Kawasaki ZX-6 and ZZR600 Gen 1 (1990-2004) Maintenance Schedule and Service Intervals
This is the maintenance schedule with associated service intervals for the Kawasaki ZZR600, previously (or in other markets) known as the ZX-6. This is the 1st gen ZZR600 before it was re-issued in the 2000s.
The Kawasaki ZZR600 (ZX-6) was a sports motorcycle, later re-classified as a sports-touring motorcycle. It was Kawasaki’s flagship 600cc until the ZX-6R was released in 1995.
In Europe, the model was always known as the ZZR600, but in some other markets, it was renamed from the ZX-6 to the ZZR600.
From 2005, the ZZR600 evolved slightly, taking on the engine from the earlier generation ZX-6R. See here for the maintenance schedule for the 2nd gen ZZR600 / ZX-6.
This site has links for things like oil and spark plugs from which we earn a commission (which unfortunately nobody can save, not even us). If you appreciate this work, then please use those links. Thanks!
Maintenance Schedule for Kawasaki ZZR600 Gen 1 (1990-2004)
Below is the maintenance schedule for the first generation Kawasaki ZZR600.
The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.
- For higher odometer readings, repeat at the frequency interval established here
- For items marked “check” — adjust, replace, or tighten if necessary.
- #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
The maintenance for the Kawasaki ZZR600 is broken into two sections: Emission Related, and Non-Emission Related.
|mi x 1000||3||6||9||12||15||18|
|km x 1000||5||10||15||20||25||30||Every|
|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 / replace||•||•||•||Replace every 5 cleanings|
|Fuel system – check||•||•||•|
|Evaporative emission control system – check||•||•||•||•||•||•|
|Brake light switch — check||•||•||•||•||•||•|
|Brake pad wear – check||•||•||•||•||•||•|
|Brake fluid level – check||•||•||•||•||•||•||month|
|Brake fluid – change||•||2 years|
|Clutch – adjust||•||•||•||•||•||•|
|Steering – check||•||•||•||•||•||•|
|Drive chain wear – check||•||•||•||•||•||•||More often if riding in harsh conditions|
|Nuts, bolts, and fasteners tightness — check †||•||•||•|
|Tire wear – check||•||•||•||•||•||•|
|Engine oil – change||•||•||•||year|
|Oil filter – replace||•||•||•|
|General Lubrication – perform||•||•||•||•||•||•|
|Front fork oil – change||•|
|Swingarm pivot, uni-trak linkage – lubricate||•||•||•|
|Coolant – change||•||2 years|
|Radiator hoses, connections – check||•||•||•||year|
|Steering stem bearing–lubricate||•||2 years|
|Master cylinder cup and dust seal -replace||2 years|
|Caliper piston seal and dust seal – replace||2 years|
|Brake hose – replace||4 years|
|Fuel hose – replace||4 years|
|Brake hoses, connections – check||•||•||•||•||•||•|
|Fuel hoses, connections – check||•||•||•||•||•||•|
Maintaining Your Chain on the Kawasaki ZZR600 / ZX-6
It’s important to maintain your chain on the ZZR600 / ZX-6, as on any chain-driven motorcycle. Use a good-quality chain lubricant like Motul chain paste, or a Motul chain care kit which comes with a couple of handy tools to maintain the chain.
Kawasaki recommends you follow the following chain maintenance schedule:
|Chain maintenance item||Every|
|Check drive chain lubrication condition, lubricating if necessary (Motul chain paste)||400 mi / 600 km|
|Check drive chain slack, adjusting if necessary||600 mi / 1000 km|
- Do these items (checking/adjusting slack, and checking/applying lubrication) more often if you ride your ZZR600 / ZX-6 in dusty or rainy conditions, or if stressing your motorcycle a lot.
- Always lubricate the chain after washing the motorcycle.
Tire size and tire pressure for the Kawasaki ZZR600 / ZX-6
The Kawasaki ZZR600 has the following tires and tire sizes standard (tubeless type), plus the following recommended tyre pressures when cold.
The ZX-6 / ZZR600 shipped with street/sport tires of a type that’s no longer available.
|Front||120/60 ZR17 (55W)||250 kPa/36 psi|
|Rear||160/60 ZR17 (69W)||290 kPa/41 psi|
About the Kawasaki ZZR600
The original Kawasaki ZZR600 is powered by a compact 599cc liquid-cooled four-cylinder engine similar to the high-performance ZX-6R powerplant.
It’s a very modern engine, with dual overhead cams, four valves per cylinder, and a range of technologies from higher-end sportbikes to make sure the engine is both high-power and has quick throttle response.
In the heyday of the 1990s, the most popular motorcycle category was the 600cc class. They were considered the best compromise between power and handling. Bigger bikes were too heavy or cumbersome, and of course smaller bikes were too slow!
But even in the 1990s, riders recognised that not everyone could afford to be — or would want to be — on a track-focused superbike. Thus was born the category of street-friendly supersports like the Kawasaki ZZR600.
These days, you’d equate the ZZR600 to something like the Honda CBR650R — a sport bike that could do double duty in street and track riding.
While the original ZZR600 / ZX-6 is aging, it’s no slouch. The 599 cc engine pumps out 98 hp / 73 kW at 11500 rpm, a very respectable number, with peak torque coming on at 9500 rpm and at 64 Nm / 47 ft-lb. Though you’d probably need to give a little attention to the engine to make sure it was operating at its full potential.
Final drive is via a 6 speed transmission and a chain.
Brakes are pretty impressive for a so-called road bike, too, with 300 mm discs and 4-piston calipers. And the tyres are the spec you’d expect on a sport bike — 17 inch front and rear, though with an older-fashioned 160/60 profile at the rear.
Manual for the Kawasaki ZZR600
The above maintenance schedule comes directly from the user’s manual for the 2003-2004 Kawasaki ZZR600. You can access the manual for the ZZ-R600 from Kawasaki’s website here.