Deagostini Suzuki Hayabusa GSX 1300R User guide

Brand: Deagostini

Model: Suzuki Hayabusa GSX 1300R

Category: Motorcycle Accessories

Type: User guide

Pack 09

HAYABUSA

SUZUKI GSX 1300R

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SUZUKI GSX 1300R HAYABUSA

CONTENTS

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Stage 28: The left crankcase cover and drive sprocket

Stage 29: The drive chain

Stage 30: The right crankcase half

Page

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.

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.

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.

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

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

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!

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.

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

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.

2.3 × 5mm

screw

2.3 × 6mm

(silver) screw

2.0 × 5mm

countersunk

screw

2.6 × 14mm

self-tapping screw

2.0 × 5mm

self-tapping hex

screw

2.0 × 5mm

hex screw

2.3 × 4mm

self-tapping screw

2.3 × 8mm

hex cap screw

2.3 × 6mm

(silver) self-

tapping screw

2.3 × 5mm

self-tapping screw

with washer

2.0 × 11mm

lag screw

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!

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 ecient.

Check the dierent 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

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.

Stage

complete!

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Deagostini Suzuki Hayabusa GSX 1300R User guide

Brand: Deagostini

Model: Suzuki Hayabusa GSX 1300R

Category: Motorcycle Accessories

Type: User guide

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Deagostini Suzuki Hayabusa GSX 1300R User guide

Deagostini Suzuki Hayabusa GSX 1300R User guide

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