79
Pack 08
HAYABUSA
SUZUKI GSX 1300R
TM
www.model-space.com
SUZUKI GSX 1300R HAYABUSA
CONTENTS
TM
www.model-space.com
Stage 25: The swingarm
Stage 26: The swingarm subframe
Stage 27: The left crankcase half
Page
81
83
86
Assembly Guide
Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP.
Published in the UK by De Agostini UK Ltd, Battersea Studios 2,
82 Silverthorne Road, London SW8 3HE.
Published in the USA by De Agostini Publishing USA, Inc., 915 Broadway,
Suite 609, New York, NY 10010.
All rights reserved © 2014
Not suitable for children under the age of 14.
is product is not a toy and is not designed or intended for use in play.
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 25
The swingarm Area you are working on Detail
Swingarm
Rear axle (nut pre-tted)
Sticker A
Tools
Tweezers
File
Masking tape
Your parts
Because of the high speed and
overwhelming power that the
Hayabusa delivers, the performance of
the swingarm is extremely important.
Its combination of strength and
rigidity, while allowing comfortable
suspension movement and ensuring
good traction, helped to win the
Hayabusa a reputation for ease of
riding compared to other super
sports bikes.
Remove the pre-tted nut from the end of
the rear axle.
Hold the swingarm the correct way up,
with the side shown in the parts photo on
the left facing down. Test-t the axle by
inserting the end from which you removed
the nut into the hole at the end of the arm.
1
2
RearFront
View from below
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
This stage is now complete. Make sure
that the nut is screwed back onto the end
of the axle so that the two parts don't get
separated, and store them away safely until
they are needed again.
The ats at the end of the axle match the
straight-cut sides of the hole, so to t the
axle into the hole you will need to turn it so
that these match up. When you have made
this test t, remove the axle and screw the
nut back onto the end.
Use tweezers to peel sticker A from its
backing sheet.
When the sticker’s position is correct, press
the rest of it onto the swingarm, moving
smoothly from left to right to ensure that
there are no creases. Then remove the
masking tape from under the front of the
sticker, and stick that down as well.
Sticker A received with this stage will be
placed in the blue-shaded area.
Place some masking tape in line with the
front of the blue-shaded area shown in
Step 4.
Stick only the front (left-hand) end of the
sticker onto the masking tape. Then it will
be easy to adjust the sticker’s position by
simply moving the tape.
3
6 8
4
5
7
Locate any leftover casting ash or burrs
around the holes in the swingarm, such
as the one circled, and remove them
with a le, as they may prevent proper
assembly of the parts.
Tip
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Area you are working on
Detail
STAGE 26
The swingarm
subframe
Tools Prepare
Phillips screwdriver (size 1) Swingarm (Stage 25)
Plastic bag
Pen
Your parts
The subframe of the swingarm is
above the main part of the swingarm,
and so is less visible when all the
fairings are tted to the bike. The
subframe on the actual bike is welded
to the swingarm, to ensure strength
and rigidity. This area also houses the
coil spring and shock absorber, which
make up the rear suspension, and the
mudguard, which protects the internal
parts from mud and other road debris.
Swingarm subframe
Mudguard
2.3 × 6mm self-tapping
screws × 11
Hold the mudguard and swingarm
subframe together, as shown.
Fit the two pins in the subframe into the
holes in the tabs on the mudguard.
1
2
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Hold the subframe and the swingarm from the previous
stage, as shown. Identify all of the connecting points shown
in the photo above.
Match the positions of the pins on the swingarm to the
holes in the subframe.
Align the two projections at the end of the mudguard
with the two arrowed recesses, and the sides with the two
shaded areas.
Once you have aligned all of the points indicated
in the previous four steps, carefully push the subframe
onto the swingarm.
Push the mudguard onto the subframe to ensure that the
pins are fully seated in the holes.
Make sure that the two small projections at the end
of the mudguard will t into the two rectangular
recesses in the swingarm.
4
7
5
8
3
6
85
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Loosely place 2.3 × 6mm screws into the
three remaining holes, then, following
the order shown above, tighten each one
halfway in. Following the same order as in Step12,
tighten the screws fully.
12
13
The swingarm is now complete. Make sure to save the remaining 2.3 × 6mm screws for
later use (you will need one in the next stage), in a bag labelled with the stage number.
While holding the parts together, insert a 2.3 × 6mm screw
into the hole shown.
Tighten the 2.3 × 6mm screw into the hole.Make sure the ends of both pieces have been tted
together properly.
10
119
86
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Area you are working on Detail
STAGE 27
The left
crankcase half
Left crankcase half
Tools Prepare Optional
Phillips screwdriver (size 1) 2.3 × 6mm screw
(spare from previous stage)
Cross wrench or tap wrench
2.3mm tap
Your parts
The heart of the Hayabusa is
undoubtedly its engine, a compact
powerhouse designed specically to t
within the connes of the bike’s frame.
When the bike is covered in its fairings,
the massive 1,300cc engine is hidden
from view, demonstrating the high
level of attention to detail paid when
designing the bike. Though you won't
be assembling the crankcase just yet,
you can still appreciate its design.
Check the dierent aspects of the left
half of the crankcase, shown here, to
locate the circled screw holes.
1
Outside
Bottom surface
Inside
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
To tap the screw holes in the crankcase, use a spare 2.3 ×
6mm screw left over from the previous stage.
Clean o any metal swarf that has been produced by the
tapping, so that the hole is clean, as shown above. Then
repeat the tapping process to thread the rest of the holes
circled in Step 1.
Insert the 2.3 × 6mm screw into one of the holes in the
crankcase, circled in Step 1. Turn it into the hole until about
two-thirds of the threaded portion is inside it, then slowly
unscrew it and remove it from the hole.
2
4
3
This stage is now complete. Tapping screw holes prior to
assembly can improve the way parts t together, and make
things easier later in the series.
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Tap wrench
In this stage, you cut threads in the screw holes in the crankcase using a spare screw
from the previous stage. To make the cutting of threads easier, you can use a tap
wrench and taps to prepare the holes, rather than using leftover screws. For example,
you could use a 2.3mm tap in this stage instead of the 2.3 × 6mm screw.
A tap wrench and 2.3mm tap. Wrenches
and taps are available from hobby
shops, tool stores and online retailers.
Instead of using a tap wrench, you can
often use the cross wrench, which has a
hole that can be used to hold a tap.
With the tap securely held in the jaws
of the wrench, insert the cutting end of
the tap into the hole you want to thread
and slowly turn the wrench clockwise.
The tap will screw itself into the hole,
cutting a thread as it goes. Make sure
you keep the tap straight as you turn it.
The cross wrench is used in the same
way as the tap wrench: turn it clockwise
to cut the thread, and anti-clockwise to
remove it from the threaded hole.
A
C
B
D
Tap wrench
2.3mm tap
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
TM
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