2004 Kawasaki ZRX1200R in green
Kawasaki ZRX1200 Specs…..
The Kawasaki ZRX1200 was a retro-styled muscle bike that was inspired by Eddie Lawson’s 1980s superbike and was manufactured from 2001 to 2005.
The ZRX1200 featured a 1,164cc inline-four engine producing around 122 horsepower and 82 lb-ft of torque, delivering strong midrange performance and a top speed near 150 mph.
The bike came in several variantions, including the ZRX1200R with a bikini fairing, the naked ZRX1200C and the partially faired ZRX1200S.
Need parts for your ZRX1200? Kawasaki ZRX 1200 used parts…
A little bit about the Kawasaki ZRX1200…..
Basic model info…
| Basic model info… | |
|---|---|
| Manufacturer: | Kawasaki |
| Model: | ZRX1200 |
| Model code: | ZR1200 |
| CC: | 1164cc |
| Engine type: | Inline 4 cylinder (4 stroke) |
| Years in production: | 2001 to 2007 |
| Style of bike: | Retro/muscle bike |
| Insurance: | Group 13 (of 17) |
| Preceded by: | Kawasaki ZRX1100 |
| Replaced by: | Kawasaki ZRX1200 DAEG (fuel injected – Japanese market only) |
Panoramic view of a 2004 ZRX1200R
Panoramic view of a 2004 ZRX1200R
Models, prices and years (in the UK)
| Models and years (in the UK) | |
|---|---|
| Note: The bike is referred to as the ‘ZR1200’ in the info below, the ‘ZR1200’ and ‘ZRX1200’ are the same bike (ZR1200 was the model code Kawasaki used for the ZRX1200). | |
| ZRX1200S | |
| ZR1200 B1 (Jan 2001 to Oct 2001)….. | |
| Frame number started: | |
| Description: | Half faired retro/muscle bike with a braced swinging arm, twin rear shocks, 43mm front forks and 3 spoke alloy wheels. |
| Available colours: | |
| Price (new): | £6595 |
| ZR1200 B2P (Nov 2001 to Oct 2002)….. | |
| Frame number started: | |
| Description: | Same as above model |
| Available colours: | Silver, red or blue |
| Price (new): | £6595 |
| ZR1200 B3P (Nov 2002 to Aug 2004)….. | |
| Frame number started: | |
| Description: | Same as above model. |
| Available colours: | |
| Price (new): | £6595 |
| ZRX1200R | |
| ZR1200 A1 (Jan 2001 till Oct 2001)….. | |
| Frame number started: | JKAZRT20AAA0000—– |
| Description: | Bikini/headlight faired retro/muscle bike with a braced swinging arm, twin rear shocks, 43mm front forks and 3 spoke alloy wheels and stepped dual seat. Retro style headlight fairing and looks inspired by Eddie Lawson’s bike. |
| Available colours: | |
| Price (new): | £6395 |
| ZR1200 A2P (Nov 2001 till Oct 2002)….. | |
| Frame number started: | JKAZRT20AAA0105—– |
| Description: | Same as above model. |
| Available colours: | |
| Price (new): | £6395 |
| ZR1200 A3P (Nov 2002 till Jan 2004)….. | |
| Frame number started: | |
| Description: | Same as above model. |
| Available colours: | |
| Price (new): | £6395 |
| ZR1200 A4H (Feb 2004 till Dec 2004)….. | |
| Frame number started: | |
| Description: | Same as above model with minor detail changes. |
| Available colours: | Green |
| Price (new): | £6395 |
| ZR1200 A5H (Jan 2005 till Oct 2005)….. | |
| Frame number started: | |
| Description: | Same as above model with a stainless steel exhaust. |
| Available colours: | |
| Price (new): | £6745 |
| ZR1200 A6F (Nov 2005)….. | |
| Frame number started: | |
| Description: | Same as above model. |
| Available colours: | |
| Price (new): | £6745 |
| ZR1200 A7F (2007 model)….. | |
| Frame number started: | |
| Description: | |
| Available colours: | |
| Price (new): | |
| ZR1200 A8F (2008 model)….. | |
| Frame number started: | |
| Description: | |
| Available colours: | |
| Price (new): | |
Engine and gearbox specs
2004 Kawasaki ZRX1200R engine
| Engine and gearbox specs….. | |
|---|---|
| Displacement: | 1164 cc |
| Engine type: | Inline 4 cylinder |
| Note: An inline-four cylinder engine (also known as a straight-four), is an engine where all four cylinders are arranged in a row using a single crankshaft. | |
| Stroke: | 4 stroke |
| Bore×Stroke: | 79×59.4mm |
| No. of cylinders: | 4 |
| Cam shaft configuration: | DOHC (double overhead cam) |
 Double overhead cams in an ER5 engine | |
