Kawasaki ZZR1200 (2002-2005) Maintenance Schedule and Service Intervals
This is the maintenance schedule with associated service intervals for the Kawasaki ZZ-R1200, which people often abbreviate to ZZR1200.
The ZZ-R1200 is a sport bike made between 2002-2005 and sold alongside the ZX-12R, and also serves as a successor to the ZX-11.
Unlike the ZX-12R, the ZZ-R1200 is carburettor-fed. The suspension is also a little softer, but given its age, adding newer springs, fresh fork oil, and valves to teh ZZ-R1200 should make it into a weapon.
Maintenance Schedule for Kawasaki ZZ-R1200
Below is the maintenance schedule for the Kawasaki ZZ-R1200.
The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.
Notes:
- For higher odometer readings, repeat at the frequency interval established here
- K: Kawasaki suggests these should be serviced by an authorized Kawasaki dealer
- †: Replace. add. adjust, or torque if necessary.
- #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
| Operation | Every | 1000 km (600 mi) | 6000 km (4000 mi) | 12000 km (7500 mi) | 18000 km (12000 mi) | 24000 km (15000 mi) | 30000 km (20000 mi) | 36000 km (24000 mi) | |
|---|---|---|---|---|---|---|---|---|---|
| Carburetor synchronization — check † | • | • | • | ||||||
| Idle speed–check † | • | • | • | • | |||||
| Throttle grip play–check † | • | • | • | • | |||||
| Spark plug–clean and gap † | • | • | • | • | • | • | |||
| Valve clearance–check † | • | • | • | ||||||
| Air suction valve — check † | • | • | • | • | • | • | |||
| Air cleaner element and air vent filter–clean † # | • | • | • | ||||||
| Evaporative emission control system (CA only) –check † | • | • | • | • | • | • | • | ||
| Brake light switch — check † | • | • | • | • | • | • | • | ||
| Brake pad wear– check † # | • | • | • | • | • | • | |||
| Brake/clutch fluid level — check † | month | • | • | • | • | • | • | • | |
| K | Brake/clutch fluid — change | 2 years | • | ||||||
| K | Steering –check † | • | • | • | • | • | • | • | |
| Drive chain wear–check † # | • | • | • | • | • | • | |||
| Nuts, bolts, and fasteners tightness — check † | • | • | • | • | |||||
| Tire wear–check † | • | • | • | • | • | • | |||
| Engine oil–change # | 6 months | • | • | • | • | • | • | • | |
| Oil filter–replace | • | • | • | • | |||||
| General Lubrication–perform | • | • | • | ||||||
| K | Front fork oil–change | 2 years | • | ||||||
| K | Swingarm pivot, uni-trak linkage – lubricate | • | • | • | |||||
| K | Coolant–change | 2 years | • | ||||||
| Radiator hoses, connections–check † | • | ||||||||
| K | Steering stem bearing–lubricate | 2 years | • | ||||||
| K | Brake/clutch master cylinder cup and dust seal–replace | 4 years | |||||||
| K | Caliper piston seal and dust seal–replace | 4 years | |||||||
| K | Clutch slave cylinder piston seal – replace | 4 years | |||||||
| K | Fuel hoses, connections – check † | • | • | • | • | • | • | ||
| K | Brake/clutch hoses, connections – check † | • | • | • | • | • | • | ||
| Front fork oil leak–check † | • | • | • | ||||||
| Rear shock absorber oil leak – check † | • | • | • | ||||||
| Drive chain–lubricate # | Every 600 km (400 mi) | ||||||||
| Dive chain slack–check † # | Every 1000 km (600 mi) |
Tyre size and tyre pressure for the Kawasaki ZZ-R1200
The Kawasaki ZZR1200 has the following tyres and tyre sizes standard (tubeless type):
Front:
- 120/70 ZR17 M/C (58W)
- BRIDGESTONE “BT020F RADIAL AA”
- DUNLOP “D220F STP”
Rear:
- 180/55 ZR17 M/C (73W)
- BRIDGESTONE “BT020R RADIAL AA”
- DUNLOP “D220 STP”
The manual for the 2004-2005 Kawasaki ZZR1200 recommends the following tyre pressures (when cold):
- Front: 290 kPa/42 psi
- Rear: 290 kPa/42 psi
General information about the Kawasaki ZZ-R1200
The ZZ-R1200 is a sports-tourer sibling to the ZX-12R.
It’s a similar kind of a bike — a high-speed tourer — but has carburettors and simpler front suspension, as well as a more comfortable riding position.
The engine is still a liquid-cooled, DOHC, four-stroke inline-four engine with 1,164 cc of capacity. The ZZ-R 1200 can produce rear-wheel horsepower of 145 hp — it’s no slouch! In fact, it’s considered the most powerful motorcycles ever made with carbureted induction.
Kawasaki engineers based the ZZR1200’s engine after the one in the ZRX1200 but modified the ZZR’s 16-valve engine to be a stronger performer in the low- and mid-range sections of the powerband. The ZZR1200 uses twin fuel pumps that feed four Keihin 40mm downdraft carburetors equipped with the Kawasaki Throttle Responsive Ignition Control (K-TRIC) system.
While the ZZR1200’s engine performance crosses boundaries uncharted by other sport touring machines, the same can be said for its chassis. The aluminum perimeter-style frame is reinforced with internal ribbing to withstand mass miles of sport touring. Meanwhile, a steel subframe accommodates saddlebags available through Kawasaki Accessories or color-matched luggage offered by Givi.
To give the ZZR1200 the light-handling nature associated with sport-touring bikes, ball bearings are used in the steering head to maintain a light-steering feeling. Also, the lightweight swingarm is designed relatively low to improve traction. Kawasaki’s UNI-TRAK rear suspension system produces progressive rates on the shock for an overall smooth ride.
Bringing the ZZR1200 to a stop are opposed four-piston calipers, which grip 320mm dual-discs in the front, complemented by a 250mm rear disc brake.
Manual for the Kawasaki ZZ-R1200
The above maintenance schedule comes directly from the user’s manual for the 2004-2005 Kawasaki ZZR1200, which is available here.
