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Winning Is Everything

The racetrack is an unforgiving place. It rewards performance, and accepts no excuses. It is a place of absolutes, where there can be just one winner. Introducing the 2004 Suzuki GSX-R600. Built with genuine Suzuki engineering. Lighter. Better handling. Stronger. Delivering the best power-to-weight ratio in its class. With performance features straight out of the factory racing department. Titanium valves. Inverted forks. Radial- mount brake calipers and a radial master . Advanced ram-air intake. A powerful digital and engine management system with more computing power, running larger bodies. Designed with one goal in mind: Winning.

A 600 Like No Other

Leading the class is one thing. Leaving it far behind is another. The 2004 Suzuki GSX-R600 reallyis in a class of its own. With the most torque. The lowest dryweight, and the best power-to-weight ratio. Designed with better aerodynamics. A more effective ram-air intake system. Stronger brakes. More linear torque delivery. Better acceleration. The goal is winning. The plan, overwhelm the would- be competition, and establish domination. In other words, Own The Racetrack. With a 600 like no other.

With Titanium V With Titanium Valves A More Efficient Engine, Mor 0.634:1. of ratio 0.634:1. / of of ratio a 599.4cc bore/stroke and for for a displacement stroke, stroke, and of 42.5mm 42.5mm displacement 599.4cc a a and and bore bore 67.0mm 67.0mm oversquare, oversquare, a a is is with with It It transmission. transmission. six-speed six-speed a a and and fuel injection injection cylinder cylinder, per per valves valves four four (DOHC), (DOHC), inline overhead camshafts an double is with it cooled, terms, liquid basic cylinder cylinder, In four four engine. the with starts all It ,

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Cylinder head

Ventilation holes The narrower valve angle also allows the intake ports to Titanium New internal passageways carry oil to the automatic, be straighter, with a steeper downdraft angle, 49 degrees valves are hydraulic cam chain tensioner, instead of using an from the cylinder surface versus 44 degrees. significantly external oil feed line, saving another 70 grams of weight. The straighter, steeper intake ports reduce intake flow lighter than resistance, improving cylinder charging and combustion conventional efficiency. The narrower valve angle also allows the steel valves, The oil-to-coolant oil cooler, positioned between the cylinder head itself to be 8mm shorter front-to-rear, each 27.2mm crankcases and the spin-on , is now thicker, which saves 80 grams of weight. The bolts which hold intake valve carrying eight layers of coolant passageways instead of the cylinder head to the cylinder blockare 0.5mm weighing 5.6 Titanium valves and valve springs six, increase cooling smaller in diameter, and each weigh 3.5 grams less; the grams less for capacity by 13%, from 10 lighter bolts save a total of 35 grams. a combined total of 44.8 grams, and each 22.0mm exhaust 3.35 kw to 3.80 kw. The valve weighing 4.4 grams less for a combined total of radiator is 40mm 35.2 grams. The valves are operated by smaller, lighter narrower (340mm The exhaust ports are 2mm larger in diameter, reducing bucket , the new intake valve buckets measuring instead of 380mm) and exhaust flow resistance. 25.0mm instead of 26.0mm and the exhaust valve buckets 2mm thinner (22mm measuring 23mm instead of 24mm. Each intake valve instead of 24mm), but is Oil cooler (8 layers of bucket is now 0.8 grams lighter, or 6.4 grams in total, and 10mm taller (248mm coolant passageways) 8mm shoter each exhaust valve bucket is also 0.8 grams lighter, or 6.4 instead of 238mm). The 12 degrees 10 degrees grams in total. The lighter valves and buckets allow the result is 8.0% more cooling capacity, from 26.8 kw to 29 steel-alloy valve springs to have a 10% lighter rate kw, with a weight savings of 125 grams. The electric despite a 1,350 rpm increase in maximum engine speed. assembly mounted on the radiator uses a new one-piece Valve spring retainers are aluminum. plastic cooling fan featuring a ring molded to the tips of the individual blades. The integrated ring eliminates the gap between the blade tips and the housing used in The valves are opened by new, hollow camshafts with conventional fan designs, making the fan more efficient thinner walls, the inner diameter increased from 15.5mm even though it is 4.2mm thinner (19mm instead of to 16.5mm and the outer diameter remaining unchanged 23.2mm) and 12mm smaller in diameter (160mm instead at 24.0mm. The changes make the intake 45 of 172mm). grams lighter and the exhaust camshaft 35 grams lighter. The lighter weight 49 degrees reduces inertia and allows the camshafts to be more accurately 2mm larger controlled by the exhaust port Sectional drawing of cylinder head cam chain, Camshafts especially at higher engine speeds. Radiator with cooling fan Advanced Digital Fuel Injection And Emissions Controls

