Market Segment:
Supersport / Superbike
Category:
Middleweight Sportbike
Key Competitors:
Honda CBR600RR, Yamaha YZF-R6, Suzuki GSX-R600, Triumph Daytona 675.
Engine Type:
High-revving, inline-four cylinder, DOHC, 16-valve.
Chassis Design:
Lightweight aluminum twin-spar frame, advanced suspension geometry.
Aerodynamics:
Aggressive, wind-tunnel tested fairing design for stability at high speeds.
Braking System:
Radial-mount front calipers, petal-style discs, optional ABS.
Engine Mechanical:
Full engine disassembly, assembly, inspection, and overhaul procedures for the 600cc inline-four engine.
Engine Electrical:
Ignition system, fuel injection system (EFI), starting system, charging system, sensor diagnostics, ECU troubleshooting.
Transmission:
Clutch system, gearbox internal inspection and repair, shift drum and fork alignment, lubrication.
Chassis And Suspension:
Front fork (USD, SFF – Separate Function Fork) disassembly, assembly, and tuning; rear shock absorber service; swingarm and linkage inspection; steering system maintenance.
Brakes:
Front and rear brake caliper overhaul, master cylinder service, brake line replacement, ABS system (if equipped) diagnostics and bleed procedures.
Electrical System:
Wiring diagrams, lighting system, horn, battery, fuse box, starter relay, instrument panel operation and troubleshooting.
Fuel System:
Fuel pump, fuel injectors, fuel filter replacement, fuel tank maintenance, evaporative emission control system (EVAP).
Cooling System:
Radiator service, coolant replacement, fan operation, thermostat testing, water pump inspection.
Exhaust System:
Catalytic converter inspection, muffler service, lambda sensor (O2 sensor) troubleshooting.
Bodywork And Trim:
Fairing removal and installation, seat service, fuel tank cover, fender maintenance.
Diagnostic Codes:
OBD-II (On-Board Diagnostics II) fault codes, troubleshooting procedures for specific error codes.
Routine Maintenance:
Oil and filter changes, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, brake fluid flush.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptoms and probable causes, wiring harness testing.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair.
Special Tools:
Listing and explanation of specialized tools required for specific repair procedures.
Torque Specifications:
Detailed torque values for all critical fasteners across various systems.
Clearances And Tolerances:
Precise measurements for engine components, bearings, and other critical parts during rebuilds.
Wiring Diagrams:
Comprehensive, color-coded wiring diagrams for easy electrical system diagnosis.
Schematics:
Detailed schematics for hydraulic, pneumatic, and electrical systems.
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to complete engine and chassis overhauls.
Target Audience:
Professional motorcycle technicians, advanced DIY enthusiasts, and workshop owners.
Engine Type:
4-stroke, Liquid-cooled, DOHC, 16-valve inline-four
Displacement:
599 cc (599 cubic centimeters)
Bore X Stroke:
67.0 mm x 42.5 mm
Compression Ratio:
12.9:1
Horsepower:
Approx. 128-134 PS (94-98.5 kW) at 13,500 rpm (at crankshaft, claimed)
Torque:
Approx. 65-67 Nm (48-49 lb-ft) at 11,700 rpm (claimed)
Fuel System:
Fuel injection with dual injectors per cylinder (Keihin 43mm throttle bodies)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Ignition:
Digital CDI with electronic advance
Lubrication System:
Forced lubrication, wet sump
Transmission Type:
6-speed, constant mesh, return shift
Clutch Type:
Wet, multiple disc, manual
Final Drive:
Sealed chain
Gear Ratios:
1st: 2.750 (33/12), 2nd: 2.000 (32/16), 3rd: 1.700 (34/20), 4th: 1.500 (30/20), 5th: 1.333 (32/24), 6th: 1.150 (23/20)
Transmission Fluid:
Kawasaki Motorcycle Gear Oil (or equivalent API GL-4, SAE 75W-90)
Instrument Cluster:
Digital speedometer, analog tachometer, gear position indicator, fuel gauge, clock, trip meters, engine temperature warning.
ABS System:
Optional Intelligent ABS (KIBS) on some models, providing advanced braking control.
Immobilizer:
Standard Kawasaki Smart Entry System (KISS) on later models, with an immobilizer key.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Inspect every 6,000 km (3,700 miles), clean or replace as needed.
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles).
Coolant Replacement:
Replace every 24,000 km (15,000 miles) or 24 months.
Brake Fluid Flush:
Flush and replace every 24,000 km (15,000 miles) or 24 months.
Chain Lubrication:
Lubricate every 1,000 km (600 miles) or after riding in the rain or through puddles.
Engine Oil Type:
SAE 10W-40 API SG or SH, or JASO MA certified.
Engine Oil Capacity:
3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant (50% solution with distilled water).
Fork Oil Type:
KHL15-12 (or Showa SS-13, SAE 5W) (Refer to manual for specific quantity and level)
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires.
Engine Specific Concerns:
While generally reliable, some owners report occasional issues with fuel injectors or throttle body synchronization if not properly maintained. High-revving nature requires diligent oil changes.
Suspension Notes:
The Separate Function Fork (SFF) requires precise attention during servicing to maintain optimal damping and spring performance.
Electrical Gremlins:
As with many motorcycles of this era, wiring harness integrity, particularly around the steering head and under the seat, should be checked periodically for wear or damage.
