Kawasaki ZX1200-B3H 2004 User Manual

Motorcycle Service Data Sheet Model: ZX1200-B3H (2004)

This sheet is intended as a quick reference guide for technicians and service booking staff. Please use it together with the service checklist and refer to the service manual as needed.

Service Data

Engine oil Type API SE, SF or SG or API SH or SJ with JASO MA

Fuel system Throttle grip free play 2 ~ 3 mm

Coolant Capacity 3.6 L Clutch Clutch lever free play 2 ~ 3 mm Valve clearance Exhaust 0.22 ~ 0.31 mm

Tyre size Front 120/70 ZR17

Tyre pressure Front 290 kPa (2.90 kgf/cm², 42 psi)

Final drive Drive chain slack 25 ~ 35 mm

Brakes Brake fluid DOT4

Electrical system Spark plug gap 0.7 ~ 0.9 mm

Torque (Only key torque figures are listed - refer to the service manual for others)

20 Nm Engine oil drain bolt 78 Nm Steering stem head nut 31 Nm Oil filter 13 Nm Spark plug 10 Nm Cylinder head cover bolts 59 Nm Engine mounting bolts and nuts (M12) 12 Nm Camshaft cap bolts 25 Nm Engine mounting bolts and nuts (M8)

127 Nm Rear axle nut 44 Nm Engine mounting bracket bolts (M10)

34 Nm Brake hose banjo bolts 34 Nm Muffler body connection nuts 34 Nm Front caliper mounting bolts 127 Nm Front axle 15 Nm Front brake pad pins 20 Nm Front axle clamp bolts 25 Nm Rear caliper mounting bolts 59 Nm Rear shock absorber bracket nut 20 Nm Front fork clamp bolts (upper) 34 Nm Rear shock absorber nuts 20 Nm Front fork clamp bolts (lower) 127 Nm Swingarm pivot shaft nut 34 Nm Handlebar bolts 98 Nm Swingarm pivot adjusting collar locknut

Service Parts Notes

Oil filter 16097-0004 x 1 Oil drain bolt gasket 92065-097 x 1 Air cleaner element 11013-0005 x 2 Spark plug (CR9EKPA) 92070-1254 x 4 Front brake pads 43082-0030 x 2 Rear brake pads 43082-1257 x 1 Rear axle cotter pin 550D4040 x 1 Cylinder head cover gasket 11061-0090 x 1 Spark plug hole gasket 11061-0105 x 4

Viscosity SAE 10W-40 Capacity (when filter is not removed) 2.5 L Capacity (when filter is removed) 2.8 L Oil Level Between upper and lower level lines (wait 2 ~ 3 minutes after idling or running)

Idle speed 1 000 ± 50 r/min Engine vacuum at idle speed 26 ± 1.3 kPA (195 ± 10mmHg)

Inlet 0.15 ~ 0.24 mm

Rear 200/50 ZR17

Rear 290 kPa (2.90 kgf/cm², 42 psi)

Drive chain wear service limit (20-link length) 323 mm

Brake pad lining thickness service limit 1 mm

Motorcycle Service Checklist Model: ZX1200-B3H (2004)

Each scheduled service should be done in accordance with the Periodic Maintenance Chart in the owner's manual or relevant service manual. Refer to the Periodic Maintenance chapter in the service manual for detailed procedures. This check list should be issued to the customer and a copy kept for dealer records if required.

Customer Name

Inspection

Engine oil - change 6 months Oil filter - replace Valve clearance - inspect / adjust Air cleaner element - replace Spark plug - inspect Throttle control system - inspect Idle speed - inspect Engine vacuum synchronisation - inspect / adjust Fuel hose and pipe (condition, leakage, damage and installation) - inspect Cooling system (level, leakage, hose installation and condition) - inspect Air suction system - inspect Clutch operation / adjustment - inspect Wheel and tyre (condition, wear, damage and pressure) - inspect Drive chain and guide - inspect / lubricate / adjust Brake system (operation, fluid level, pad wear, hoses and light) - inspect Front forks / rear shock absorber oil leak and operation - inspect Rear suspension rocker arm and tie-rod operation - inspect Swingarm pivot and Uni-Trak linkage - lubricate Steering play - inspect Steering stem bearings - lubricate 2 Years Chassis parts - lubricate Bolts, nuts, fasteners tightness - inspect Brake fluid - change 2 Years Coolant - change 2 Years Front fork oil - change 2 Years Brake master cylinder and caliper seals - replace 4 Years / 30 000 Miles

Other work carried out (please specify) - Remind the customer to fill in the

Frequency Which ever comes

VIN

Every

first

REG

- - - - - - -

600

Miles

4 000 Miles

7 500 Miles

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12 000

Miles

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MILES

15 000

Miles

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20 000

Miles

24 000

Miles

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Retail Satisfaction Programme survey (www.kawasaki.co.uk).

Labour time

Dealer Stamp ATTENTION REQUIRED (Advice only)

Service Sign-off

Technician Name: Signature: Date:

Brakes: Suspension: Chassis: Final Drive: Electrical: Wheels / Tyres: Engine: Other:

Mileage: Date:

Next Service Due