Deagostini Suzuki Hayabusa GSX 1300R User guide

Brand: Deagostini

Model: Suzuki Hayabusa GSX 1300R

Type: User guide

162

Pack 15

HAYABUSA

SUZUKI GSX 1300R

www.model-space.com

SUZUKI GSX 1300R HAYABUSA

CONTENTS

Assembly Guide

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.

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

164

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.

Wide Narrow

165

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

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

166

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 dierent,

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

When the green connector is plugged into

socket JP3 on the LED tester board, the

tail light should come on.

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.

168

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

Ret 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 ret 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.

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.

170

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).

Place a 2.3 × 5mm screw with washer into

the hole in the footrest.

Tighten the screw into the hole to secure

the brake pedal.

171

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.

Test that the footrest moves freely up and down (arrowed).

Push the two parts together.

172

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.

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.

Stage

complete!

173

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 conrmation (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 dierent 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

174

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 reector stay (Stage 47)

Rear left reector stay (Stage 47)

Rear reector 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.

175

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Insert the projection of the left reector

into the hole in the fender.

Push the two parts together to ensure that

the adhesive sticks properly.

Turn the two reectors 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 reector lenses

(Stage 47). Then remove the backing from

the adhesive disc.

Push the reector into place.

Repeat Steps 2 to 5 to assemble the

second reector.

Take the rear fender (Stage 48), and

align the T-shaped projection of the left

reector with the corresponding hole in

the left-hand side of the rear fender.

Place the reector into the recessed circle

of one of the rear reector stays (from

Stage 47).

176

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Turn the indicator around so that the

raised projection lines up with the notch

in the hole.

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).

1614

Line up the right reector with the

T-shaped hole on the right-hand side of the

rear fender. Push the right reector 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

177

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

19 21

Stage

complete!

178

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Deagostini Suzuki Hayabusa GSX 1300R User guide

Deagostini Suzuki Hayabusa GSX 1300R User guide

Deagostini Suzuki Hayabusa GSX 1300R User guide

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