Suzuki GSX-R600 User Manual

1D-82 Engine Mechanical:
Cylinder + Piston + Piston Ring
Unit: mm (in)
Conrod + Crankshaft
Unit: mm (in)
Throttle Body
Item Standard Limit
Compression pressure 1 200 – 1 600 kPa (12 – 16 kgf/cm
2
, 171 – 228 psi)
900 kPa
(9 kgf/cm
2
, 128
psi)
Compression pressure difference —
200 kPa
(2 kgf/cm
2
, 28 psi)
Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047)
Cylinder bore 67.000 – 67.015 (2.6378 – 2.6384)
No nicks or
Scratches
Piston diam.
66.965 – 66.980 (2.6364 – 2.6370)
Measure 15 mm (0.6 in) from the skirt end.
66.880 (2.6331)
Cylinder distortion — 0.02 (0.008)
Piston ring free end gap
1st IT Approx. 5.5 (0.22) 4.4 (0.17)
2nd 2T Approx. 7.5 (0.30) 6.0 (0.24)
Piston ring end gap
1st IT
0.06 – 0.21 (0.002 – 0.008) 0.50 (0.020)
2nd 2T
Piston ring-to-groove clearance
1st — 0.180 (0.0071)
2nd — 0.150 (0.0059)
Piston ring groove width
1st 1.01 – 1.03 (0.0398 – 0.0406) —
2nd 0.81 – 0.83 (0.0319 – 0.0327) —
Oil 1.51 – 1.53 (0.0594 – 0.0602) —
Piston ring thickness
1st 0.97 – 0.99 (0.0382 – 0.0390) —
2nd 0.77 – 0.79 (0.0303 – 0.0311) —
Piston pin bore 14.002 – 14.008 (0.5513 – 0.5515) 14.030 (0.5524)
Piston pin O.D. 13.995 – 14.000 (0.5510 – 0.5512) 13.980 (0.5504)
Item Standard Limit
Conrod small end I.D. 14.010 – 14.018 (0.5516 – 0.5519) 14.040 (0.5528)
Conrod big end side clearance 0.10 – 0.20 (0.004 – 0.008) 0.3 (0.012)
Conrod big end width 19.95 – 20.00 (0.7854 – 0.7874) —
Crank pin width 20.10 – 20.15 (0.7913 – 0.7933) —
Conrod big end oil clearance 0.032 – 0.056 (0.0013 – 0.0022) 0.080 (0.0031)
Crank pin O.D. 30.976 – 31.000 (1.2195 – 1.2205) —
Crankshaft journal oil clearance 0.010 – 0.028 (0.0004 – 0.0011) 0.080 (0.0031)
Crankshaft journal O.D. 29.982 – 30.000 (1.18039 – 1.18110) —
Crankshaft thrust bearing thickness
Right side 2.425 – 2.450 (0.0955 – 0.0965) —
Left side 2.350 – 2.500 (0.0925 – 0.0984) —
Crankshaft thrust clearance 0.055 – 0.110 (0.0022 – 0.0043) —
Crankshaft runout — 0.05 (0.002)
Item Specification
Bore size 40 mm (1.57 in)
I.D. No. 37H1 (For E-33), 37H0 (For the others)
Idle r/min 1 300 ± 100 r/min
Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in)

Suzuki GSX-R600 Specifications

General

Engine Type	4-stroke, liquid-cooled, DOHC
Bore x Stroke	67.0 mm x 42.5 mm
Compression Ratio	12.9:1
Fuel System	Fuel injection
Starter	Electric
Final Drive	Chain
Front Suspension	Inverted telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Engine Displacement	599cc
Transmission	6-speed, constant mesh
Front Tire Size	120/70ZR17M/C (58W)
Rear Tire Size	180/55ZR17M/C (73W)
Overall Length	2030 mm
Overall Width	710 mm
Seat Height	810 mm
Ground Clearance	130 mm
Curb Weight	187 kg
Fuel Tank Capacity	17.0 L