| Note: The term ‘double overhead cams’ (or DOHC for short) refers to the layout and number of camshafts used in the engine. So ‘double overhead cam’ refers to 2 cam shafts situated in the top of the engine (as in the ER-5 engine pictured above). | |
| Compression ratio: | 10.1:1 |
| Cylinder compression pressure: | 9.1 to 14 bar (132 to 203 psi) |
| Valves: | 16 valve (4 per cylinder) |
| Spark plug: | NGK CR9EK (x4) |
| Spark plug gap: | 0.7 to 0.8mm |
| Spark plug torque: | 14nm |
| Spark plug socket size: | 16mm |
| Firing order: | 1 – 2 – 4 – 3 |
| Engine oil: | 10w40 API SG/JASO MA or higher |
| Note: You can use any grade oil in the ZRX1200 engine (mineral, semi synthetic or full synthetic). Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a semi synth as it’s a good balance between engine protection and price. More info… | |
| Engine oil capacity: | 3.0 litres (oil and filter change only) |
| Engine oil drain bolt location: | Bottom/underneath of the engine |
| Oil filter type: | Cartridge/paper type |
| Oil filter: | Hiflo HF401 / Filtrex OIF001 |
| Oil filter cover bolt torque: | 20nm |
| Cooling system: | Liquid cooled |
| Cooling system capacity: | 3 litres |
| Clutch: | Wet (oil immersed) multiplate clutch |
| Clutch operation: | Hydraulic |
| Gearbox: | 5 Speed manual (1st gear down, 2nd to 5th gears up, neutral between 1st and 2nd gears) |
| BHP: | 123 bhp |
| Torque: | 112nm (82.6ft/lb) |
| Top speed (claimed): | 155 mph |
| 0 to 60mph time (claimed): | 2.9 seconds |
| Quater mile time (claimed): | 11.4 seconds |
| Note: Top speed, 0-60 time, 1/4 mile time etc are all very APPROX!! as it’s not unusual for these figures to be slightly inflated by the manufacturer to help sell more bikes! It is also worth noting Kawasaki stated the top speed was tested on a flat road with no wind (and probably a rider who weighted slightly more then a cat!) 😀 | |
| Piston ring to cylinder bore clearance: | New: 0.010mm / Max 0.037mm |
| Valve clearance (inlet): | 0.13mm to 0.19mm (when cold) |
| Valve clearance (exhaust): | 0.18mm to 0.24mm (when cold) |
| Idle speed: | 1,100rpm (+/- 50) |
Panoramic view of a 2004 ZRX1200R with the bodywork removed
Panoramic view of a 2004 ZRX1200R with the bodywork/fairings removed
Final drive stuff
| Final drive stuff….. | |
|---|---|
| Final drive: | Chain |
| Front sprocket: | 17 teeth |
| Engine/chain sprocket nut tightening torque: | 127nm |
| Rear sprocket: | 42 teeth |
| Rear sprocket nuts tightening torque: | 59nm |
| Chain pitch/length: | 530 pitch / 110 links |
| Chain free play: | 15 to 25mm |
| Chain stretch limit: | 317.5 to 318.2mm over 20 links (max 323mm) |
| Chain lubrication: | Chain lube |
| How often should you lube the chain? Now repeat after me… ‘I MUST LUBE MY CHAIN LITTLE AND OFTEN!!’ 😀 | |
Top view of a ZRX1200
Top view of a 2004 ZRX1200R
Carb, fuel and oil stuff
Kawasaki ZRX 1200 Hiflo HF401 oil filter
| Carb, fuel and oil stuff….. | |
|---|---|
| Fuel system: | Carburetor |
| MPG (average): | 35 miles per gallon (very approx) |
| Fuel tank range (approx): | 125 miles |
| There are variations in MPG and tank range between users, mainly due to different riding styles and areas (e.g. city riding vs open road, weekend blast vs touring etc) | |
| Fuel tank capacity: | 19 litres |
| Fuel type: | Unleaded petrol (95 octane grade – aka standard petrol from your local garage) |
| Note: Yes, you can run the ZRX1200 on the newer E10 petrol, but MAKE SURE you drain all the E10 petrol from the tank and carbs if the bikes not being used (e.g. being stored up over winter). E10 grade fuel causes horrendous problems clogging up carb jets and moving parts when left for longer periods! More info… | |
| Carb make: | Keihin (4x) |
| Carb type: | CVK 36 |
| Pilot screw opening: | 2 1/4 (2 and a quarter) turns |
| Engine oil: | 10w40 API SG/JASO MA or higher |
| Note: You can use any grade oil in the ZRX1200 engine (mineral, semi synthetic or full synthetic). Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a semi synth as it’s a good balance between engine protection and price. More info… | |