Fuel injection is all The new GSX-R600's dual, double-barrel throttle about getting the right bodies are simpler and about 370 grams lighter amount of atomized than a bank of individual single-barrel throttle fuel and air into the bodies, and use all-resin fuel delivery pipes cylinders to ensure a instead of aluminum-and-resin fuel delivery pipes. homogenous intake The pitch, or center-to-center distance between the charge and the most adjacent barrels in each throttle body, is reduced efficient combustion 5mm, to 75mm, making the throttle body possible, under all Dual double-barrel throttle bodies assembly more compact. The more compact conceivable throttle body assembly works with a 20mm conditions. Like other narrower ram-air airbox, which allows the fuel GSX-Rmodels, the tank to be narrower. The pitch between the two GSX-R600 uses the throttle bodies is 80mm. innovative SDTV (Suzuki Dual Throttle Valve) digital fuel injection system. Each SDTV throttle body throat carries SDTV Fuel injection system two butterfly throttle valves, a primary throttle valve controlled by the throttle twist grip on the handlebar, and a secondary throttle valve positioned between the primary throttle valve and the airbox, opened and closed by a step motor controlled by the ECM (Engine Control Module, or engine management system computer ) based on engine rpm, gear position and primary throttle position. Much like a CV incorporates a butterfly valve controlled by the rider and a throttle 75mm 80mm 75mm slide opened by intake vacuum, the SDTV system opens the 80mm 80mm 80mm secondary valve the right amount to match intake area to current engine operating conditions, maintaining optimum intake velocity, in turn producing more efficient combustion, smoother power delivery, and cleaner exhaust. The SDTV system works like a digital CV carb, and is especially effective in the on-off-on throttle conditions typically encountered entering and exiting corners. Each throttle body barrel is larger at the intake side, 46mm The ECM calculates injection volume using eight In European markets, the carries an exhaust instead of 41mm, and tapers down to an unchanged 38mm different maps, two for each cylinder. When the engine catalyzer. All models use Suzuki's reed-valve-controlled at the cylinder head. The individual injectors are load is light-such as cruising at moderate speed-fuel PAIR(Pulsed-AIR)injection system, which injects fresh positioned at a steep, 60-degree angle relative to the injection volume is calculated based on engine rpm and air from the airbox into the exhaust ports, igniting centerline of the throttle body throat, and are aimed so that intake air pressure. Under heavy load-such as unburned hydrocarbons and reducing carbon monoxide the fuel spray hits the primary throttle valve when it is accelerating hard down a racetrack straightaway in close- emissions. The 2004 GSX-R600 has larger PAIR between halfway and fully open, improving fuel course competition, fuel injection volume is calculated passageways, 8.0mm versus 6.7mm, increasing the atomization. At smaller throttle openings, the air rushing using throttle opening and engine rpm. volume of fresh air reaching the exhaust ports. around the partially closed throttle valve is turbulent enough to ensure excellent The ECM also controls ignition timing with eight Combined with the new internal engine design features, fuel atomization. The fuel separate maps, two for each cylinder, using one set of the GSX-R600's fuel injection and engine management injectors now have a maps in 1st, 2nd, 3rd and 4th gear, and using another set system contribute to more efficient combustion, with multi-hole tip instead of a of maps in 5th and 6th gear. more torque, and lower emissions. The improved torque pintle-type tip, improving delivery is especially noticeable in the middle and high fuel atomization, charge rpm ranges most used on the racetrack. The emissions homogenization and The 4-into-2-into-1 is made of stainless levels of European models are well below the levels set combustion efficiency. steel, and ends in a new muffler built using titanium core by EURO 2 regulations. The new injectors improve Multi-hole injector pipes and core pipe mounting plates, with an aluminum torque by about 1%. muffler sleeve. The titanium-and-aluminum muffler is about 700 grams lighter than an equivalent muffler built using steel core pipes and core pipe mounting plates, and An Auto Fast Idle System (AFIS) improves cold starting is about 300 grams lighter than an equivalent all-titanium by monitoring coolant temperature and automatically muffler. The new muffler is also 10mm larger in opening the throttle valves the correct amount. diameter, measuring 130mm instead of 120mm.

