Deagostini Suzuki Hayabusa GSX 1300R User guide

Brand: Deagostini

Model: Suzuki Hayabusa GSX 1300R

Type: User guide

145

Pack 19

HAYABUSA

SUZUKI GSX 1300R

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

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.

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.

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.

5 7

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.

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.

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).

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.

911

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.

17 19

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.

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.

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.

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).

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.

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.

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.

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.

911

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.

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

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.

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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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