Kawasaki ZRX1200S 2004 Maintenance Schedule
The 2004 Kawasaki ZRX1200S maintenance schedule below covers the manufacturer's recommended service intervals for oil, valve clearance, general maintenance, brake fluid, tires, coolant, drive chain maintenance, spark plugs and air filter. Intervals are shown in kilometres by default and can be switched to miles.
1164ccEngine size
34Maintenance items
Official manufacturer manual
Sourced from Kawasaki Motors Official Owner Center (Service Manual) (this document covers model years 2001–2004): kawasaki.com
Full schedule
| Task | Interval | Difficulty | Notes |
|---|---|---|---|
| Engine oil & filter change | Every 6,000 km (first at 1,000 km) · Every 6 months | Easy | Change engine oil. |
| Valve clearance check | Every 12,000 km · Every 24 months | Advanced | Inspect and adjust valve clearances. |
| Idle speed check | Every 12,000 km (first at 1,000 km) | Easy | Check idle speed. |
| Brake/clutch hoses and connections check | Every 6,000 km | Easy | Inspect brake and clutch hoses and connections (dealer item). |
| Brake light switch check | Every 6,000 km (first at 1,000 km) | Easy | Check front and rear brake light switch operation. |
| Brake pad wear check | Every 6,000 km | Easy | Inspect front and rear brake pad wear. |
| Brake/clutch fluid change | Every 24,000 km · Every 24 months · Replace every 24 months | Moderate | Replace brake and hydraulic clutch fluid. |
| Tire wear check | Every 6,000 km | Easy | Inspect tire tread depth and condition. |
| Oil filter replacement | Every 12,000 km (first at 1,000 km) | Easy | Replace engine oil filter. |
| Brake/clutch fluid level check | Every 6,000 km (first at 1,000 km) · Every 1 month | Easy | Check brake and hydraulic clutch fluid level. |
| Front fork oil leak check | Every 12,000 km | Easy | Inspect front fork for oil leakage. |
| Coolant replacement | Every 24,000 km · Every 24 months · Replace every 24 months | Moderate | Replace engine coolant. |
| Caliper piston seal and dust seal replacement | Every 48 months · Replace every 48 months | Advanced | Replace brake caliper piston seal and dust seal. |
| Drive chain lubrication | Every 600 km | Easy | Lubricate drive chain. |
| Drive chain slack check | Every 1,000 km | Easy | Check and adjust drive chain slack. |
| Carburetor synchronization check | Every 12,000 km | Moderate | Check and synchronize carburetors. |
| Throttle grip play check | Every 12,000 km (first at 1,000 km) | Easy | Check throttle grip free play. |
| Spark plug clean and gap | Every 6,000 km | Easy | Clean and re-gap spark plugs. |
| Air suction valve check | Every 6,000 km | Moderate | Inspect Kawasaki Clean Air (air suction) valve. |
| Air cleaner element clean | Every 12,000 km | Easy | Clean air cleaner element. |
| Evaporative emission control system check | Every 6,000 km (first at 1,000 km) | Moderate | Inspect evaporative emission control system (California models only). |
| Steering check | Every 6,000 km (first at 1,000 km) | Moderate | Check steering for looseness and smooth operation. |
| Drive chain wear check | Every 6,000 km | Easy | Inspect drive chain for wear/stretch. |
| Nuts, bolts and fastener tightness check | Every 12,000 km (first at 1,000 km) | Easy | Check tightness of chassis nuts, bolts, and fasteners. |
| Fuel hoses and connections check | Every 6,000 km | Moderate | Inspect fuel hoses and connections (dealer item). |
| General lubrication | Every 12,000 km | Easy | Perform general lubrication of controls, stands, and pivot points. |
| Front fork oil change | Every 24,000 km · Every 24 months · Replace every 24 months | Moderate | Replace front fork oil. |
| Rear shock absorber oil leak check | Every 12,000 km | Easy | Inspect rear shock absorber for oil leakage. |
| Swingarm pivot lubrication | Every 12,000 km | Moderate | Lubricate swingarm pivot bearings. |
| Radiator hoses and connections check | Every 6,000 km | Easy | Inspect radiator hoses and connections for leaks and deterioration. |
| Coolant filter clean | Every 12 months | Moderate | Clean coolant filter. |
| Steering stem bearing lubrication | Every 24,000 km · Every 24 months · Replace every 24 months | Moderate | Lubricate steering stem bearings. |
| Brake/clutch master cylinder cup and dust seal replacement | Every 48 months · Replace every 48 months | Advanced | Replace brake and clutch master cylinder cup and dust seal. |
| Clutch slave cylinder piston seal replacement | Every 48 months · Replace every 48 months | Advanced | Replace clutch slave cylinder piston seal. |
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Easy: basic tools, straightforward Easy–Moderate: varies by task — somewhere between the two Moderate: some mechanical know-how helps Advanced: specialized tools/skill, still DIY-doable Expert: significant experience required Professional: dealer or shop recommended
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