To operate the GSX-R600's advanced fuel injection system, the ECM has a more powerful CPU (Central Processing Unit) with 32-bit computing power instead of the previous model's 16-bit processor. ROM memory has also been increased, from 98 kilobytes to 256 kilobytes. The ECM housing (or black box) is more compact, 19mm narrower, 9mm thinner and 1mm shorter, and is about 80 grams lighter. The crankshaft position sensor and signal generator, which sends rpm information to the ECM, now has a 22-pole trigger instead of the previous model's 8-trigger pole, increasing signal frequency and allowing Muffler the fuel injection volume calculation to be more precise. A New Chassis In Aerodynamic Bodywork, With New Electrics And Instrumentation

The 2004 GSX-R600's chassis features an all new twin-spar aluminum-alloy frame and swingarm, with a 1400mm (55.1-inch) wheelbase, 23.25 degrees of rake and 93mm (3.7 inches) of trail. Each frame spar is now made from an extrusion instead of being made of welded-together stampings, and each extrusion is divided into two internal sections by an internal rib. The new type of spar makes frame construction simpler. The extruded frame spars are welded to steering head and swingarm pivot castings, and each spar is slightly taller and thinner. The dimensional and construction changes allowed Suzuki engineers to adjust vertical and horizontal rigidity and feel under hard braking and during cornering on the racetrack.

The new frame is 15mm narrower at its widest point and 5mm narrower at the swingarm pivot, and the simpler, straighter rear subframe (or tailsection) now bolts directly to the rear of the frame, improving durability. The swingarm Distinctive bodywork comes with more than aggressive The upper headlight is multi-reflector high beam with a combines extruded new look, also delivering better aerodynamics with a 60/55-watt H4 halogen bulb, and the lower headlight is a arms and an extruded more effective ram-air intake system. Thanks to the projector low beam with a 55-watt H7 halogen bulb. pivot tube, a cast cross slightly narrower frame, the bodywork is narrower, and Both the upper and lower bulbs are always lit in brace and cast axle the front fairing carries new, vertically stacked machines sold in North American and Oceanian markets. carriers. Overall headlights which allow the ram-air intakes to be In European markets, both bulbs are lit when high beam swingarm rigidity is positioned closer to the center of the nose, where the air is selected, but only the lower bulb is lit when low beam increased by a subframe pressure is highest. The repositioned ram-air intakes is selected. of extruded tubes. Swingarm significantly increase air pressure inside the airbox, especially at racetrack speeds, improving cylinder charging and engine output. A new LED The is 15mm shorter and 30mm narrower at the taillight/stoplight rider's knees, and the footpegs are 10mm closer together. is more compact, The narrower and shorter fuel tank makes it easier for the and uses less rider to shift their weight back-and-forth and side-to-side electrical power. for cornering, and the narrower footpeg span increases New reshaped, banking angle by 1degree. The reach from the seat to smaller turn LED taillight and turn signals the handlebars is also shorter. signals are more aerodynamic and 29 grams lighter each, for a total weight savings of 116 grams.

The instrument cluster features a black-faced analog tachometer run by a step motor and an LCD (Liquid Crystal Display), including a digital speedometer and a combined odometer, dual tripmeter and clock display. LED turn-signal, high-beam, neutral, fuel level warning, FI warning, coolant temperature warning and oil pressure warning indicators are also used. A built in rpm-indicator light can be programmed, coming on at a pre-selected engine speed, in increments of 500 rpm.

