end and put the wheel in, but I was working alone so that wasn't an option. What I did was to jack up the bike as shown below. The wooden pallet and hardboard covering isn't strong enough to support the eight of the bike on the jack, so I cut out a section which allowed me to put some wooden blocks on the garage floor and use them as a support for the jack. Note that you have to loosen the hold down straps as you raise the bike.

Installing the front wheel is pretty simple and well described in the CSC assembly tutorial. You'll need to push the separate back in the housing to get the brake disk between them. You can do that by hand, or you can use a C-clamp. Push the calipers in and separate the pads. Install the oil seal on the speedometer drive side of the wheel, feed the brake disk into the gap between the pads and insert the axle. Push the axle all the way though and tighten the nut to about 55 ft-lbs. Then tighten up the two locking bolts on the lower end of the right front fork.

At this point you can ride/push the bike off the palette (it helps to have someone around to loosen the hold down straps) and with the sidestand down it will stand up on its own. I cut off the tube that's used to secure the front forks for shipping before rolling the bike off, but you can probably just roll over it.

The rest of the assembly is to put acid in the battery, charge it and install it in the bike. It's a very tight fit, but it will go. The rubber caps for the +ve and -ve terminals won't actually fit over them unless you trim off a little of the "lip" (as evidenced by the photograph in the CSC tutorial where the caps don't fit!). Once you do that, they should slide over as shown below.


That's about it. It's recommended that you drain out the oil that's in the bike and replace it with an appropriate motorcycle oil. Don't use a car oil with friction modifiers in it or you may find the clutch will slip. I've been using Shell Rotella T oil in bikes for years. It contains no friction modifiers and is much cheaper than motorcycle oil, though it's sold for diesel enongs and cars. See for more information. Lots and lots of bike owners use it, but it's your choice. There are lots of oils specifically marketed for motorcycle use. Whatever you use, conventional rather than synthetic oil is recommended for the break-in period. Then put a couple of gallons of gas (regular, 87 octane is fine)in the tank and start it up. I was surprised that mine fired up on the first attempt and it settled into a steady ~1500 rpm idle. Before you take a test ride just check over the bike once again, make sure all the important bolts are tight (like the axles, brake calipers etc.). You might also want to adjust the chain. Mine was very tight. Take it slow on your first ride. Apart from anything else the brakes have to bed-in and the tires have to be scuffed up a little before they will provide maximum grip.