Kawasaki | Motorcycles | Sportbike

2003-2004 Kawasaki ZZR600 Maintenance Schedule and Service Intervals

2003-2004 Kawasaki ZZR600 Stock Image

This is the maintenance schedule with associated service intervals for the 2003-2004 Kawasaki ZZR600.

The Kawasaki ZX-6 (ZZR600) was a Sports bike and later a sport-touring motorcycle. The ZX-6 series motorcycle was Kawasaki’s flagship 600 cc model from 1990 to 1994. It was then replaced in 1995 with the ZX-6R as the brand’s 600 cc race replica. In Europe, the model designation differed and was introduced in 1990 as the ZZR600.

This maintenance schedule applies to the following models:

  • 2003 Kawasaki ZZR600
  • 2004 Kawasaki ZZR600

The same 599 cc engine powered the bike from 1990 to 2004, then from 2005 to 2008, it used the engine from the 2004 ZX-6R. ZZR600 in North America, marketed during model years 2003 and 2004 (as well as 2005 in Canada), was based upon a previous generation sportbike (Ninja ZX-6). This indicates the motorcycle is mechanically identical to the earlier motorcycle and differs only in paint schemes.

Maintenance Schedule for 2003-2004 Kawasaki ZZR600

Below is the maintenance schedule for the 2003-2004 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.

The maintenance for the 2003-2004 Kawasaki ZZR600 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 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
Air cleaner element and air vent filter–replace5 cleanings
Fuel system–check
Evaporative emission control system (c)–check †
Non-Emission Related:
KBrake 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 †
Tire wear–check †
Engine oil–changeyear
KOil filter–replace
General Lubrication–perform
KFront fork oil–change
KSwingarm pivot, uni-trak linkage — lubricate
KCoolant–change2 years
Radiator hoses, connections–check †year
KSteering stem bearing–lubricate2 years
KMaster cylinder cup and dust seal–replace2 years
KCaliper piston seal and dust seal–replace2 years
KBrake hose–replace4 years
KFuel hose–replace4 years
KBrake hoses, connections – check †
KFuel hoses, connections – 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 2003-2004 Kawasaki ZZR600

The 2003-2004 Kawasaki ZZR600 has the following tyres and tyre sizes standard (tubeless type):

Front:

  • 120/60 ZR17 (55W)
  • BRIDGESTONE BT-50F RADIAL
  • MICHELIN A89X
  • PIRELLI MTR01
  • METZLER MEZ1 Front

Rear:

  • 160/60 ZR17 (69W)
  • BRIDGESTONE BT-50R RADIAL G
  • MICHELIN M89X
  • PIRELLI MTR02
  • METZLER MEZ1

The manual for the 2003-2004 Kawasaki ZZR600 recommends the following tyre pressures (when cold):

  • Front: 250 kPa/36 psi
  • Rear: 290 kPa/41 psi

General information about the 2003-2004 Kawasaki ZZR600

The ZZR600 is powered by a compact 599cc liquid-cooled four-cylinder engine similar to the high-performance ZX-6R powerplant. Dual overhead cams actuate four extra-light valves per cylinder, and Kawasaki Straight-Shot ports combine with narrow valve systems to provide free-flowing intake for quick throttle response.

The most popular category of sportbike in America is the 600cc class, thanks to the lightweight, nimble handling, and ever-improving power-to-weight ratio of these modern machines. And for those who want all these performance attributes in a sport touring motorcycle at a great price and is available in colors metallic ruby red.

Intake efficiency is further enhanced by the Kawasaki Twin Ram Air Induction system. Scoops at the front of the fairing supply cool air directly to the airbox, and at highway speeds this become pressurized to help pack more fuel mixture from the 36mm Keihin carburetors into the cylinders. A digital ignition system ignites the mixture as its microprocessor-controlled timing is ultra-responsive to engine speed and the system never needs adjustment. Burned gasses exit the engine through twin mufflers for smooth power throughout the rev range.

Manual for the 2003-2004 Kawasaki ZZR600

Maintenance Schedule Screenshot From Manual 2003-2004 Kawasaki ZZR600.
User manual screenshot for the 2003-2004 Kawasaki ZZR600

The above maintenance schedule comes directly from the user’s manual for the 2003-2004 Kawasaki ZZR600, which is available here.

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