162
Pack 15
HAYABUSA
SUZUKI GSX 1300R
TM
www.model-space.com
SUZUKI GSX 1300R HAYABUSA
CONTENTS
Assembly Guide
TM
www.model-space.com
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 © 2015
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.
Stage 48: LED testing
Stage 49: The rear brake pedal
Stage 50: The rear fender
Page
164
168
174
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 48 Area you are working on
LED testing
Tools Prepare
Cutter knife
Tweezers
Phillips screwdriver
Cutting mat
Rear subframe (Stage 46)
AAA batteries × 3
LED tester board (Stage 47)
Plastic bag
Pen
Your parts
Rear fender
Rear right indicator
Rear left indicator
Pivot shaft
Pivot shaft nut
3 × 68mm shaft
Cable holders × 2
There are four sizes of white socket, all
of them facing the same direction. Each
socket has one wide gap at the front, and
two narrow gaps on either side. The black and green sockets are facing the
opposite way to the white sockets. These
two sockets also have the one wide gap
and two narrow gaps.
Take the LED tester provided with Stage
47 and locate the six sockets and one LED.
2
3
1
Wide Narrow
Wide Narrow
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Remove the lid of the battery box from the
rear subframe assembly (Stage 46).
Using a knife, cut along the yellow lines shown here on the
green and black sockets.
Then cut along the red lines shown above on the
white sockets.
Place three AAA batteries into the box.
Make sure you position them the right way
round, as marked on the base of the box.
Pull the fronts of the sockets forward, as shown.
Pull the battery cable and the rear light
cable through the hole in the subframe,
as shown.
4 5
7
8
9
6
The central battery can be hard to t
into the battery box because of the
black part in the centre of the seat rail.
You may nd it easier to remove this
part before trying to t the battery.
Tip
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Look at the connectors at the end of the battery box cable
and the tail light cable. Although the colours are dierent,
both are the same shape, with a raised central rib on one
side and a pair of connector terminals on the other.
Push the black connector into the black socket.
Hold the LED tester board on its side, as shown, and hold
the battery box connector with the central rib facing
towards you.
Insert the green connector into the white
socket at the corner, with ‘JP3’ printed
below it.
10 12
11
13
When the green connector is plugged into
socket JP3 on the LED tester board, the
tail light should come on.
14
Be careful when testing the tail
light. Although the connector is
green, it’s not meant to go into
the green socket (indicated by
the red circle) in the way
that the black connector plugs
into the black socket. Instead,
the green connector should be
plugged into the white socket
JP3 (indicated by the blue
circle). The green socket is for
testing switches, such as the
rear brake pedal.
Central rib
Connector terminals
CAUTION!
167
SUZUKI GSX 1300R Hayabusa: Assembly Guide
This stage is now complete. Store the two indicators and
the LED tester board for later use.
Stage
complete!
Using tweezers – preferably with hooked
ends, like those shown above – will make
it much easier to unplug the connectors
from the LED tester.
Plug the yellow connector at the end of the rear right
indicator cable into socket JP3.
Insert the rear left indicator connector
(blue) into socket JP3.
Remove the green connector from socket
JP3, as shown.
The rear right indicator should now light up, as shown.
Unplug the connector after testing.
Plug in the rear left indicator’s connector
to check that the indicator light comes on.
Unplug the connector after testing.
15
19
17
16
20
18
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 49 Area you are working on Detail
The rear
brake pedal
Tools Prepare
Phillips screwdriver
Tweezers
Relay unit (Stage 46)
Rear subframe (Stage 46)
LED tester board (Stage 47)
AAA batteries × 3
Plastic bag
Pen
Your parts
Right front footrest
Rear brake pedal
Rear brake master cylinder
Rear brake hose
2.3 × 5mm self-tapping
screws with washers × 2
2 × 5mm hex screws × 5
Rear reservoir tank hose
Stop lamp switch wire
Remove the two screws that hold the
battery box in place on the rear subframe
(Stage 46), then remove the battery box.
Following the steps in Stage 46, remove
the seat rail from the rear subframe.
A B
The footrest of the Hayabusa
was designed to t in with the
aerodynamics of the frame. The size of
the right front footrest is slightly larger
than the left one, because it has the
rear brake master cylinder tted into it.
As on the real motorcycle, the model’s
footrests fold up.
Before working through the steps in this stage, you will need to dismantle the rear subframe to
reposition the battery box and tail light cables.
169
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Ret the seat rail to the rear subframe,
following the instructions in Stage 46.
Line up the relay unit (Stage 46) with the
seat rail, as shown.
Now pass the battery box cable through
the same hole, and ret the battery box
following the steps given in Stage 44.
Push the pin into the hole, and turn
the unit so that the U-shaped cut-out is
around the circled hole in the seat rail.
Pass the tail light cable through the
outlined hole in the rear subframe.
Turn the relay unit so that the pin is
aligned with the indicated hole in the seat
rail.
G
C
I
E
H
D
Place three AAA batteries into the
battery box.
Take the two cables extending from the
relay unit and move them outside of the
seat rail.
J
F
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Line up the rear brake pedal with the hollow post on the
right front footrest. Be careful not to damage the wires
when handling the footrest.
After tting the brake pedal, make sure that it moves freely. Also, test that the projection
engages with the switch.
Place the hole of the brake pedal over the hollow post of
the footrest. Be careful not to damage the outlined part
when handling the pedal.
Turn the brake pedal slightly so that the outlined
projection is next to the button on the switch (arrowed).
1
4
3
Place a 2.3 × 5mm screw with washer into
the hole in the footrest.
5
2
Tighten the screw into the hole to secure
the brake pedal.
6
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Rotate the master cylinder until the two
holes at its side align with the two pins on
the footrest.
