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Kawasaki ZZR600 Gen 2 (2005-2008) Maintenance Schedule and Service Intervals

2008 Blue Kawasaki ZZR600

This is the maintenance schedule with associated service intervals for the 2005-2008 Kawasaki ZZR600 Gen 2.

The Kawasaki ZZR600 was a sports bike and later a sport-touring motorcycle. The ZX-6/ZZR600 series motorcycle was Kawasaki’s flagship 600 cc model from 1990 to 1994, before the ZX-6R came along. In Europe, the bike was always known as the ZZR600.

The 2005-2008 Kawasaki ZZR600 Gen 2 was a US re-issue of the earlier ZX-6R sportbike. It’s powered by a 599cc liquid-cooled four-cylinder engine that has dual overhead cams and four valves per cylinder. The engine is fed by four Keihin CVKD carburettors and puts power down via a six-speed transmission and a chain drive.

From 2005 to 2008, the ZZR600 got the engine from the 2004 ZX-6R. The earlier model 1990-2004 ZZR600 was a stand-alone motorcycle.

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Maintenance Schedule for 2005-2008 Kawasaki ZZR600 Gen 2

Below is the maintenance schedule for the Kawasaki ZZR600 Gen 2. It’s adapted and simplified from the manual, removing some regulatory details and condensing it all into one table.

Below are the major service intervals for the ZZR600.

Service typeService itemsService interval
Oil change service interval* Change oil
* Check spark plug
* Check all fluids and exterior items to lubricate (see table for detail)
* 4000 mi / 6000 km
* 6 months (for oil only)
Major service interval* Check valve clearance
* Check / Change air filter
* Sync carbs
* Other minor service items (see table for detail)
* Tighten bolts/fasteners
* Lubricate everything
8000 mi / 12000 km
Other major services* Change coolant
* Change brake fluid
* Change brake system parts
* Change fork oil
2-4 years, see schedule
Major service intervals for the Kawasaki ZZR600

Notes:

  • For higher odometer readings, repeat at the frequency interval established here
  • Where there is a distance-based or time-based interval, follow the earlier of the two.
  • †: Replace. add. adjust, or torque if necessary.
km x 100061218243036
mi x 10004812162024Every
Engine oil – change6 months
Oil filter – replace
Spark plug – clean and gap
Valve clearance – check
Air cleaner element and air vent filter – clean / replaceMore often in dust/wet conditions
Carburetor synchronization – check
Idle speed – check
Throttle grip play – check
Air suction valve – check
Evaporative emission control system (if fitted)) – check
Brake hose, connections – check
Brake light switch – check
Brake pad wear – checkMore often when frequently starting/stopping
Brake fluid level – checkmonth
Brake fluid – change2 years
Fuel hose, connections – check
Clutch – adjust
Steering – check
Drive chain wear – checkMore often when frequently starting/stopping
Nuts, bolts, and fasteners tightness – check
Tire wear – check
General Lubrication – perform
Front fork oil – change2 years
Front fork oil leak – check
Rear shock absorber oil leak – check
Swingarm pivot – lubricate
Coolant – change2 years
Radiator hoses, connections – check
Steering stem bearing – lubricate2 years
Brake master cylinder cup and dust seal – replace4 years
Caliper piston seal and dust seal – replace4 years
Drive chain – lubricate400 mi / 600 km, more often when driving in wet/dirty conditions
Dive chain slack – check600 mi / 1000 km, more often when riding aggressively
Kawasaki ZZR600 Maintenance Schedule

Tyre size and tyre pressure for the Kawasaki ZZR600 Gen 2

The Kawasaki ZZR600 Gen 2 has the following tyre sizes standard (tubeless type), as well as the following recommended tyre pressures:

TyreSizeTyre pressure
Front120/65 ZR17 M/C (56W)250 kPa / 2.5 bar / 36 psi
Rear180/55 ZR17 M/C (73W)290 kPa / 2.9 bar / 41 psi
Tyres and tyre pressures

Originally, the ZZR600 / ZX-6 shipped with Dunlop D207T, Bridgestone BT010R, or Michelin Pilot Sport tyres — all street sport tyres. These days, a sport touring tyre would be a good choice, unless this were your dedicated track bike.

General information about the Kawasaki ZZR600 Gen 2

Kawasaki ZZR600 ZX-6 brochure photo

The Kawasaki ZZR600 from 2005-2008 is part of a small but popular class of sports motorcycles — high-powered but comfortably positioned middleweight sports bikes.

The class succumbed to the “naked” sportbike, which is essentially the same concept of bike sans fairing. But it’s still popular and is seeing a resurgence, e.g. in the 2021 Aprilia RS 660 — albeit these days with fewer cylinders.

The Kawasaki ZZR600 / ZX-6 is powered by a 599cc, liquid-cooled inline,four-cylinder engine with dual overhead cams and four valves per cylinder.

It’s fed by four 36mm carburettors, and further enhanced by Kawasaki’s Twin Ram Air induction, which forces air into the carbs via a scoop on the fairing’s front.

Before the effect of ram air, the engine is rated at 73 kW (93 bhp) at 11500 rpm, or 64 Nm (47 lb-ft) at 9500 rpm — very sporty!

The carburettors on the Kawasaki ZZR600 Gen 2 also have Kawasaki’s “Throttle Responsive Ignition Control” (K-TRIC), which monitors the throttle position and adjusts the ignition timing for the engine’s four spark-plug mounted ignition coils.

The final drive is via a sporty close-ratio six-speed transmission.

The suspension is where it becomes clear that the ZZR600 is no ordinary commuter. The front suspension is via 46m cartridge (conventional, non-inverted) forks that are fully adjustable for preload, compression damping, and rebound damping.

The rear shock is via a UNI-TRAC rear linkage with ride height adjustment and 20-way compression and rebound damping.

Braking is also sportbike spec, with 300 mm discs and six-piston calipers.

The functional but sleek lines of the Kawasaki ZZR600 Gen 2’s bodywork strike a really elegant balance between sporty and everyday comfort — quite like Kawasaki’s more sedate Ninja 650.

It makes everyday riding a pleasure, but the suspension and engine let you wind it up when roads become interesting or when you want to take it for a track day.

The ZZR600 Gen 2 has a fully electronic dash — quite modern for its time! — with a speedometer, tachometer, temperature gauge, odometer, trip meter, and digital clock. (The temp gauge and fuel meter aren’t on every motorcycle, but appeared in later years.)

Kawasaki ZZR600 instrument cluster without fuel gauge
Instrument cluster for early ZZR-600 without fuel / temp gauge

Reference — Manual for the 2005-2008 Kawasaki ZZR600

The above maintenance schedule is adapted from the user’s manual for the 2005-2008 Kawasaki ZZR600. There were no changes in this period.

Kawasaki ZZR600 Gen 2 2005-2008 Maintenance schedule
User manual screenshot for the 2005-2008 Kawasaki ZZR600

You can access the manual here.

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