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2004 Kawasaki ZRX1200 Maintenance Schedule and Service Intervals

2004 Kawasaki ZRX1200 Stock Image

This is the maintenance schedule with associated service intervals for the 2004 Kawasaki ZRX1200.

The Kawasaki ZRX1200 is part of the Kawasaki Z series manufactured in Japan from 2001 until 2007. It was sold in the US until 2005 and Europe until 2007. It was updated in 2008 with a six-speed transmission, fuel injection and still sold in Japan as the ZRX1200 DAEG model until 2016 Worldwide, the ZRX1200 was available in three guises: “S” which was partially faired; “R” which had a bikini fairing; “N” which had no fairing.

The Kawasaki ZRX1200 features a liquid-cooled 1164cc inline 4-cylinder engine. Induction comes through four 36mm Keihin Constant Velocity carburetors. The exhaust system is a 4-into-1 stainless steel unit. The exhaust system on models produced up to 2004 are painted black, with the exception of the muffler, models produced from 2004-onwards are equipped with polished exhaust systems.

Maintenance Schedule for 2004 Kawasaki ZRX1200

Below is the maintenance schedule for the 2004 Kawasaki ZRX1200.

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 – clean † # (e)
Evaporative emission control system (c) (e) –check †
KBrake/clutch hoses, connections – check †
Brake light switch — check †
Brake pad wear– check † #
Brake/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
Brake/clutch fluid level – check †month
KFuel hoses, connections – check †
General Lubrication–perform
KFront fork oil–change2 years
Front fork oil leak – check †
Rear shock absorber oil leak – check †
KSwingarm pivot — 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
Drive chain – lubricate #Every 600 km (400 mi)
Drive chain slack – check † #Every 1000 km (600 mi)
KClutch slave cylinder piston seal – replace4 years

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
(e) Emission related item

Tyre size and tyre pressure for the 2004 Kawasaki ZRX1200

The 2004 Kawasaki ZRX1200 has the following tyres and tyre sizes standard (tubeless type):

Front:

  • 120/70 ZR17 (58W)
  • BRIDGESTONE BATTLAX BT020F RADIAL L
  • DUNLOP D220F ST
  • MICHELIN Pilot SPORT

Rear:

  • 180/55 ZR17 (73W)
  • BRIDGESTONE BATTLAX BT020R RADIAL L
  • DUNLOP D220 ST
  • MICHELIN Pilot SPORT

The manual for the 2004 Kawasaki ZRX1200 recommends the following tyre pressures (when cold):

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

General information about the 2004 Kawasaki ZRX1200

The Kawasaki ZRX1200 features a liquid-cooled 1164cc inline 4-cylinder engine. Induction comes through four 36mm Keihin Constant Velocity carburetors. The exhaust system is a 4-into-1 stainless steel unit. Large 43mm cartridge-type conventional front fork features 12-way compression and rebound damping adjustment.

The frame is conventional steel tube with the engine supported in a removable cradle. The suspension configuration is similar to that found on a UJM. The laydown rear shocks, designed with a built-in remote reservoir, are adjustable for preload and damping. The front suspension consists of conventional forks with adjustable damping preload. The reinforced swing arm was designed to mimic the modified/aftermarket swing arms.

Full handlebars made of tubular aluminum are utilized. For comfort, the saddle contains more than one centimeter of padding between the seat covering and the pan. Foot pegs are position reminiscent of the classic Universal Japanese Motorcycle (UJM). Available in colors Candy Lime Green/Galaxy Silver, Candy Lightning Blue/Galaxy Silver.

Manual for the 2004 Kawasaki ZRX1200

Maintenance Schedule Screenshot From Manual 2004 Kawasaki ZRX1200.
User manual screenshot for the 2004 Kawasaki ZRX1200

The above maintenance schedule comes directly from the user’s manual for the 2004 Kawasaki ZRX1200, which is available here.

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