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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