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Pack 13
HAYABUSA
SUZUKI GSX 1300R
TM
www.model-space.com
133
SUZUKI GSX 1300R HAYABUSA
CONTENTS
Stage 41: The tail light
Stage 42: The starter motor
Stage 43: The seat rail
Stage 44: Rear subframe parts
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
Warning: 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. Items may vary from those shown.
Page
134
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 41 Area you are working on Detail
The tail light
Tail light
LED assembly
2 × 6mm self-tapping
screws × 8
Tools Prepare
Phillips screwdriver Rear subframe (Stage 39)
Pen
Adhesive
Toothpick
Your parts
The tail light of the Hayabusa was
designed so that it integrated
almost seamlessly with the rear
cowl. As well as being aesthetically
pleasing, it added to the aerodynamic
characteristics of the bike by
suppressing the turbulence generated
at the tail, which would prevent a loss
of traction on the rear wheel.
Lay out the tail light LED assembly, as shown, and identify the annotated parts. Be careful
when handling all parts of the assembly, as they are fragile; the cables are easily bent,
especially at the soldered joints, and the lens could break if too much force is applied to it.
1
Lens
LED (light-emitting
diode)
Soldered joints Cable (positive)
Cable (negative)
Heat-shrinkable tube
135
SUZUKI GSX 1300R Hayabusa: Assembly Guide
If the 2 × 6mm screws feel loose, you
may want to add a little glue to the
holes in the tail light before you screw
them into place.
Hold the tail light in one hand and the LED
in the other. Make sure to hold the LED by
the lens and avoid touching the soldered
cable joints (circled).
Hold the tail light in position and place a
2 × 6mm self-tapping screw in one of the
holes in the rear subframe.
This stage is now
complete. Place all parts into bags
for safe storage, and write the number of
the stage on them, along with the size of
the screws.
Pass the LED cables through the hole at the
back of the rear subframe from Stage 39.
Push the LED lens into the circular hole in
the centre of the tail light.
Insert the two projections on the tail light
into the two recesses in the rear subframe.
Tighten the 2 × 6mm self-tapping screw
into place. Tighten a second 2 × 6mm
self-tapping screw into place in the
second hole.
2
6
4
53
7
Stage
complete!
Tip
136
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 42 Area you are working on Detail
The starter
motor
Tools Prepare
Phillips screwdriver
Craft knife
File
Crankcase bottom (Stage 31)
2.3 × 6mm (silver) self-tapping
screws × 2 (Stage 26)
Pen
Your parts
To make the Hayabusa engine more
compact, all parts were downsized and
placed closer together. This resulted in
an engine smaller than others in
its class, while retaining a high
level of eciency.
Clutch cover
Water pump
Oil lter
Starter motor
Cylinder inlet connector
Breather cover
Engine sprocket cover
2.3 × 6mm (silver)
screws × 14
2.3 × 6mm (silver) self-
tapping screws × 4
Take the crankcase assembly and
remove any masking tape holding
the two halves together. Remove the starter cover from the right
crankcase half.
1
2
137
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Place the starter cover, with the starter
motor attached, back into place on the
right crankcase.
Take the starter motor and starter cover.
Locate the rectangular projection on
the motor and the corresponding hole
in the starter cover.
Hold the starter cover onto the crankcase
half, and turn the parts over so that the
inside of the crankcase is visible. Take a 2.3
× 6mm (silver) self-tapping screw (Stage
26) and place it into the hole circled above.
Push the projections on the starter cover
back into the holes in the crankcase.
Push the projection on the starter motor
into the hole in the starter cover.
Tighten the screw into place.
3
5 7
68
4
If the projection on the starter motor doesn’t t into the hole in the cover, there may be
some ash left on it. Try trimming it o with a craft knife and then smoothing with a le.
Tip
138
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Hold the breather cover in place and turn the
crankcase over. Place a 2.3 × 6mm (silver) tapping
screw into the hole indicated above.
Place the breather cover over the recessed area on
top of the right crankcase half.
Tighten the 2.3 × 6mm screw into the
hole, securing the breather cover to
the crankcase.
Push the breather cover down into the recessed
area, inserting the projections on it into the holes in
the crankcase.
9
11
12
10
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
Locate the hole in the bottom of the oil lter
and the matching projection at the front of
the crankcase.
