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.
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.
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 ZZR600 Gen 2 is broken into two sections: Emission Related, and Non-Emission Related.
- 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.
- (c): California model only
- #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
|Operation||Every||1000 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 (c)–check †||•||•||•||•||•||•||•|
|K||Brake hose, connections – check †||•||•||•||•||•||•|
|Brake light switch — check †||•||•||•||•||•||•||•|
|Brake pad wear– check † #||•||•||•||•||•||•|
|Brake fluid level — check †||month||•||•||•||•||•||•||•|
|K||Brake fluid — change||2 years||•|
|K||Fuel hose, connections – check †||•||•||•||•||•||•|
|K||Steering –check †||•||•||•||•||•||•||•|
|Drive chain wear–check † #||•||•||•||•||•||•|
|Nuts, bolts, and fasteners tightness — check †||•||•||•||•|
|Tire wear–check †||•||•||•||•||•||•|
|Engine oil–change #||6 months||•||•||•||•||•||•||•|
|K||Front fork oil–change||2 years||•|
|Front fork oil leak – check †||•||•||•|
|Rear shock absorber oil leak – check †||•||•||•|
|K||Swingarm pivot – lubricate||•||•||•|
|Radiator hoses, connections–check †||•|
|K||Steering stem bearing–lubricate||2 years||•|
|K||Brake master cylinder cup and dust seal–replace||4 years|
|K||Caliper piston seal and dust seal–replace||4 years|
|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 Gen 2
The Kawasaki ZZR600 Gen 2 has the following tyres and tyre sizes standard (tubeless type), as well as the following recommended tyre pressures:
|Front||120/65 ZR17 M/C (56W)||DUNLOP “D207F”|
BRIDGESTONE BT010F RADIAL
“PILOT SPORT M”
|250 kPa/36 psi|
|Rear||180/55 ZR17 M/C (73W)||DUNLOP “D207T”|
BRIDGESTONE BT010R RADIAL G
“PILOT SPORT M”
|290 kPa/41 psi|
General information about the Kawasaki ZZR600 Gen 2
A 599cc, liquid-cooled, inline, four-cylinder engine with dual overhead cams and four valves per cylinder is the core of the ZZR600 its lively performance. Further enhancing the engine is Kawasaki’s Twin Ram Air Induction system, which takes in cool air via its leading-edge air scoop on the fairing front and forces it to the ZZR600’s airbox and then into its four 36mm carburetors. The carburetors also feature the Kawasaki 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, maximizing the power at every rpm.
The high-tech engine is mated to a close-ratio six-speed transmission, providing the ZZR600 rider with the best gear for any riding situation, from freeway droning to handling some back road twisties. That excellent handling comes from the ZZR600’s chassis, a lightweight aluminum perimeter frame combined with a fully adjustable 46mm cartridge-type front fork and fully adjustable UNI-TRAK® rear suspension. Stopping power is provided by six-piston calipers gripping dual 300mm semi-floating front disc brakes and a 220mm rear disc brake.
The simple, sleek lines of the ZZR600’s aerodynamic bodywork strike an elegant-but-athletic balance with the combination of its aluminum frame, angled front fairing, performance-enhancing air scoop, and three-spoke wheels. Superbly matching this function to form, the ZZR600 makes long-distance rides a pleasure with a stepped flat seat, bars that are easy to reach, and wide mirrors that provide an exceptional view. The entirely electronic ZZR600 instrument cluster includes a speedometer, tachometer, coolant temperature gauge, odometer, trip meter, and a digital clock.
Manual for the 2005-2008 Kawasaki ZZR600
The above maintenance schedule comes directly from the user’s manual for the 2005-2008 Kawasaki ZZR600, which is available here.