| Engine oil capacity (if just changing the oil and filter): | 3.0 litres |
| Engine oil capacity (after a complete engine dismantle): | 3.5 litres |
| Engine oil drain bolt location: | Bottom/underneath of the engine |
| Engine oil drain bolt torque: | 20nm |
| Oil filter type: | Cartridge/paper type |
| Oil filter: | Hiflo HF401 / Filtrex OIF001 |
| Oil filter cover bolt torque: | 20nm |
ZRX1200 exhaust down pipes
Kawasaki ZRX1200R coils on the bike (part no: 21121-1268)
Kawasaki ZRX1200 CDI and fuse box under the seat
Electrical stuff
| Electric stuff….. | |
|---|---|
| Ignition type: | Electronic CDI |
| Starter: | Electric start |
| Electrical system voltage: | 12 volts |
| Battery voltage (fully charged): | 13 to 13.2 volts |
| Battery will need charging if below: | 12.6 volts |
| Regulated voltage (GPZ500 A – Up to Jan 1994): | 14 to 15 volts |
| Spark plug: | NGK CR9EK (x4) |
| Spark plug gap: | 0.7 to 0.8mm |
| Spark plug torque: | 14nm |
| Spark plug socket size: | 16mm |
| Note: If your not using a torque wrench, spark plugs should be tightened up to a half turn past finger tight. This means tighten up the plug by hand (being careful not to cross thread the pug into the cylinder head) and then tighten the plug a further half turn using a socket. | |
| Spark plug ignition: | 2 x coil |
| Battery location: | Under the seat, just below the airbox (More detailed info with pics…) |
| Battery type: | Sealed / maintenance free |
| Battery capacity: | 12 volts / 12 amp/hours (12v / 12ah) |
| Battery: | CTX14-BS / YTX14-BS / GTX14-BS |
| Notes: The YTX14-BS battery is a 12 volt, 12 amp/hour battery and is length: 150mm width: 87mm height: 145mm in size (more info…). The 1st letter(s) of the battery reference code are a manufacturers reference mark and may vary between different battery makes (different battery manufacturers use different 1st letters), so CTX14-BS, YTX14-BS and DTX14-BS (etc) are all the same battery just from different manufacturers (more info…). Also…… Avoid buying the cheapest of the cheap type batteries online as they have a horrendous failure rate (and they can be a bug!er to post back when it fails). | |
Kawasaki ZRX1200 battery (CTX14-BS).
Under the ZRX1200 seat showing the surprisingly large amount of storage space
ZRX1200 left side panel with the seat lock in the top/right corner
Eccentric chain adjusters on the ZRX 1200 swing arm
Shocks, brakes and wheels
| Shocks, brakes and wheel specs….. | |
|---|---|
| Front wheel type: | 3 spoke alloy wheel |
| Front tyre size: | 120/70-17 |
| Front tyre pressure: | 36psi (2.5 bar) |
| Recommended min tread depth: | 1mm |
| Front wheel spindle torque: | 127nm |
| Front wheel spindle clamp bolt torque: | 20nm |
| Rear wheel type: | 3 spoke alloy wheel |
| Rear tyre size: | 180/55-17 |
| Rear tyre pressure: | 36psi (2.5 bar) |
| Recommended min tread depth (up to 80mph): | 2mm |
| Recommended min tread depth (over to 80mph): | 3mm |
| Note: To pass an MOT in the UK the tyre must have at least 1mm of visible tread over 75% of the tyre and the tread must be continuous (so you can’t have 40% of the tyre on each side with good tread and a bald stripe in the middle! More info…). Also, tyres must not have any lump, bulge or tear caused by separation or partial failure of its structure and, although subject to the MOT testers discretion, tyres can fail because of age related cracking (depending on the severity).It’s worth noting most tyre manufacturers recommend changing the tyre once the tread depth is down to 2mm as once the tread gets below 2mm performance can be severely affected! | |
| Rear wheel spindle torque: | 98nm |
| Rear wheel spindle/swing arm clamp bolts: | 39nm |
| Front brake: | Twin hydraulic Tokico disc brakes with 6 piston calipers |
| Front brake caliper mounting bolt torque: | 34nm |
| Front brake disc: | 310mm floating disc. Part no: EBC MD4012X (2x) |
| Front brake pad: | EBC FA188 (2x) |
| Brake fluid (front): | DOT 4 brake fluid |
| Rear brake: | Single hydraulic disc brake with 2 piston caliper |
| Rear brake caliper mounting bolt torque: | 25nm |
