Kawasaki Model: ZX1200-B3H (2004) Utility Trailer User Manual


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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