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2004-2005 Kawasaki ZZR1200 Maintenance Schedule and Service Intervals

2004-2005 Kawasaki ZZR1200 Stock Image

This is the maintenance schedule with associated service intervals for the 2004-2005 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:

  • 2004 Kawasaki ZZR1200
  • 2005 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 2004-2005 Kawasaki ZZR1200

Below is the maintenance schedule for the 2004-2005 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.

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)
Carburetor synchronization — check † (e)
Idle speed–check † (e)
Throttle grip play–check † (e)
Spark plug–clean and gap † (e)
Valve clearance–check † (e)
Air suction valve — check † (e)
Air cleaner element and air vent filter–clean † # (e)
Evaporative emission control system (c) (e)–check †
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
(e) Emission related item

Tyre size and tyre pressure for the 2004-2005 Kawasaki ZZR1200

The 2004-2005 Kawasaki ZZR1200 has the following tyres and tyre sizes standard (tubeless type):

Front:

  • 120/70 ZR17 M/C (58W)
  • BRIDGESTONE “BT020F RADIAL AA”
  • DUNLOP “D220F STP”

Rear:

  • 180/55 ZR17 M/C (73W)
  • BRIDGESTONE “BT020R RADIAL AA”
  • DUNLOP “D220 STP”

The manual for the 2004-2005 Kawasaki ZZR1200 recommends the following tyre pressures (when cold):

  • Front: 290 kPa/42 psi
  • Rear: 290 kPa/42 psi

General information about the 2004-2005 Kawasaki ZZR1200

Kawasaki engineers based the ZZR1200’s double-overhead-cam 1164cc inline-four engine after the muscular ZRX1200 but modified the ZZR’s 16-valve engine to be a stronger performer in the low- and mid-range sections of the powerband. The ZZR’s aluminum cylinders utilize chrome composite plating rather than cylinder liners to provide a lightweight package and quick heat transfer. The ZZR1200 uses twin fuel pumps that feed four Keihin 40mm downdraft carburetors equipped with the Kawasaki Throttle Responsive Ignition Control (K-TRIC) system.

While the ZZR1200’s engine performance crosses boundaries uncharted by other sport touring machines, the same can be said for its chassis. The aluminum perimeter-style frame is reinforced with internal ribbing to withstand mass miles of sport touring. Meanwhile, a steel subframe accommodates saddlebags available through Kawasaki Accessories or color-matched luggage offered by Givi.

To give the ZZR1200 the light-handling nature associated with sport-touring bikes, ball bearings are used in the steering head to maintain a light-steering feeling. Also, the lightweight swingarm is designed relatively low to improve traction. Kawasaki’s UNI-TRAK® rear suspension system produces progressive rates on the shock for an overall smooth ride. Bringing the ZZR1200 to a stop are opposed four-piston calipers, which grip 320mm dual-discs in the front, complemented by a 250mm rear disc brake.

Manual for the 2004-2005 Kawasaki ZZR1200

Maintenance Schedule Screenshot From Manual 2004-2005 Kawasaki ZZR1200.
User manual screenshot for the 2004-2005 Kawasaki ZZR1200

The above maintenance schedule comes directly from the user’s manual for the 2004-2005 Kawasaki ZZR1200, which is available here.

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