High-throughput protease enzymology reveals that SARS-CoV-2 viral fitness is constrained not by single-substrate catalytic efficiency but by balanced polyprotein processing across all eleven cleavage junctions, where mutations that alter substrate specificity—even while maintaining or enhancing activity on individual sites—disrupt the coordinated release of nonstructural proteins and impair viral replication.

Proteases govern essential biological processes and are key drug targets, yet how protease sequence variation quantitatively reshapes biochemical parameters and constrains biological fitness remains poorly understood. Here, we integrate high-throughput in vitro enzymology with cellular assays to link protease sequence, biochemistry, and fitness. We extend a microfluidic platform for high-throughput protease enzymology (HT-MEKpro), which is broadly applicable across protease families and catalytic classes, enabling measurement of catalytic turnover (kcat), Michaelis constant (KM), inhibitor potency (IC50), and relative substrate specificity for 102-103 variants. Applied to the SARS-CoV-2 main protease (Mpro), HT-MEKpro generated parallel catalytic and inhibitory landscapes for >400 variants. Integration with viral replication and in-cell cleavage assays reveals that variants with altered substrate specificity fail to support replication, suggesting imbalanced polyprotein processing as a constraint on viral fitness. More broadly, these data can enable mechanistically grounded modeling of protease sequence–property relationships and inform strategies for pharmacological modulation beyond active-site inhibition.