Kawasaki Model: ZX1200-B3H (2004) - Manual
Kawasaki Model: ZX1200-B3H (2004) – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.
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
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)
Fuel system
Throttle grip free play
2 ~ 3 mm
Idle speed
1 000 ± 50 r/min
Engine vacuum at idle speed
26 ± 1.3 kPA (195 ± 10mmHg)
Coolant
Capacity
3.6 L
Clutch
Clutch lever free play
2 ~ 3 mm
Valve clearance
Exhaust
0.22 ~ 0.31 mm
Inlet
0.15 ~ 0.24 mm
Tyre size
Front
120/70 ZR17
Rear
200/50 ZR17
Tyre pressure
Front
290 kPa (2.90 kgf/cm², 42 psi)
Rear
290 kPa (2.90 kgf/cm², 42 psi)
Final drive
Drive chain slack
25 ~ 35 mm
Drive chain wear service limit (20-link length)
323 mm
Brakes
Brake fluid
DOT4
Brake pad lining thickness service limit
1 mm
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
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