| Rear brake disc: | 250mm single solid disc. Part no: EBC MD4133 (1x) |
| Rear brake pad: | EBC FA161 (1x) |
| Brake fluid (front): | DOT 4 brake fluid |
| Front suspension: | Telescopic forks |
| Front fork stanchion diameter: | 43mm |
| Recommended fork oil: | 10w fork oil |
| Fork oil volume (if just changing the fork oil): | 400ml (per fork) |
| Fork oil volume (after complete strip/rebuild): | 466 to 474ml (per fork) |
| Fork length: | 83cm |
| Rear Suspension: | Twin nitrogen filled shock absorbers with adjustable spring preload and 4-way compression/rebound damping |
Front and rear brake caliper on a 2004 ZRX1200 R
Kawasaki ZRX1200 front brake master cylinder
Weights, measures ‘n stuff
| Weights, measures ‘n stuff….. | |
|---|---|
| Overall length: | 2120mm |
| Overall width: | 780mm |
| Overall height: | Between 1095mm and 1230mm |
| Wheelbase: | 1,465mm |
| Seat height: | 790mm |
| Ground clearance: | 135mm |
| Dry weight (without oils/fluids etc): | Between 223kg and 227kg |
| Wet weight (with oils/fluids): | 247kg (very approx!) |
| Turning radius: | 2.7 meters |
ZRX1200 handlebar controls showing starter button, light and indicator controls
Useful torque settings
| Useful torque settings….. | |
|---|---|
| Camshaft cap bolts: | 12nm |
| Cylinder head cover bolts: | 10nm |
| Cylinder head bolts (6mm): | 10nm |
| Cylinder head bolts (10mm): | 41nm |
| Cylinder head bolts (11mm): | 57nm |
| Cylinder bolts (6mm): | 15nm |
| Chain tensioner mounting bolts: | 10nm |
| Chain Tensioner cap: | 20nm |
| Spark plugs: | 14nm |
| Front wheel spindle bolt: | 127nm |
| Front wheel spindle clamp bolts: | 20nm |
| Rear wheel spindle bolt: | 98nm |
| Rear wheel spindle/swing arm clamp bolts: | 39nm |
| Engine/chain sprocket nut: | 127nm |
| Rear sprocket nuts: | 59nm |
| Alternator mounting bolts: | 25nm |
| Camshaft sprocket: | 15nm |
| Clutch hub: | 135nm |
| Oil filter cover torque: | 20nm |
| Engine oil drain plug: | 20nm |
| Front brake caliper mounting bolts: | 34nm |
| Front brake disc mounting bolts: | 27nm |
| Rear brake caliper mounting bolts: | 25nm |
| Rear brake disc mounting bolts: | 27nm |
| Front fork yoke upper stanchion allen bolts: | 29nm |
| Front fork yoke lower stanchion allen bolts: | 21nm |
| Rear shock absorber upper bolts: | 29nm |
| Rear shock absorber lower bolts: | 21nm |
| Handlebar clamp bolts: | 25nm |
| Footpeg hanger bracket mounting bolts: | 34nm |
| Side stand bolt: | 44nm |
ZRX1200 rear suspension
Servicing stuff
| Service stuff….. | |
|---|---|
| Servicing your bike? You’ll need a workshop manual… | |
| Engine oil | |
| Engine oil change frequency: | Every 6,000km (approx 3,728 miles) or 6 months |
| Engine oil: | 10w40 API SG/JASO MA or higher |
| Engine oil capacity (if just changing the oil): | 2.7 litres |
| Engine oil capacity (if just changing the oil and filter): | 3.0 litres |
| Engine oil capacity (after a complete engine dismantle/rebuild): | 3.5 litres |
| Engine oil drain bolt location: | Bottom/underneath of the engine |
| Engine oil drain bolt: | 20nm |
| Engine oil drain bolt location: | Bottom/underneath of the engine |
| Oil filter type: | Cartridge/paper type |
| Oil filter: | Hiflo HF401 / Filtrex OIF001 |
| Oil filter cover bolt torque: | 20nm |
| Chain drive | |
| Chain lubrication: | Chain lube |
| How often should you lube the chain? Now repeat after me… ‘I MUST LUBE MY CHAIN LITTLE AND OFTEN!!’ 😀 | |
| Hydraulic brake system (front and rear) | |
| Brake fluid change frequency: | Change every 24 months or 24,000km (approx 14,912 miles) |
| Brake fluid: | DOT 4 brake fluid |
| Note: Brake fluid is hygroscopic (which means it absorbs moisture from the air) and becomes less effective over time. As the fluid absorbs more moisture it becomes less effective (because water compresses much more then brake fluid). Brake fluid goes yellow when it absorbs moisture (the darker the colour the more water it has absorbed), which is why it is almost clear when new. More info… | |
| Fork oil | |
| Front fork oil check: | 12,000km (approx 7,456 miles) or 24 months |