Locate the spring on the footrest, then
grip the loop on the free end with pliers
and hook it over the projection on the
brake pedal.
Line up the black tip of the brake pedal
with the rear brake master cylinder, as
shown above.
Push the two holes onto the pins.
Push the loop down over the projection so
that it’s secure.
11
7
13
9
12
8
Test that the footrest moves freely up and down (arrowed).
Push the two parts together.
10
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
The right front footrest assembly should
now look like this.
Push the connector into the socket.
This stage is now complete. Store any
unused parts in labelled bags.
Push the battery box connector into the
black socket of the LED tester board.
Prepare the battery box cable and the LED
tester board, as in Stage 48.
Move the brake pedal to engage it with the switch on the footrest bracket. This should
light up the LED on the board. When you have checked this, remove the connectors
from the board.
14
18
16
15
19
Line up the connector at the end of the
rear brake cable with the green socket
on the board. The central ridge on the
connector should be facing outwards.
17
Stage
complete!
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
The LED tester is designed to test the various LED components of your Honda CB750. The purpose of testing them at this stage is to check that they are all
working now, rather than nding out that they don’t work when it is too late to replace them without dismantling your model.
Power socket (JP1)
This is the socket that the battery box will be connected
to. If the LED doesn’t light up when connected, then there
is an issue with either the battery box, the positions of the
batteries, the cable, or the connection.
Switch conrmation (LED)
When you check the rear brake pedal by plugging it in
and then pushing down on it to complete the circuit, the
LED mounted on the tester should light up. If the LED
doesn’t light up, then there is a problem with either a
cable or a connection.
Switch component socket (JP2)
This socket is used only for testing switch-activated
components, such as the rear brake pedal or the ignition
switch. This socket should not be used for LEDs.
2-pin socket (JP3)
The smallest of the LED connectors is the 2-pin socket,
JP3. This socket will accommodate the tail light and the
headlight connectors. If the LED of the tested part doesn’t
illuminate, the cable may be broken.
3-pin socket (JP4)
The 3-pin socket, JP4, is used for the rear indicators only.
This is the middle-sized socket. If the tested LED doesn’t
illuminate, then the cable may be broken.
4-pin socket (JP5)
The next socket on the LED tester is the 4-pin JP5. This
socket will take the connectors of the front indicators. If
any of the LEDs don’t light when tested, then the cable is
probably broken.
7-pin socket (JP6)
The largest of the sockets on the LED tester is the 4-pin
JP5. This socket will take the connector of the instrument
panel. If any of the LEDs don’t light when tested, then the
cable is probably broken.
The LED tester
There are three types of socket in four sizes. JP3, JP4,
JP5 and JP6 are LED sockets, in four dierent sizes; JP1 is
the socket for the battery box; and JP2 is the socket for
switches. Note that when you plug multiple connectors
into a socket, the voltage will be reduced, so when
testing the components, it’s best to test one at a time.
You will, however, always need to keep the battery box
plugged into the JP1 socket.
⑥
① ② ③
⑦
⑤ ④
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 50 Area you are working on Detail
The rear fender
Tools Prepare
Tweezers Adhesive backing (Stage 47)
Rear right reector stay (Stage 47)
Rear left reector stay (Stage 47)
Rear reector lens × 2 (Stage 47)
Horn (Stage 47)
Horn stay (Stage 47)
Rear fender (Stage 48)
Rear right indicator (Stage 48)
Rear left indicator (Stage 48)
Your parts
The tail of the Hayabusa tapers into
a point to improve the aerodynamics
of the bike. Even the fronts of the rear
indicators, which protrude from the
sides of the tail, are shaped to reduce
wind resistance.
Bracket B
Bracket E
Right front footrest
Fuel cock
4 × 7mm washer screws × 4
1.8 × 6mm self-tapping
screws × 2
Base frame 1
Take the adhesive backing from Stage 47
and peel back the covering over the discs.
Remove the backing from one of the discs.
1
2
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Insert the projection of the left reector
into the hole in the fender.
Push the two parts together to ensure that
the adhesive sticks properly.
Turn the two reectors over, and locate
the letters on their backs (circled) that
label them as left or right.
Place the adhesive disc in the centre of
the back of one of the rear reector lenses
(Stage 47). Then remove the backing from
the adhesive disc.
Push the reector into place.
Repeat Steps 2 to 5 to assemble the
second reector.
Take the rear fender (Stage 48), and
align the T-shaped projection of the left
reector with the corresponding hole in
the left-hand side of the rear fender.
Place the reector into the recessed circle
of one of the rear reector stays (from
Stage 47).
7
3
9
5
10
6
8
4
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Turn the indicator around so that the
raised projection lines up with the notch
in the hole.
17
Insert the connector into the hole on the
left side of the rear fender.
Pass the left indicator cable through the
hole in the rear fender.
Locate the raised projection (red circle) on
the rear left indicator (blue connector).
15
1614
Line up the right reector with the
T-shaped hole on the right-hand side of the
rear fender. Push the right reector into place. Locate the holes on either side of the rear fender (circled). The hole on the left-hand
side has a notch in it (red circle).
11 13
12
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Fit the indicator into place on the fender,
then push it from the outside while
pushing the rear fender from the inside, to
ensure that the two engage properly.
Push the projection into the hole in the
back of the horn.
Fit the indicator into place on the fender. Insert the right indicator connector
(yellow) through the hole in the right-
hand side of the fender.
Prepare the horn and horn stay (Stage 47).
Hold the stay, as shown, with the shorter
projection (red circle) closest to the horn.
Push the indicator from the outside while
pushing the rear fender from the inside, to
ensure that the two engage properly.
Pass the cable through the hole, and turn
the right indicator around to face the same
way as the one on the left.
22 24
18 20
23
19 21
Stage
complete!
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
TM
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