Segment:
High-performance sportbike, 500cc class.
Competitors:
Yamaha RD500LC, Honda NS400R, Kawasaki KR-1.
Engine Layout:
Square-four, two-stroke, liquid-cooled.
Frame Technology:
Lightweight aluminum twin-spar frame, Suzuki Full Floater rear suspension.
Cooling Technology:
Suzuki Advanced Cooling System (SACS) for engine efficiency.
Performance Focus:
Designed for racing homologation and track-day performance.
Engine:
Complete engine overhaul, top-end and bottom-end, porting details, cooling system.
Transmission:
Clutch, gearbox internals, shifting mechanism, lubrication.
Fuel System:
Carburetor tuning and rebuilding (Mikuni VM26SS), fuel pump, fuel lines.
Ignition System:
CDI ignition, spark plug specifications, timing, stator and rotor.
Exhaust System:
Expansion chamber analysis, silencer packing, leak checks.
Cooling System:
Liquid cooling system, radiator, water pump, coolant types.
Frame And Suspension:
Frame inspection, front fork (SACS - Suzuki Advanced Cooling System) service, rear monoshock (Full Floater) suspension adjustment and rebuild.
Brakes:
Front and rear disc brake service, caliper overhaul, master cylinder, fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, lighting, battery, charging system, starter, fuses, troubleshooting.
Bodywork And Trim:
Fairing removal and installation, seat, tank, body panel care.
Maintenance:
Routine servicing, oil changes, chain adjustment, air filter cleaning/replacement, spark plug replacement.
Troubleshooting:
Comprehensive diagnostic flowcharts for common issues, ignition problems, fuel delivery, starting difficulties.
Engine Repair:
Piston and cylinder replacement, crankshaft seal inspection, reed valve service.
Transmission Repair:
Gear set inspection, shift drum and fork alignment, bearing replacement.
Suspension Rebuild:
Front fork seal replacement, oil level and viscosity, rear shock absorber service.
Carburetor Rebuild:
Jetting specifications, needle positions, float bowl adjustment.
Electrical Diagnostics:
Voltage checks, continuity testing, component testing (stator, CDI).
Level:
Professional grade, suitable for amateur and professional mechanics.
Detail Level:
Step-by-step instructions with detailed photos and exploded diagrams for every procedure.
Specifications:
Includes torque values, clearances, tolerances, fluid capacities, and electrical schematics.
Type:
498cc, 2-stroke, liquid-cooled, V-arrangement of two parallel-twin cylinder blocks (square-four configuration).
Bore X Stroke:
56.0 mm x 50.6 mm
Compression Ratio:
7.4:1 (typical)
Power Output:
Approx. 95 hp @ 9,500 rpm (claimed, depending on market restrictions)
Torque:
Approx. 75 Nm @ 8,500 rpm (claimed)
Top Speed:
Over 240 km/h (150 mph)
Carburetor:
Four Mikuni VM26SS constant velocity carburetors.
Fuel Type:
Unleaded gasoline, minimum 98 RON recommended for optimal performance.
Fuel Mixture:
Automatic oil injection system for 2-stroke oil.
Type:
6-speed constant mesh gearbox.
Clutch:
Wet multi-plate clutch, cable-actuated.
Gear Ratios:
Specific ratios provided in manual for each gear.
Final Drive:
Chain drive (RK or similar).
Transmission Oil:
Manual specifies Suzuki Gear Oil SJ or equivalent (e.g., SAE 80W-90).
Oil Change:
Every 3,000-5,000 km (or as per manual recommendations for gearbox and 2-stroke oil).
Spark Plugs:
Check at 3,000 km, replace as needed (e.g., NGK BR9ES or equivalent).
Chain Maintenance:
Clean and lubricate every 1,000 km or after riding in wet conditions.
Engine Rebuild:
Recommended after significant mileage or performance degradation (e.g., 20,000-30,000 km, depending on usage).
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil.
Coolant Type:
Ethylene glycol-based antifreeze mixture, typically 50/50 with distilled water.
Brake Fluid:
DOT 4 brake fluid.
Carburetor Cleaning:
Can be prone to clogging due to fuel quality or age, requiring regular cleaning and synchronization.
Power Valve Maintenance:
Rave (Rotary Apex Valve) system requires periodic cleaning and lubrication for optimal performance.
Reed Valves:
Can wear over time, affecting power delivery and low-end torque.
Cooling System Leaks:
Aging hoses and seals can lead to coolant leaks.
