Kawasaki ZR-7 and ZR-7S (1999-2005) Maintenance Schedule and Service Intervals

This is the maintenance schedule with associated service intervals for the Kawasaki ZR-7, also released in a fully faired version, the ZR-7S.

The Kawasaki ZR-7 was sold in the United States from 1999 through 2003 and sold in a few other countries through the 2005 model year.

The ZR-7 and the ZR-7S differs from fairing and associated headlight, instrument cluster, and stiffer fork springs, and of course overall weight.

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Maintenance Schedule for Kawasaki ZR-7S

Below is the maintenance schedule for the Kawasaki ZR-7S.

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 Kawasaki ZR-7S is broken into two sections: Emission Related, and Non-Emission Related.

Notes:

• For higher odometer readings, repeat at the frequency interval established here
• K: Should be serviced by an authorized Kawasaki dealer
• †: 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

	Operation	Every	800 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 valves – check †			•	•	•	•	•	•
	Air cleaner element — clean		•		•		•		•
	Air cleaner element — replace	5 cleanings					•
	Fuel system–check				•		•		•
	Cylinder head bolt tightness – check †		•		•		•		•
	Evaporative emission control system (c)–check †		•	•	•	•	•	•	•
	Non-Emission Related:
	Brake light switch — check †		•	•	•	•	•	•	•
	Brake pad wear– check † #			•	•	•	•	•	•
	Brake fluid level — check †	month	•	•	•	•	•	•	•
K	Brake fluid – change	2 years					•
	Clutch – adjust		•	•	•	•	•	•	•
K	Steering –check †		•	•	•	•	•	•	•
	Drive chain wear – check † #			•	•	•	•	•	•
	Nuts, bolts, and fasteners tightness — check †		•		•		•		•
K	Muffler, exhaust pipe mounting nuts and bolts tightness – perform †		•		•		•		•
	Tire wear–check †			•	•	•	•	•	•
	Engine oil–change #	year	•		•		•		•
	Oil filter–replace		•		•		•		•
	General Lubrication–perform			•	•	•	•	•	•
K	Swingarm pivot, uni-trak linkage — lubricate				•		•		•
K	Front fork oil – change								•
K	Steering stem bearing–lubricate	2 years					•
K	Brake master cylinder cup and dust seal–replace	2 years
K	Brake caliper piston seal and dust seal–replace	2 years
K	Brake hose –replace	4 years
K	Fuel hose–replace	4 years
	Drive chain – lubricate #	Every 600 km (400 mi)
	Drive chain slack – check † #	Every 1000 km (600 mi)

Tyre size and tyre pressure for the Kawasaki ZR-7 and ZR-7S

The Kawasaki ZR-7 has the following tyres and tyre sizes standard (tubeless type), and the following recommended tyre pressures.

Tyre	Size	Brand(s)	Tyre pressure
Front	120/70 ZR17 (58W)	BRIDGESTONE BT020F RADIAL J DUNLOP D220 F ST MICHELIN MACADAM 100X	250 kPa/36psi
Rear	160/60 ZR17 (69W)	BRIDGESTONE BT020 R RADIAL DUNLOP D220 ST MICHELIN MACADAM 100X	250 kPa/36psi

General information about the Kawasaki ZR-7 and ZR-7S

The Kawasaki ZR-7 and its sibling the ZR-7S are powered by an inline four-cylinder double-overhead-cam air-and-oil-cooled 738 cc engine, generating 57 kW and 63 ·m.

They use carburettors — four constant-velocity Keihin CVK 32 mm carbs. The final drive is via chain, and the transmission is a 5-speed (with positive neutral finder), coupled with a wet clutch.

The striking ZR-7 has the same appeal as the ZR-7S counterparts, but at a more affordable price and reduced dry weight.

On both motorcycles, the engine offers terrific smoothness and response, while the two-up seating, half-fairing, and available hard saddlebags (on the ZR-7S) make them as versatile as they are spirited.

The engine has a high capacity oil lubrication system to increase longevity, a 7-row oil cooler and special jets that squirt cooler oil to the undersides of the high-compression pistons.

They also use Kawasaki’s electronic throttle position sensor for exceptionally smooth throttle response: The system adjusts the digital ignition timing in relation to throttle, although fuelling is still by carburettor. The four-into-one polished stainless steel exhaust system adds performance and modern style to both motorcycles.

Kawasaki’s exclusive positive neutral finder makes finding neutral easy when the bike is stopped.

The advanced aerodynamic design of the frame-mounted, half-fairing, and windscreen delivers the twin benefits of great wind protection and terrific styling. Multi-reflector headlights produce a broad beam for clear night vision.

The analog instrumentation houses a centrally positioned tachometer.

Manual for the Kawasaki ZR-7S

The above maintenance schedule comes directly from the user’s manual for the 2001-2003 Kawasaki ZR-7S, which is available here.