145
Pack 19
HAYABUSA
SUZUKI GSX 1300R
TM
www.model-space.com
SUZUKI GSX 1300R HAYABUSA
CONTENTS
Stage 61: Fitting the radiator
Stage 62: Combining the frame assemblies
Stage 63: The instrument panel LED board
Stage 64: The left front footrest
Page
236
240
249
253
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.
236
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 61 Area you are working on Detail
Fitting the
radiator
Tools Prepare
Phillips screwdriver
Tweezers
Cutters
Multi-purpose adhesive
Toothpick
Front fork assembly (Stage 54)
Radiator and oil cooler (Stage 34)
Breather hose (Stage 34)
Radiator inlet hose connector (Stage 51)
Left frame half (Stage 54)
Engine block (Stage 59)
2.3 × 6mm (silver) screw × 1 (Stage 37)
Plastic bag
Pen
Your parts
The pipes and hoses coming from the
radiator and oil cooler double up as
stays, holding in place the parts that
would otherwise only be secured to the
frame at the top of the radiator.
Side panel LH
Water bypass hose
Nut
Steering stem
Prepare the radiator (Stage 34) and the
radiator inlet hose connector (Stage 51).
Insert the connector into the hole in the
back of the radiator.
1
2
237
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Take the engine block (Stage 59), and
locate the ends of the hoses and pipes
on it (circled on the left). Then look for
the corresponding holes in the radiator
and the oil cooler (Stage 34).
First, place the two indicated hose ends
into the holes in the radiator.
Now t the remaining hoses and pipes into
the three holes indicated above.
Push the two hose ends into place. This
should now hold the radiator in position.
Place the radiator on the front of the engine,
aligning its holes with the corresponding
hoses and pipes on the block.
3
5 7
6
4
If any of the ends of the pipes or hoses
are loose, apply multi-purpose adhesive
to the joins to secure them.
Tip
238
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Place one of the ends of the breather hose (Stage 34)
above the pin projecting from the breather cover, towards
the rear of the engine.
Then take the hose extending from the radiator cap and
hold it next to the radiator inlet hose to check how much
excess there is.
Bend the breather hose over and place the other end onto
the pin on the oil return tank.
Push the hose onto the pin projecting from the radiator
inlet hose.
Push the end of the hose onto the pin.
Cut o the excess hose.
8
11
10
13
9
12
Excess hose
239
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Remove the steering damper case from the front fork
assembly (Stage 54).
Tighten the screw into the hole in the frame half, as shown.
Insert the end of the screw into the hole indicated at the
front of the left frame half.
Insert a 2.3 × 6mm (silver) screw (Stage 37) into the
indicated hole in the case.
This stage is now complete. Store the
assembled and unused parts in bags labelled
with the stage number.
14
17
16
15
Stage
complete!
240
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 62 Area you are working on
Combining the
frame assemblies
Tools Prepare
Phillips screwdrivers (sizes 1 and 2)
Needle-nose pliers
Paddock stand (Stage 38)
Frame bridge B (Stage 39)
Frame bridge D (Stage 39)
Pivot shaft (Stage 48)
Pivot shaft nut (Stage 48)
3 × 68mm shaft (Stage 48)
Swingarm (Stage 60)
Right frame half (Stage 60)
Engine block (Stage 61)
Left frame half (Stage 61)
2.3 × 6mm (silver) self-tapping screws × 2 (Stage 39)
2.3 × 10mm self-tapping screw (Stage 36)
2.3 × 12mm screws × 2 (Stage 36)
2.3 × 6mm (silver) screws × 5 (Stage 42)
Thick sheet of sponge (see Step 4)
Assembly Guides of Stages 36, 37 and 60
Your parts
Upper panel
Left intake joint
Right intake joint
Upper panel decal
Left air intake pipe A
Left air intake pipe B
Insert the left intake joint into the
hole in the left frame half (Stage 61),
with the 'L' at the bottom. Insert the right intake joint into the
corresponding hole in the right frame half
(Stage 60), with the identifying letter at the
bottom.
Identify the left and right intake joints by
the 'L' and 'R' stamped on them (insets).
3
2
1
Position identifying
letter at the bottom.
