Market Segment:
Sportbike, Middleweight Performance
Target Audience:
Enthusiasts, DIY mechanics, professional technicians working on Suzuki sportbikes of the early 90s
Competitors:
Honda CBR600F, Yamaha FZR600, Kawasaki Ninja ZX-6
Manual Value Proposition:
Provides factory-accurate information for comprehensive repair and maintenance, enabling cost savings and extended vehicle lifespan
User Friendliness:
Designed for both novice and experienced users with clear instructions and detailed visuals
Digital Convenience:
Instant access, portability across devices, no physical storage required
Engine:
Complete engine overhaul, disassembly, assembly, tuning, diagnostics
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank inspection and cleaning
Lubrication System:
Oil pump, oil passages, oil filter replacement, oil change procedures
Cooling System:
Radiator, hoses, water pump, thermostat, fan operation, coolant specifications
Ignition System:
Spark plugs, ignition coils, CDI unit, timing specifications
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator), lighting, starter motor, switches, fuses
Chassis:
Frame inspection, suspension (front fork, rear shock), steering system, wheel bearings
Brake System:
Front and rear brake caliper service, master cylinders, brake lines, brake pad replacement, brake fluid specifications
Clutch System:
Clutch lever, cable adjustment, clutch plate inspection and replacement
Exhaust System:
Exhaust pipe and muffler inspection and maintenance
Bodywork:
Fairing removal and installation, seat, tank, and fender components
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake adjustments
Troubleshooting:
Diagnostic procedures for common problems, fault finding guides
Repair:
Step-by-step repair instructions for all major components
Rebuild:
Engine and carburetor rebuild procedures
Restoration:
Guidance for refurbishment and restoration projects
Disassembly Assembly:
Detailed instructions for taking apart and reassembling components
Technical Depth:
Comprehensive, Factory-level detail for DIY and professional mechanics
Illustrations:
Detailed diagrams, exploded views, and illustrations
Wiring Schematics:
Complete electrical system wiring diagrams
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Engine Type:
Inline Four-Cylinder, DOHC, 16-valve
Displacement:
599 cc (36.6 cu. in.)
Bore X Stroke:
65.0 mm x 45.2 mm (2.56 in x 1.78 in)
Compression Ratio:
11.3:1
Cooling System:
Liquid-cooled
Horsepower Claimed:
Approx. 85-90 HP at 11,000 RPM (varies by market/tune)
Torque Claimed:
Approx. 42 lb-ft at 9,000 RPM (varies by market/tune)
Carburetion:
Mikuni BST36SS (Constant Velocity) x 4
Fuel Capacity:
17 Liters (4.5 US gal)
Recommended Fuel:
Unleaded gasoline, 91 octane or higher
Length:
Approx. 2,120 mm (83.5 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1,180 mm (46.5 in)
Wheelbase:
Approx. 1,425 mm (56.1 in)
Dry Weight:
Approx. 185 kg (408 lbs)
Wet Weight:
Approx. 200 kg (441 lbs)
Max Load Capacity:
Typically rated for rider and passenger, plus minimal luggage.
Safety Ratings:
N/A (Motorcycle safety ratings not standardized like cars)
Braking System:
Dual Disc Front, Single Disc Rear (Hydraulic)
Suspension Design:
Telescopic front forks, Monoshock rear suspension (SACS - Suzuki Advanced Cooling System for engine design)
Frame Construction:
Aluminium Twin-Spar frame for rigidity and lightweight
Lighting:
Halogen headlight, LED taillight
Infotainment System:
N/A (Mechanical Analog Gauges)
Driver Assistance Systems:
N/A
Connectivity Features:
N/A
Instrument Cluster:
Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, indicator lights.
Lighting Technology:
Halogen headlight for illumination, simple electrical systems for signals and rear lighting.
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. Manual will specify exact intervals.
Chain Lubrication Inspection:
Every 1,000 km (600 miles) or as needed, check chain slack.
Spark Plug Replacement:
Typically around 10,000-15,000 km (6,000-9,000 miles). Manual will provide exact spec.
Valve Clearance Check:
Major service interval, e.g., 12,000 km (7,500 miles) or as specified.
Engine Oil Type:
API SG, JASO MA certified, SAE 10W-40 or 20W-50 depending on temperature. Manual confirms specific viscosity.
Engine Oil Capacity:
Approx. 3.4 Liters (3.6 US qt) with filter change. Manual will have exact figure.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Manual will specify concentration.
Brake Fluid Type:
DOT 4 recommended.
Fork Oil Type And Viscosity:
Typically SAE 10W or 15W. Manual will specify exact type and volume per fork leg.
Typical Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals.
Common Problems:
Carburetor synchronization issues, electrical connector corrosion, rear shock absorber wear over time.
Carburetor Issues:
Early models might experience carburetor jetting or synchronization drift requiring periodic adjustment.