Instrument cluster Inverted Forks, Piggy back Shock, Cast Aluminum Wheels, And Radial Mount Front Brakes

The GSX-R600 has inverted The cast aluminum front wheel measures 3.50 x 17- Showa cartridge front forks with inches and carries a 120/70ZR17 radial tire. The cast 43mm stanchion tubes and fully aluminum rear wheel measures 5.50 x 17-inches and adjustable spring preload, carries a 180/55ZR17 radial tire. rebound damping and compression damping. The Showa piggyback-reservoir rear Because the mounts are more rigid, radial-mount front shock is also fully adjustable for brake calipers resist distortion, improving braking spring preload, rebound efficiency. The rigid mounts also reinforce the front fork damping and compression axle carriers, reducing flex. The GSX-R600 is fitted with damping, and shock rod race-proven Tokico four-aluminum-piston radial-mount Front forks with diameter has been increased to front brake calipers. A 43mm stanchion tubes 16mm, from 14mm. Front wheel Nissin radial-piston front travel is 120mm (4.72 inches) master cylinder improves and rear wheel travel is 130mm lever feel, and because the (5.12 inches). calipers are more efficient, smaller-and-lighter, 300mm (11.81-inch) full- Radial-piston floating front discs can be front master cylinder used. Piggyback-reservoir rear shock

The rear disc measures 220mm (8.66 inches) and works with a dual- opposed-piston caliper indexed to the swingarm

Radial-mount itself, eliminating a front brake conventional torque link Rear brake and tire rod. Ready To Win

Own The Racetrack is not just a slogan. For Suzuki, it is historical fact. A new GSX-R is introduced, and overwhelms the would-be competition. Three or four years later, the opposition almost catches up-just in time for another new GSX-R to be born. Now history becomes the future, again. In the formof the 2004 Suzuki GSX-R600. Built knowing that Winning Is Everything. Ready to win. Waiting for you. GSX-R600 SPECIFICATIONS

Engine type 4-stroke, Suspension Rear Link type, oil damped, coil spring, liquid-cooled, DOHC, spring pre-load fully adjustable, 4-cylinder rebound and compression damping Bore x stroke 67.0mm x 42.5mm force fully adjustable Displacement Wheels Front 599.4cc (599.4cm3) 17M/C x MT3.50, cast aluminium alloy Rear 12.5:1 17M/C x MT5.50, cast aluminium alloy Carburetion Brakes Front Fuel injection 38mm Radial mount, 4-piston calipers, Oil capacity (overhaul) 3.6L 300mm dual-disc brake Ignition Rear Electronic ignition (transistorized) 2-piston caliper, 220mm disc brake system Tyres Front LR5: Pearl Suzuki Deep Blue No.2 / Glass Splash White Electric Lubrication system Rear 120/70ZR17M/C(58W) Transmission Wet Fuel tank 180/55ZR17M/C(73W) Primary drive ratio 6-speed, constant mesh Overall length 17L Final drive ratio 1.926 (79/41) Overall width 2,055mm (80.9in.) Frame type 2.812 (45/16) Overall height 715mm (28.1in.) Rake/trail Twin-spar (aluminium alloy) Wheelbase 1,150mm (45.3in.) Suspension Front23.25degree / 93.0mm (3.7in.) Ground clearance 1,400mm (55.1in.) Inverted telescopic, coil spring, Seat height 135mm (5.3in.) spring pre-load fully adjustable, Dry weight 825mm (32.5in.)

YEC: Pearl Flash Yellow rebound and compression 161kg (354.9lbs.) damping force fully adjustable

OTHER FEATURES

019: Solid Black

Headlights Passenger seat Front tire

SUZUKI MOTOR CORPORATION reserves the right to change, without notice, equipment, specifications, colors, materials and other items to apply to local conditions. Each model might be discontinued without notice. Please inquire at your local dealer for details of any such changes. Actual body colors might differ slightly from the colors in this brochure. Always wear helmet, eye protection, and protective clothing Read your owner's manual carefully Enjoy riding safely Never ride under the influence of alcohol or other drugs PRINTED IN JAPAN GSX-R600 Catalogue 99999-A0111-141 DATE OF ISSUE DEC.' 03 S Printed on 100% recycled paper. SUZUKI MOTOR CORPORATION 300 Takatsuka, Hamamatsu, Japan