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2001-2003 Kawasaki ZR-7S Maintenance Schedule and Service Intervals

2001-2003 Kawasaki ZR-7S Stock Image

This is the maintenance schedule with associated service intervals for the 2001-2003 Kawasaki ZR-7S.

The Kawasaki ZR-7 was sold in the United States from 1999 through 2003 and sold in a few other countries through the 2005 model year. The ZR-7 and the ZR-7S differs from fairing and associated headlight, instrument cluster, and stiffer fork springs. The ZR-7S has an advertised dry weight of 210 kg. The ZR-7 has a wet mass of 231 kg.

This maintenance schedule applies to the following models:

  • 2001 Kawasaki ZR-7S
  • 2002 Kawasaki ZR-7S
  • 2003 Kawasaki ZR-7S

The Kawasaki ZR-7 is powered by an inline 4-cylinder 4-stroke, double-overhead-cam DOHC air-and-oil-cooled 738 cc engine, generating 57 kW and 63 N·m. Carburetors are four constant-velocity (CV) Keihin CVK 32 mm. The final drive is via chain; the transmission is a 5-speed (equipped with positive neutral finder), coupled with a wet clutch. The seat height is 800 mm.

Maintenance Schedule for 2001-2003 Kawasaki ZR-7S

Below is the maintenance schedule for the 2001-2003 Kawasaki ZR-7S.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

The maintenance for the 2001-2003 Kawasaki ZR-7S is broken into two sections: Emission Related, and Non-Emission Related.

Periodic Maintenance Chart

OperationEvery800 km (500 mi)5000 km (3000 mi)10000 km (6000 mi)15000 km (9000 mi)20000 km (12000 mi)25000 km (15000 mi)30000 km (18000 mi)
Emission Related:
Carburetor syncronization – check †
Idle speed–check †
Throttle grip play–check †
Spark plug–clean and gap †
Valve clearance – check †
Air suction valves – check †
Air cleaner element — clean
Air cleaner element — replace5 cleanings
Fuel system–check
Cylinder head bolt tightness – check †
Evaporative emission control system (c)–check †
Non-Emission Related:
Brake light switch — check †
Brake pad wear– check † #
Brake fluid level — check †month
KBrake fluid – change2 years
Clutch – adjust
KSteering –check †
Drive chain wear – check † #
Nuts, bolts, and fasteners tightness — check †
KMuffler, exhaust pipe mounting nuts and bolts tightness – perform †
Tire wear–check †
Engine oil–change #year
Oil filter–replace
General Lubrication–perform
KSwingarm pivot, uni-trak linkage — lubricate
KFront fork oil – change
KSteering stem bearing–lubricate2 years
KBrake master cylinder cup and dust seal–replace2 years
KBrake caliper piston seal and dust seal–replace2 years
KBrake hose –replace4 years
KFuel hose–replace4 years
Drive chain – lubricate #Every 600 km (400 mi)
Drive chain slack – check † #Every 1000 km (600 mi)

Notes:

K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
(c): only on California model

Tyre size and tyre pressure for the 2001-2003 Kawasaki ZR-7S

The 2001-2003 Kawasaki ZR-7S has the following tyres and tyre sizes standard (tubeless type):

2001 Kawasaki ZR-7S

Front:

  • 120/70 ZR17 (58W)
  • BRIDGESTONE BT020F RADIAL J

Rear:

  • 160/60 ZR17 (69W)
  • BRIDGESTONE BT020 R RADIAL

2002-2003 Kawasaki ZR-7S

Front:

  • 120/70 ZR17 (58W)
  • BRIDGESTONE BT020F RADIAL J
  • DUNLOP D220 F ST
  • MICHELIN MACADAM 100X

Rear:

  • 160/60 ZR17 (69W)
  • BRIDGESTONE BT020 R RADIAL
  • DUNLOP D220 ST
  • MICHELIN MACADAM 100X

The manual for the 2001-2003 Kawasaki ZR-7S recommends the following tyre pressures (when cold):

  • Front: 250 kPa/36psi
  • Rear: 250 kPa/36psi

General information about the 2001-2003 Kawasaki ZR-7S

The striking ZR-7S has the same appeal but at a more affordable price and reduced dry weight. Its air-cooled 738cc DOHC In-Line Four engine offers terrific smoothness and response, while the two-up seating, half-fairing, and available hard saddlebags make the ZR-7S as versatile as it is spirited. Displacing 738cc, the Double Overhead Cam, 8-valve engine develops broad power for a wide range of riding conditions.

The air-cooled engine features a high capacity oil lubrication system. An efficient 7-row oil cooler and special jets that squirt cooler oil to the undersides of the high-compression pistons. Kawasaki’s exclusive electronic K-TRIC throttle position sensor for exceptionally smooth throttle response: The system adjusts the digital ignition timing in relation to throttle position for crisp and clean engine response. The 4-into-1 polished stainless steel exhaust system adds performance and modern style to the ZR-7S.

Kawasaki’s exclusive Positive Neutral Finder makes finding neutral easy when the bike is stopped. The advanced aerodynamic design of the frame-mounted, half-fairing, and windscreen delivers the twin benefits of great wind protection and terrific styling. Multi-reflector headlights produce a broad beam for clear night vision. The analog instrumentation houses a centrally positioned tachometer.

Manual for the 2001-2003 Kawasaki ZR-7S

Maintenance Schedule Screenshot From Manual 2001-2003 Kawasaki ZR-7S.
User manual screenshot for the 2001-2003 Kawasaki ZR-7S

The above maintenance schedule comes directly from the user’s manual for the 2001-2003 Kawasaki ZR-7S, which is available here.

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