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2002 Suzuki Gsx-r1300 Hayabusa Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: GSX-R1300 Hayabusa Year: 2002 👋 Introduction Market Position Segment: Hyperbike / Sport Touring Reputation: Renowned for its extreme speed, aerodynamic design, and muscular...
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Type: Motorcycle
Vendor:
Sku: 604336
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🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSX-R1300 Hayabusa
Year:
2002
👋 Introduction
Market Position
Segment:
Hyperbike / Sport Touring
Reputation:
Renowned for its extreme speed, aerodynamic design, and muscular performance.
Competitive Analysis
Key Rivals Era:
Kawasaki Ninja ZX-11/ZZ-R1100, Honda CBR1100XX Super Blackbird, Ducati 916/996.
Key Features
Aerodynamics:
Distinctive aerodynamic fairing designed for high-speed stability and rider comfort.
Performance Benchmark:
Set new benchmarks for top speed and acceleration upon its release.
Engine Design:
Powerful inline-four engine with a focus on torque and high-RPM power delivery.
📋 Manual Details
Coverage Areas
Systems Covered:
• Engine
• Fuel System
• Ignition System
• Cooling System
• Lubrication System
• Clutch
• Transmission
• Drivetrain
• Chassis
• Suspension (Front & Rear)
• Braking System (Front & Rear)
• Wheels & Tires
• Steering
• Electrical System (Wiring Diagrams, Components)
• Lighting
• Instrumentation
• Bodywork
• Frame
• Troubleshooting
• Maintenance Schedules
• Specifications
Page Count
Pages:
Estimated 500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, assembly, component inspection, tolerances, timing, and rebuild procedures for the 1299cc inline-four engine.
Fuel And Ignition:
Detailed coverage of the Suzuki Fuel Injection (SFI) system, sensors, ECU, ignition timing, spark plug specifications, and troubleshooting.
Drivetrain And Transmission:
Clutch operation, transmission gear inspection, shift mechanism, final drive, chain and sprocket maintenance, and fluid specifications.
Suspension And Steering:
Front fork disassembly, seal replacement, oil type and level, rear shock absorber adjustment and rebuild, steering head bearing inspection and adjustment.
Braking System:
Front and rear brake caliper service, master cylinder replacement, brake fluid type and bleeding procedures, rotor inspection and replacement.
Electrical System:
Comprehensive wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, battery), lighting circuits, and instrument cluster diagnostics.
Procedures Included
Preventative Maintenance:
Oil and filter change intervals, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, coolant checks.
Troubleshooting Guides:
Systematic troubleshooting steps for common performance issues, electrical faults, starting problems, and braking system malfunctions, often organized by symptom.
Repair Procedures:
Step-by-step instructions for engine component replacement, fuel system servicing, clutch and transmission overhauls, suspension rebuilds, and electrical component diagnosis.
Diagnostic Codes:
Information on reading and interpreting diagnostic trouble codes (DTCs) if applicable to the 2002 model's EFI system.
Technical Depth
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
16-valve, DOHC, Inline-4, 4-stroke
Displacement:
1299 cc (79.3 cu in)
Bore X Stroke:
81.0 mm x 63.0 mm
Compression Ratio:
11.0:1
Cooling System:
Liquid-cooled
Performance
Horsepower Claimed Crank:
Approx. 175 PS (173 hp; 129 kW) @ 9800 rpm (rated at crank)
Torque Claimed Crank:
Approx. 138 Nm (14.1 kgf⋅m; 102 lb⋅ft) @ 7000 rpm (rated at crank)
Fuel System
Fuel Delivery:
Suzuki Fuel Injection (SFI) with Twin Fuel Injectors per Cylinder
Fuel Type:
Unleaded gasoline, 95 RON (91 AKI) or higher recommended.
Ignition System
Ignition:
Digital Electronic Ignition
Lubrication System
Oil Type Specification:
SAE 10W-40 API SG, SH, SJ or JASO MA recommended.
Oil Capacity
Oil Capacity W Filter:
Approx. 3.4 L (3.6 US qt; 3.0 Imp qt)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
Gear Ratios:
Refer to manual for specific gear ratios.
Features
Clutch Type:
Wet, multi-plate, back-torque limiter clutch
Final Drive:
RK525XSO, 118 links chain, 17T front sprocket, 45T rear sprocket
📐 Dimensions
Exterior
Length:
2,140 mm (84.3 in)
Width:
740 mm (29.1 in)
Height:
1,155 mm (45.5 in)
Wheelbase:
1,485 mm (58.5 in)
Ground Clearance:
130 mm (5.1 in)
Weights
Dry Weight:
215 kg (474 lbs)
Wet Weight:
Approx. 250 kg (551 lbs) (with all fluids)
Fuel Tank Capacity:
21 L (5.5 US gal; 4.6 Imp gal)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not Applicable (Motorcycle)
Active Features
Braking System:
Dual 320mm discs with 6-piston calipers (front), Single 240mm disc with 2-piston caliper (rear).
Suspension Features:
Fully adjustable front forks and rear shock absorber for optimized handling and stability.
Passive Features
Lighting:
Integrated front and rear lighting system, including brake lights and turn signals.
Frame Construction:
Lightweight and rigid twin-spar aluminum frame for high-speed stability.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on performance, not infotainment)
Driver Assistance
Assistance Features:
Back-torque limiting clutch for smoother downshifts and reduced rear-wheel hop.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or 6 months.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ or JASO MA
Coolant Type:
Suzuki Super Long Life Coolant or equivalent ethylene glycol-based antifreeze/coolant.
Brake Fluid Type:
DOT 4
Fork Oil Type:
Show (Showa) SS-07 or equivalent SAE 7.5 fork oil (check manual for exact specification and quantity).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, head bearings due to high performance.
Efi System Notes:
While generally reliable, proper maintenance of sensors and fuel system components is crucial for optimal performance.
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki has a long history of producing high-performance motorcycles, particularly in the sportbike category.
Model Evolution
Introduction Year:
1999
Generation 1 Period:
1999-2007
Model Significance:
The Hayabusa quickly became the fastest production motorcycle in the world, leading to the 'Gentleman's Agreement' among manufacturers to limit top speeds.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Top Speed Record:
Recognized as the fastest production motorcycle at its launch.
Design Awards:
Acclaimed for its groundbreaking aerodynamic design.
Ratings
Performance Magazine Reviews:
Consistently rated highly by motorcycle publications for its power, handling, and speed.