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Kawasaki ZZR1200 (2002-2005) Maintenance Schedule and Service Intervals

Black Kawasaki ZZ-R1200 diagonal

This is the maintenance schedule with associated service intervals for the Kawasaki ZZ-R1200, which people often abbreviate to ZZR1200.

The ZZ-R1200 is a sport bike made between 2002-2005 and sold alongside the ZX-12R, and also serves as a successor to the ZX-11.

Unlike the ZX-12R, the ZZ-R1200 is carburettor-fed. The suspension is also a little softer, but given its age, adding newer springs, fresh fork oil, and valves to teh ZZ-R1200 should make it into a weapon.

Maintenance Schedule for Kawasaki ZZ-R1200

Below is the maintenance schedule for the Kawasaki ZZ-R1200.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

Notes:

  • For higher odometer readings, repeat at the frequency interval established here
  • K: Kawasaki suggests these 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
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 †
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 (CA only) –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)
Kawasaki ZZ-R1200 Maintenance Schedule

Tyre size and tyre pressure for the Kawasaki ZZ-R1200

The 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 Kawasaki ZZ-R1200

The ZZ-R1200 is a sports-tourer sibling to the ZX-12R.

It’s a similar kind of a bike — a high-speed tourer — but has carburettors and simpler front suspension, as well as a more comfortable riding position.

The engine is still a liquid-cooled, DOHC, four-stroke inline-four engine with 1,164 cc of capacity. The ZZ-R 1200 can produce rear-wheel horsepower of 145 hp — it’s no slouch! In fact, it’s considered the most powerful motorcycles ever made with carbureted induction.

Kawasaki engineers based the ZZR1200’s engine after the one in the 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 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 Kawasaki ZZ-R1200

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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