Push the oil lter onto the projection.
13 14
This stage is now complete. The two halves of the crankcase will be
screwed together in Stage 45, so leave them separate for the moment.
Store any unused parts in a bag labelled with the stage number.
Stage
complete!
140
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 43 Area you are working on Detail
The seat rail
Seat rail
Rear reservoir tank
Tools Prepare
Phillips screwdriver
Cross wrench
Swingarm (Stage 37)
Pen
Glue
Your parts
The seat rail is a frame made of
aluminium alloy pipes, connecting the
main frame with the rear subframe.
Though the pipes appear very thin at
rst glance, the way they are assembled
and placed around the rear subframe
increase the strength and rigidity, while
the weight keeps the inuence on the
centre of gravity minimal.
Check the screws in the black part at the
rear of the seat rail. If they have loosened,
then tighten them up again.
Take the rear reservoir and locate the
hole in the side of it. Then locate the
corresponding projection on the inside of
the seat rail.
1
2
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
This stage is now complete. If the reservoir is a loose t, it
may fall o at this point, but when the rail is tted to the
subframe at a later stage, it will then be secure. You can
use a drop of glue to secure it now if you want to keep it
safely in place.
The rear reservoir should look like this when you have
tted it to the rail.
Push the rear reservoir onto the projection on the rail.
43
Stage
complete!
142
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 44 Area you are working on Detail
Rear subframe
parts
Tools Prepare
Phillips screwdriver Battery box (Stage 40)
Rear subframe (Stage 41)
Seat rail (Stage 43)
2.3 × 6mm (silver) self-tapping screws × 2 (Stage 39)
2 × 6mm self-tapping screws × 2 (Stage 41)
Tape
Your parts
The left side guard, tted to the side of
the seat rail, creates a space between
the cowl and the frame in the area
where parts such as the rectier are
positioned. This not only protects
the parts in the event of a crash, but
also protects the cowl from the heat
generated by the parts.
Control unit cover
Tool bag
Rear subframe front
Left side guard
Look at the battery box
supplied with Stage 40.
You will see that a wire is
soldered at each end of
the battery box. It is best
to tape the wires to the
box, to reduce the chance
of them coming loose.
1
Tape the wires down
143
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Tighten a 2.3 × 6mm screw into the left-
hand hole in the battery box, then fully
tighten the other screw, securing the box
in place.
Tighten the 2.3 × 6mm screw into the hole,
just enough to hold the box in place.
Loosen the screws holding the battery box
lid in place, and then remove it.
Check that the holes on the left-hand side
are still aligned. If necessary, adjust the
position of the battery box to line them
up correctly.
5 7
86
Take the rear subframe assembled in Stage 41, and pass
the wire from the tail light and the battery box through the
hole in the centre, as shown. Place the battery box directly above the rear subframe,
and align the holes at the side of the box with those in
the subframe.
Place a 2.3 × 6mm (silver) self-tapping screw (Stage 39) into
the right-hand hole, as shown.
2
3
4
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
The two square projections at the front
end of the control unit cover should sit in
the cutout like this (circled).
15
9
10
Take the tool bag and t the two holes in its underside over
the two projections on the battery box lid. The holes and
projections are dierent sizes, so the tool bag will only t if
it is the right way round. Push the tool bag down onto the lid.
Screw the battery box lid back into place.
11
Align the projections with the holes and
push the subframe front into place.
Place the two square projections at the
front end of the control unit cover into the
two cutout sections at the front
of the subframe.
Take the rear subframe front, and identify
the projections on the top side: one is
thick and the other is thin. Then match
them up with the corresponding holes in
the underside of the rear subframe.
13
1412
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
This stage is now complete. Store the rear subframe in a
bag to protect the cables.
Tighten the screw into place, but don't
overtighten it as it may damage the rail.
Tighten the second 2 × 6mm self-tapping
screw into the hole in the seat rail that is
aligned with the end of the side guard.
19
20
Align the projections at the ends of the left side guard with
the corresponding holes in the seat rail, as shown.
Push the left side guard into the holes in the seat rail.
Place a 2 × 6mm self-tapping screw into the hole in the
seat rail.
16
17
18
Stage
complete!
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SUZUKI GSX 1300R Hayabusa: Assembly Guide
TM
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