Position identifying
letter at the bottom.
Left Right
241
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Place the engine block and the swingarm
onto a thick, suitably sized sheet of sponge
or similar cushioning material, arranged as
shown in the photograph.
Insert a 2.3 × 12mm screw (Stage 36) into
the screw hole shown.
Take the right frame half and hold it above
the rest of the assembly, aligning the
recessed area (inset) with the matching
shape at the end of frame bridge C (circled).
Insert a 2.3 × 6mm (silver) screw (Stage 39)
into the hole indicated above.
Position frame bridge C on either side of
the cylindrical projection at the bottom
of the engine block, aligning the holes as
shown. Position the oil pan cable in the
gap, as shown in the inset.
Tighten the screw into place. Tighten the screw into the hole.
Slowly lower the frame half onto the rest
of the assembly, placing the recessed area
onto the end of frame bridge C.
4
8
6
10
5
911
7
Position the cable
in the gap
Align the
holes
242
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Hold all the parts together and turn the
assembly over.
Take the drive chain and pull it forward
over the drive sprocket.
Pass the 3 × 68mm shaft right through
the engine and into the right frame
half (circled).
Take frame bridge D (Stage 39) and place
it between the two holes (circled) in the
projections at the top of the radiator. At
the same time, t it into the corresponding
area of the right frame half.
Insert the 3 × 68mm shaft (Stage 48) into
the circled hole in the engine block.
Turn the drive sprocket slowly to engage
the chain with the teeth. If the chain is too
tight, loosen the two circled screws.
Lower the left frame half onto the
assembly. Try to place it into roughly the
correct position.
Place main frame bridge B (Stage 39)
into the corresponding hole in the right
frame half.
12
16
14
18
13
17 19
15
243
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Place the corresponding parts of the frame half onto
the ends of frame bridge A, frame bridge B and the 3 ×
68mm shaft.
Insert a 2.3 × 12mm screw (Stage 36) into the indicated
hole at the bottom of the left frame half.
Position the left frame half onto frame bridges C and
D, and then gently push the two halves of the frame
together to engage them fully.
Tighten the screw into the hole.
20
22
21
23
Frame bridge C Frame bridge D
244
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Insert a 2.3 × 6mm (silver) screw (Stage 42) into the hole
towards the front of the left frame half.
Insert the pivot shaft (Stage 48) into the indicated hole in
the left frame half. Adjust the position of the swingarm so
that the shaft can pass through it.
Tighten the screw into the frame half.
Continue to push the shaft through the swingarm until
it protrudes from the right frame half. If necessary, use a
screwdriver to help you push it through.
24
26
25
27
245
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Align the holes of the left frame half and seat rail (see
Stage 60 for reference) and place a 2.3 × 6mm (silver)
screw (Stage 42) into the indicated hole.
Tighten another 2.3 × 6mm (silver) screw into the hole
above the rst, as shown.
Tighten the screw into the hole.
Insert a 2.3 × 6mm (silver) screw (Stage 42) into the hole
at the front of the left frame half.
28
30
29
31
246
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Tighten the screw into place.
Tighten the screw into the hole.
Insert a 2.3 × 6mm (silver) self-tapping screw (Stage 39)
into the hole in the top of the radiator that is aligned
with the hole in frame bridge D (Step 18).
Turn the assembly over, and place the pivot shaft nut
(Stage 48) onto the end of the pivot shaft (Steps 26 and
27).
32
34
33
35
247
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Turn the pivot shaft into the nut, using a screwdriver.
Tighten the screw into the aligned holes of the radiator
and frame bridge D.
Place a 2.3 × 6mm (silver) self-tapping screw (Stage 39)
into the hole at the top right of the radiator.
Pass a 2.3 × 10mm self-tapping screw (Stage 36) through
frame bridge B and the shock absorber lever, as shown.
36
38
37
39
248
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Pass a screwdriver through the hole shown in the
photo, and tighten the 2.3 × 10mm self-tapping screw
into the hole.
Lift the rear of assembly onto the paddock stand
(Stage 38).
Continue to tighten the screw until its tip protrudes from
the left side of frame bridge B.
