De Agostini MODEL SPACE SUZUKI GSX 1300R HAYABUSA User manual

Pack 03
HAYABUSA
SUZUKI GSX 1300R
TM

23
SUZUKI GSX 1300R HAYABUSA
CONTENTS
TM
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
24
27
30
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.
All rights reserved © 2014
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.

24
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.
1
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)

25
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.
2
6
4
8
3
7
5
9
Match the direction of the tread
on the tyre to that shown here
Note the position of
the caliper

26
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.
10
14
A B C
12
11 13
Stage complete!

27
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).
1
2
STAGE 09

28
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.
3
6 8
4
7
5
9
2 × 5mm
self-tapping
hex screw
2 × 5mm
hex screw

29
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.
10
14
12
11
15
13
This stage is now complete. Go over
the six screws, and tighten them a bit
more to reduce the looseness.
Stage complete!

30
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.
1
2
STAGE 10

31
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.
3
7
5
9
4
8
6
Stage complete!

32
SUZUKI GSX 1300R Hayabusa: Assembly Guide
TM