Deagostini Suzuki Hayabusa GSX 1300R User guide

Brand: Deagostini

Model: Suzuki Hayabusa GSX 1300R

Type: User guide

Pack 03

HAYABUSA

SUZUKI GSX 1300R

SUZUKI GSX 1300R HAYABUSA

CONTENTS

www.model-space.com

Stage 08: The right front brake, front wheel and forks

Stage 09: The front fender

Stage 10: The throttle body

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 08

The right front

brake, front

wheel and forks

Tools Prepare Useful tool

Cross wrench Front wheel assembly (Stage 4)

Forks (Stage 7)

Brake disc (Stage 7)

2.3 × 8mm hex cap screws × 2 (Stage 7)

Multi-purpose adhesive

Prepare the front wheel assembly from Stage 4 and the

brake disc from Stage 7. Place the brake disc on one side of

the front wheel, tting the projection on the disc into the

recess on the wheel, both circled in the inset.

Your parts The axle shaft, the point of rotation of

the front wheel, is held in place by the

axle nut. It was developed by Suzuki’s

motor sport division, and designed for

durability and reliability to support the

world’s fastest motorcycle.

Area you are working on Detail

Brake disc

Right front brake caliper

Front axle (front axle nut

already installed)

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Push the brake disc fully onto the wheel by

pressing rmly on its centre, as indicated

by the arrows. Then t the brake disc

received with this stage onto the other

side of the wheel. If the discs t loosely on

the wheel, you can apply a small amount

of adhesive to secure them.

Insert the end of the front axle into the

hole in the end of one of the forks.

Hold the wheel and forks in the

orientations shown above. Place the wheel

between the front forks (Stage 7).

Turn the assembly over so that you can

see the end of the axle. Place the axle nut

remove in Step 3 over the end of the axle.

Unscrew the axle nut from the front axle.

Push the front axle all the way through

the assembly. If it does not pass all the

way through, check that the holes are still

aligned. Re-align them if necessary.

Align the holes at the ends of the forks

with the hole through the centre of

the wheel.

Screw the axle nut onto the end of the axle

by hand.

Match the direction of the tread

on the tyre to that shown here

Note the position of

the caliper

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Turn the assembly over again, so that the

right side is facing up. Align the circled

holes of the right brake caliper with the

corresponding holes in the front fork.

Using the cross wrench, tighten the

second 2.3 × 8mm hex cap screw into the

hole. The brake caliper may still be a little

loose, but this is ne for the moment.

This stage is now complete. The front brake

discs, wheel, forks and right brake caliper

have all been assembled. Be sure to check

that the orientation of the tread pattern on

the tyre matches the one shown above.

Insert the head of a 2.3 ×

8mm hex cap screw into

the corresponding hole of

the cross wrench, and turn

to see if the wrench grips it

properly.

Apply a small amount of

instant adhesive to the tip

of a toothpick.

Spread a layer of adhesive

over the inside surface of

the hole in the wrench,

and leave to dry. Then try

Step A again to check that

the wrench now grips the

screw. If not, repeat Steps

B and C.

The hexagonal holes of the cross wrench can wear with use. If the wrench is not

gripping the hex cap screws, you can adjust it as shown below.

What to do if the holes in the cross wrench wear

Tighten the hex cap screw into the hole

with the cross wrench from Stage 7.

Insert one of the 2.3 × 8mm hex cap

screws received with Stage 7 into the

upper hole (arrow).

Insert a 2.3 × 8mm hex cap screw into the

lower hole.

A B C

11 13

Stage complete!

SUZUKI GSX 1300R Hayabusa: Assembly Guide

What to do if the holes in the cross wrench wear

The front fender

Tools Prepare

Hex wrench Front fork (Stage 8)

Your parts

Large enough to cover a third of the

front wheel, the front fender of the

Hayabusa became a major feature of

the design. The fenders were designed

to be aerodynamic while allowing good

manoeuvrability.

Area you are working on

Detail

Front fender

Hex wrench

2 × 5mm self-tapping

hex screws × 3 (1 spare)

2 × 5mm hex screws × 5

(1 spare)

Place the front fender between the forks,

as shown.

Match the circled holes with the

corresponding holes on the front

fender (arrowed).

STAGE 09

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Adjust the position of the fender to align

the holes.

Place another 2 × 5mm hex screw onto the

end of the hex wrench and insert it into

the hole below the rst one.

Place a 2 × 5mm self-tapping hex screw

onto the end of the wrench, and insert it

into the hole just behind the fork.

Hold a 2 × 5mm hex screw on the end of the hex wrench and insert into the

rst hole (arrowed). Please note that the 2 × 5mm hex screw is dierent to the

2 × 5mm self-tapping hex screw, which can be identied by the wider spaces

between the threads, as shown above right.

Tighten the second hex screw into place.

Again, leave it a little loose.

Tighten the 2 × 5mm hex screw into the

hole. Because there is a risk of damage if

the screw is over-tightened, leave it a

little loose.

Tighten the self-tapping hex screw into

the hole.

6 8

2 × 5mm

self-tapping

hex screw

2 × 5mm

hex screw

SUZUKI GSX 1300R Hayabusa: Assembly Guide

Turn the assembly over, and place a

2 × 5mm hex screw into the arrowed hole

shown in the photo above.

Insert the tip of the hex wrench into a 2

× 5mm self-tapping hex screw, and then

place the screw in the arrowed hole.

Insert a 2 × 5mm hex screw into the

second hole (arrowed) on the left side of

the fender.

Tighten the screw into place, leaving it

slightly loose.

Tighten the screw into the hole until

it holds.

Tighten the screw into the hole, as with

the previous screws.

This stage is now complete. Go over

the six screws, and tighten them a bit

more to reduce the looseness.

Stage complete!

SUZUKI GSX 1300R Hayabusa: Assembly Guide

The throttle body

Air cleaner connectors × 4

Throttle body A

Throttle body B

Throttle body C

Your parts

The throttle body is positioned just

below the air cleaner. It looks like

a carburettor at rst glance, but it

controls only the air intake.

Area you are working on Detail

Hold throttle body A as shown, and

identify the shorter section (arrowed).

The opening on the left of throttle body B

has a shorter internal step (arrowed) than

the other three openings.

STAGE 10

SUZUKI GSX 1300R Hayabusa: Assembly Guide

This stage is now complete. Store the

throttle body assembly in a plastic bag

with the stage number marked on it.

Combine throttle bodies A and B, aligning

the shorter section of A with the shorter

internal section of B.

Insert one of the air cleaner connectors

into throttle body A (arrowed).

Insert the three projections on throttle

body C into the three holes in body B.

Fit the other three connectors into the

remaining holes in throttle body A.

Push throttle body A down into throttle

body B.

Push the connector (arrowed) straight

down into the opening until it won't go

any further.

Push the three projections on throttle

body C fully into the three holes in body B.

Stage complete!

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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