This stage is now complete. Take extra
care when storing the assembly from now
on, and keep the unused parts near to
hand because you will be using them in
the next stage.
40
42
41
Stage
complete!
249
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 63 Area you are working on
The instrument
panel LED board
Tools Prepare
Phillips screwdriver
Cutters
Instrument panel (Stage 13)
Instrument panel case (Stage 13)
Sprocket cover (Stage 42)
Main assembly (Stage 62)
Left air intake pipe A (Stage 62)
Left air intake pipe B (Stage 62)
2.3 × 4mm self-tapping screws × 2 (Stage 13)
2.3 × 6mm (silver) screw (Stage 42)
Plastic bag
Pen
Your parts
Right air intake pipe B
Right air intake pipe A
Cowling brace
LED board
2.3 × 5mm self-tapping
screws × 3
2.3 × 6mm (silver)
screws × 4
Insert the thinner posts of left air intake
pipe B into the wider posts of left air
intake pipe A. Push left air intake pipes A and B together.
Take left air intake pipes A and B (Stage 62)
and align the indicated posts.
3
2
1
A
B
250
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Follow Steps 1-3 to combine the two
halves of the right air intake pipe.
Fit the LED board cables into the cutout of
the case (inset).
Take the LED board, and align the three
circled holes with the three circled posts on
the instrument panel case. Avoid touching
the circuitry of the LED board if possible.
Lightly push the pins of the case into the
holes in the instrument panel.
Prepare the instrument panel and the
instrument panel case, and two 2.3 × 4mm
self-tapping screws (all from Stage 13).
Insert the four pins on the case into the
four corresponding holes in the back of the
instrument panel.
Take the end of the LED board cables and
pass it through the central opening in the
cowling brace.
Push the holes onto the posts, as shown.
4
8
6
10
5
911
7
Curved side
251
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Align the three posts on the rear of the
case with the three holes in the front of the
cowling brace.
Tighten another 2.3 × 4mm self-tapping screw into the
other hole in the cowling brace.
Insert a 2.3 × 4mm self-tapping screw into
the indicated hole in the rear of the brace.
Locate the two circled holes in the left side of the engine
block. The pins of the sprocket cover will be inserted into
these holes.
Push the instrument panel into place.
Locate the two pins on the inside of the sprocket cover
(Stage 42).
Tighten the screw into the hole.
12
16
14
18
13
17
15
252
SUZUKI GSX 1300R Hayabusa: Assembly Guide
Insert the upper pin of the sprocket cover
into the upper hole in the crankcase.
Tighten the screw into place.
Insert a 2.3 × 6mm (silver) screw (Stage 42)
into the hole in the sprocket cover.
This stage is now complete. Store the
air intakes until they are needed at a
later stage. The instrument panel will be
used in the next stage.
22 24
23
Line up the pins on the sprocket cover with the holes in
the engine block.
Push the lower pin of the sprocket cover into the lower
hole, then rotate the top of the cover to the rear so that it
ts into the frame.
Tilt the sprocket cover forwards, and insert the bottom of it
between the gearshift shaft and the crankcase. The upper
section (circled in red) may not t into the frame. If that is
the case, carefully trim it down with cutters.
19 21
20 Trim this section if it
hits the frame.
Plugged into the inside
of the gearshift shaft.
Stage
complete!
253
SUZUKI GSX 1300R Hayabusa: Assembly Guide
STAGE 64 Area you are working on
The left front
footrest
Tools Prepare
Phillips screwdriver
Allen key
Sidecutters
Tweezers
Multi-purpose adhesive
Toothpick
Gear cover (Stage 28)
LED tester board (Stage 47)
Left front footrest (Stage 59)
Water bypass hose (Stage 61)
Main frame (Stage 63)
Instrument panel (Stage 63)
2 × 5mm hex screws × 2 (Stage 49)
1.8 × 6mm self-tapping screw (Stage 50)
AAA batteries × 3
Your parts
Front cowl
Front indicators
Insert the battery box connector (black)
into the black socket on the LED tester
board (Stage 47). Insert the white instrument panel
connector (6-pin) into the corresponding
socket on the tester board.
Insert three AAA batteries into the
battery box.
3
2
1
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