Pack 09
HAYABUSA
SUZUKI GSX 1300R
TM
www.model-space.com
91
SUZUKI GSX 1300R HAYABUSA
CONTENTS
TM
www.model-space.com
Stage 28: The left crankcase cover and drive sprocket
Stage 29: The drive chain
Stage 30: The right crankcase half
Page
92
94
96
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.
92
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 28
The left crankcase
cover and drive
sprocket
Area you are working on Detail
Place one of the unused 2.3 × 6mm screws
from Stage 21 into the hole in the centre of
the left crankcase cover. Use the 2.3 × 6mm screw to tap the hole in
the centre of the cover.
1
2
Left crankcase cover
Drive sprocket
Washers × 2
Gear cover × 1
Tools Prepare
Phillips screwdriver Left crankcase (Stage 27)
2.3 × 6mm (silver) screws × 3 (Stage 21)
Plastic bag
Pen
2.3mm tap
Cross wrench/tap holder
The left crankcase cover – the circular
black part shown above – houses the
alternator (generator) unit and clutch.
The part for the model is recreated in
metal and painted black, just as on the
real motorcycle.
Your parts
93
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Align the projections of the left crankcase
cover with the holes in the left half of the
crankcase, indicated by the arrows.
Turn the crankcase over while holding the
cover in place. Next, place the 2.3 × 6mm
screw that was used to tap the hole in Step
1 into the hole, and tighten it.
Place one of the washers over the hole and
insert a 2.3 × 6mm screw into it.
Place a washer over the second hole of the
drive sprocket, and tighten another 2.3 ×
6mm screw through them.
Push the projections into the holes. Place the drive sprocket between the two
raised ridges on the left crankcase, in the
area shown above.
3 5
7 9
4
8
6
Tighten the screw into place, but just
enough to hold it in position, as you will
need to adjust it later.
This stage is now complete. The crankcase
cover is in place, and the drive sprocket has
been tted in preparation for adjustment
later on. Keep the gear cover stored until it
is needed.
Align the holes
Stage
complete!
94
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 29
The drive chain Area you are working on Detail
Lay the chain on your work surface to check
that it lies at. Look between each of the
links to locate any leftover materials from
the assembly process. Place the chain into a plastic bag (the one
that it was supplied in is ne), and spray
lubricating oil into the bag and onto the
chain. We recommended that you use WD-
40 for this process. This will help prevent rust
and help the chain to move smoothly.
1
2
Drive chain
Prepare
Rear sprocket (Stage 24)
Left crankcase (Stage 28)
Cloth or old towel
Lubricating oil spray
Plastic bag
The drive chain transfers the enormous
power from the 1,300cc engine to the
rear wheel. Suzuki had to make sure
that the drive chain could handle the
power, speed and high performance
expected from the Hayabusa. It was
made more wear-resistant by being
covered with a protective coating that
improved its reliability and durability.
Your parts
95
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Using a cloth or an old towel, lightly wipe
away the excess oil from the chain.
Lightly pull the rear sprocket (blue arrow),
while holding the left crankcase assembly
to tension the chain. Check that both
sprockets turn freely, and the chain with
them (red arrows).
Fit the chain around the rear sprocket (Stage
24), then put the other end of the chain
around the drive sprocket on the crankcase.
Make sure the links are positioned properly
over the teeth of the sprockets.
3 54
This stage is now complete. Place the chain
back into the plastic bag and store for later
use, and t the rear sprocket back onto the
rear wheel.
Screw list This table will help you to check the screws provided so far. They are listed by type and size, along with the stage
numbers they were supplied with, how many were provided and how many were used.
A
2.3 × 5mm
screw
B
2.3 × 6mm
(silver) screw
C
2.0 × 5mm
countersunk
screw
D
2.6 × 14mm
self-tapping screw
E
2.0 × 5mm
self-tapping hex
screw
F
2.0 × 5mm
hex screw
H
2.3 × 4mm
self-tapping screw
I
2.3 × 8mm
hex cap screw
J
2.3 × 6mm
(silver) self-
tapping screw
V
2.3 × 5mm
self-tapping screw
with washer
W
2.0 × 11mm
lag screw
X
2.6 × 6mm
screw
Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used Supplied Used
Stage 1 3 2
Stage 2 3 2
Stage 3 3 2
Stage 5 2 1 2
Stage 6 2 1 2 2
Stage 7 5 2
Stage 8 2
Stage 9 3 2 5 4
Stage 11 6 1
Stage 12 1
Stage 13 1 3 3
Stage 15 1
Stage 17 3
Stage 18 2 1 3 2
Stage 21 12 2 1
Stage 26 11 4
Stage 28 3
Remaining 3 11 2 2 1 1 3 1 13 1 1 1
Stage
complete!
96
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 30
The right
crankcase half
Area you are working on Detail
Right crankcase half
2.3 × 8mm (silver) screws × 5
Tools Prepare
Phillips screwdriver 2.3 × 6mm (silver) screw (spare)
Left crankcase half (Stage 28)
Masking tape
2.3mm tap
Cross wrench/tap holder
File
The left side of the crankcase houses
parts such as the alternator and the
transmission, whereas the right side of
it houses parts including the clutch and
the starter. They were tightly packed
together, which made the engine
smaller and more ecient.
Check the dierent aspects of the right
half of the crankcase, shown above and
right, to locate the circled screw holes. We
recommend that you tap these holes with a
2.3 × 6mm screw or tap.
1Outside
Bottom surface
Inside
Your parts
97
SUZUKI GSX 1300R Hayabusa: Assembly Guide
This stage is now complete, and the left and right halves
of the crankcase have been temporarily assembled. Store
the unused screws to one side in a labelled bag until they
are needed.
After tapping the holes, clean away any swarf created by
the process.
If there is a gap between the two halves, separate them and
check for any burrs that might be causing it, such as the
one circled above. Use a le to remove any you nd.
Push the two halves of the crankcase together. There
should be a visible join between them, but not a gap.
Align the indicated projections and holes on the left
crankcase half from Stage 28 with those on the right
crankcase half.
Place the two halves of the crankcase together again. If
they now t properly, use some masking tape to hold
them together.
2
5
4
3
6
Stage
complete!
98
SUZUKI GSX 1300R Hayabusa: Assembly Guide
TM
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