This is the maintenance schedule with associated service intervals for the 2002-2003 Kawasaki ZZR1200.
The ZZ-R1200 is a sport bike from (2002-2005). Identified by its model number ZX1200-C1, it is the successor to the ZX-11(1990-2001). Instead of its 36mm CV carbs, the ZZ-R gets a water jacket and head bolt layout to accommodate a bank of 40mm downdraft CVs with a throttle-position sensor. Tougher pistons from the Ninja ZX-12R are used in the ZZ-R, and the bike’s rebalanced crankshaft is said to increase torque.
This maintenance schedule applies to the following models:
- 2002 Kawasaki ZZR1200
- 2003 Kawasaki ZZR1200
Considered a sport-tourer, it had a twin-spar aluminum frame and a liquid-cooled, DOHC, four-stroke inline-four engine. It has twin fans, fuel pumps, and headlights. Additionally, hard-touring bags can be added as an option. With factory rear-wheel horsepower of 145HP; it is widely regarded to be the most powerful production motorcycle ever built with carbureted induction.
Maintenance Schedule for 2002-2003 Kawasaki ZZR1200
Below is the maintenance schedule for the 2002-2003 Kawasaki ZZR1200.
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 2002-2003 Kawasaki ZZR1200 is broken into two sections: Emission Related, and Non-Emission Related.
Periodic Maintenance Chart
|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 (c)–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||•||•||•||•||•||•||•|
|K||Front fork oil–change||2 years||•|
|K||Swingarm pivot, uni-trak linkage – lubricate||•||•||•|
|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)|
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.
(c): California model only
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
Tyre size and tyre pressure for the 2002-2003 Kawasaki ZZR1200
The 2002-2003 Kawasaki ZZR1200 has the following tyres and tyre sizes standard (tubeless type):
- 120/70 ZR17 M/C (58W)
- BRIDGESTONE “BT020F RADIAL AA”
- 180/55 ZR17 M/C (73W)
- BRIDGESTONE “BT020R RADIAL AA”
The manual for the 2002-2003 Kawasaki ZZR1200 recommends the following tyre pressures (when cold):
- Front: 290 kPa/42 psi
- Rear: 290 kPa/42 psi
General information about the 2002-2003 Kawasaki ZZR1200
At the heart of the ZZ-R1200 is the liquid-cooled, transverse in-line four from the ZRX. But instead of its 36mm CV carbs, the ZZ-R gets a new water jacket and head bolt layout to accommodate a bank of 40mm downdraft CVs with a throttle-position sensor. Kawasaki says the larger mixers enhance low- and midrange power. Tougher pistons from the Ninja ZX-12R are used in the ZZ-R, and the bike’s rebalanced crankshaft is said to increase torque.
The revised powerplant is hung in a ZX-11-type aluminum perimeter frame with tubular-steel front downtubes that are removable for engine service. Thicker rails and a new reinforced steering head stiffen the aluminum chassis for better handling. Steering rake and fork offset were both reduced to “maintain a light-steering feeling,” and the aluminum box-section swingarm was lightened and pivots slightly lower in the frame to improve traction and squat characteristics.
To accommodate the extra weight and stress from a pair of hard saddlebags, the original aluminum seat sub-frame was replaced with a stronger steel unit. To compensate for changing loads, the ZZ-R’s 43mm cartridge fork has an adjustable spring preload, and the new single shock in the back offers both a remote hydraulic adjuster knob for preload and a four-position rebound-damping adjuster.
Manual for the 2002-2003 Kawasaki ZZR1200
The above maintenance schedule comes directly from the user’s manual for the 2002-2003 Kawasaki ZZR1200, which is available here.