Kawasaki ZX-6 and ZZR600 Gen 1 (1990-2004) Maintenance Schedule and Service Intervals

This is the maintenance schedule with associated service intervals for the Kawasaki ZZR600, previously (or in other markets) known as the ZX-6.

The Kawasaki ZZR600 (ZX-6) was a sports motorcycle, later re-classified as a sports-touring motorcycle. It was Kawasaki’s flagship 600cc until the ZX-6R was released in 1995.

In Europe, the model was always known as the ZZR600, but in some other markets, it was renamed from the ZX-6 to the ZZR600.

From 2005, the ZZR600 evolved slightly, taking on the engine from the earlier generation ZX-6R.

Maintenance Schedule for Kawasaki ZZR600 Gen 1 (1990-2004)

Below is the maintenance schedule for the first generation 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.

Notes:

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

The maintenance for the Kawasaki ZZR600 is broken into two sections: Emission Related, and Non-Emission Related.

	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 valve — check †			•	•	•	•	•	•
	Air cleaner element and air vent filter–clean		•		•		•		•
	Air cleaner element and air vent filter–replace	5 cleanings					•
	Fuel system–check				•		•		•
	Evaporative emission control system (c)–check †		•	•	•	•	•	•	•
	Non-Emission Related:
K	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 †		•		•		•		•
	Tire wear–check †			•	•	•	•	•	•
	Engine oil–change	year	•		•		•		•
K	Oil filter–replace		•		•		•		•
	General Lubrication–perform			•	•	•	•	•	•
K	Front fork oil–change								•
K	Swingarm pivot, uni-trak linkage — lubricate				•		•		•
K	Coolant–change	2 years							•
	Radiator hoses, connections–check †	year	•		•		•		•
K	Steering stem bearing–lubricate	2 years					•
K	Master cylinder cup and dust seal–replace	2 years
K	Caliper piston seal and dust seal–replace	2 years
K	Brake hose–replace	4 years
K	Fuel hose–replace	4 years
K	Brake hoses, connections – check †			•	•	•	•	•	•
K	Fuel hoses, connections – check †			•	•	•	•	•	•
	Drive chain–lubricate #	Every 600 km (400 mi)
	Dive chain slack–check † #	Every 1000 km (600 mi)

Tyre size and tyre pressure for the Kawasaki ZZR600

The Kawasaki ZZR600 has the following tyres and tyre sizes standard (tubeless type), plus the following recommended tyre pressures when cold.

Tyre	Size	Brand(s)	Tyre pressure
Front	120/60 ZR17 (55W)	BRIDGESTONE BT-50F RADIAL MICHELIN A89X PIRELLI MTR01 METZLER MEZ1 Front	250 kPa/36 psi
Rear	160/60 ZR17 (69W)	BRIDGESTONE BT-50R RADIAL G MICHELIN M89X PIRELLI MTR02 METZLER MEZ1	290 kPa/41 psi

General information about the 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 Kawasaki ZZR600

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