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2002-2003 Kawasaki ZZR1200 Maintenance Schedule and Service Intervals

2002-2003 Kawasaki ZZR1200 Stock Image

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

OperationEvery1000 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)
Emission Related:
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 †
Non-Emission Related:
Brake light switch — check †
Brake pad wear– check † #
Brake/clutch fluid level — check †month
KBrake/clutch fluid — change2 years
KSteering –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
KFront fork oil–change2 years
KSwingarm pivot, uni-trak linkage – lubricate
KCoolant–change2 years
Radiator hoses, connections–check †
KSteering stem bearing–lubricate2 years
KBrake/clutch master cylinder cup and dust seal–replace4 years
KCaliper piston seal and dust seal–replace4 years
KClutch slave cylinder piston seal – replace4 years
KFuel hoses, connections – check †
KBrake/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)

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.
(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):

Front:

  • 120/70 ZR17 M/C (58W)
  • BRIDGESTONE “BT020F RADIAL AA”

Rear:

  • 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

Maintenance Schedule Screenshot From Manual 2002-2003 Kawasaki ZZR1200.
User manual screenshot for the 2005-2008 Kawasaki ZZR600

The above maintenance schedule comes directly from the user’s manual for the 2002-2003 Kawasaki ZZR1200, which is available here.

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