Kawasaki Utility Trailer Model 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  
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  
1 000 ± 50 r/min  
26 ± 1.3 kPA (195 ± 10mmHg)  
3.6 L  
Idle speed  
Engine vacuum at idle speed  
Coolant  
Capacity  
Clutch  
Clutch lever free play  
2 ~ 3 mm  
Valve clearance  
Exhaust  
0.22 ~ 0.31 mm  
0.15 ~ 0.24 mm  
120/70 ZR17  
Inlet  
Tyre size  
Front  
Rear  
200/50 ZR17  
Tyre pressure  
Final drive  
Front  
290 kPa (2.90 kgf/cm², 42 psi)  
290 kPa (2.90 kgf/cm², 42 psi)  
25 ~ 35 mm  
Rear  
Drive chain slack  
Drive chain wear service limit (20-link length)  
Brake fluid  
323 mm  
Brakes  
DOT4  
Brake pad lining thickness service limit  
Spark plug gap  
1 mm  
Electrical system  
0.7 ~ 0.9 mm  
Torque (Only key torque figures are listed - refer to the service manual for others)  
20 Nm  
31 Nm  
10 Nm  
12 Nm  
127 Nm  
34 Nm  
34 Nm  
15 Nm  
25 Nm  
20 Nm  
20 Nm  
34 Nm  
Engine oil drain bolt  
Oil filter  
78 Nm  
13 Nm  
59 Nm  
25 Nm  
44 Nm  
34 Nm  
127 Nm  
20 Nm  
59 Nm  
34 Nm  
127 Nm  
98 Nm  
Steering stem head nut  
Spark plug  
Cylinder head cover bolts  
Camshaft cap bolts  
Engine mounting bolts and nuts (M12)  
Engine mounting bolts and nuts (M8)  
Engine mounting bracket bolts (M10)  
Muffler body connection nuts  
Front axle  
Rear axle nut  
Brake hose banjo bolts  
Front caliper mounting bolts  
Front brake pad pins  
Rear caliper mounting bolts  
Front fork clamp bolts (upper)  
Front fork clamp bolts (lower)  
Handlebar bolts  
Front axle clamp bolts  
Rear shock absorber bracket nut  
Rear shock absorber nuts  
Swingarm pivot shaft nut  
Swingarm pivot adjusting collar locknut  
Service Parts  
Notes  
Oil filter  
16097-0004  
92065-097  
11013-0005  
92070-1254  
43082-0030  
43082-1257  
550D4040  
x 1  
x 1  
x 2  
x 4  
x 2  
x 1  
x 1  
x 1  
x 4  
Oil drain bolt gasket  
Air cleaner element  
Spark plug (CR9EKPA)  
Front brake pads  
Rear brake pads  
Rear axle cotter pin  
Cylinder head cover gasket  
Spark plug hole gasket  
11061-0090  
11061-0105  
 

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