| Front fork oil change: | 24,000km (approx 14,912 miles) or 24 months |
| Recommended fork oil: | 10w fork oil |
| Fork oil volume (oil change only): | 400ml (per fork) |
| Fork oil volume (after strip/rebuild): | 466 to 474ml (per fork) |
| Cooling system | |
| Change every: | 20,000km (approx 12,427 miles) or 24 months |
| Cooling system: | Liquid cooled |
| Cooling system capacity: | 3 litres |
ZRX1200-R clocks showing the fuel gauge, speedo and rev counter
Frame number location
Frame number location…..
The frame number is usually stamped onto the right side of the headstock (the front part of the frame just below the handle bars).
ZRX1200 fusebox lid showing the fuse layout
Useless stuff…..
The Kawasaki ZRX1200 was produced from 2001 to 2007 (with a Japanese market only DAEG model until 2016) and is a retro-styled motorcycle that pays homage to the legendary Eddie Lawson Replica KZ1000R of the 1980s.
It was designed to offer modern performance while retaining a classic look and was available in either unfaired, semi faired (S model) or bikini faired (R model) variations.
The ZRX was designed for owners looking for a blend of character, style and raw power.
The ZRX1200 attracted riders who appreciate vintage looks but want modern reliability. Owners typically include seasoned riders and fans of retro superbikes. Many are former sportbike riders looking for something more comfortable without giving up speed and character.
The ZRX1200 enjoyed considerable popularity, especially the ‘R’ variant with its distinctive bikini fairing and green, Eddie Lawson colours, thanks to its nostalgic appeal and strong performance.
The engine, which was derived from the 1990’s ZZR1100 engine was known for its toughness, reliability and ability to handle high mileages.
While carbureted in most markets, the ZRX1200 DAEG in Japan had fuel injection and a six-speed transmission.
Despite the weight and size of the bike, riders often praised the surprising agility at speed and its impressive mid-range pull.
The bike was (is!) popular among customizers and many have been converted into cafe racers and streetfighters (personal note – for the love of god…. WHY?????).
Buying advice…..
Generally the ZRX1200 was a good, solid and reliable bike and often owned by older owners who looked after the bike and serviced it regularly.
All the usual stuff applies with bike buying though, check service history and make sure to HPI check it before buying and check the usual stuff older bikes suffer from, check the fork seals/stanchions, wheel and sprocket bearings, handle bar switches etc etc.
As far as we know, these bikes weren’t raced so ex race bikes shouldn’t be a problem.
However, these bikes are getting older now and, as with all bike, they do have a few weak points that should be checked before buying.
- Pre 2005 the ZRX came with mild steel exhaust systems which are likely to have rusted and been repaired by now (post 2005 Kawasaki used stainless steel exhausts).
- The standard rear shocks (the ‘piggyback’ ones) can wear out early so check carefully for leaks or a bouncy ride.
- The automatic cam chain tensioner was a weak point and was prone to failing, many owners upgraded to a manual one.
When you start the bike check for any cam chain noise which is likely to be a rattling, slapping, or clattering noise from the engine or noises from the clutch that might indicate something rubbing on it (we have seen this, the tesioner can cause massive damage to the clutch basket in extreme cases!)
- A very rare fault usually caused by excessive and heavy handed wheelies is cracks on the swing arm.
- In the unlikely event that it’s still got the original rubber brake and clutch hoses these will need replacing (although most will have been replaced by braided/metal hoses now)
- It’s also worth checking for a weak spark as this can be due to a blown resistor in the base of the ignition switch (not tested this, just something we’ve heard about)
Happy biking 🙂
ZRX1200 radiator
Sources / Thanks to / Useful sites:
Whitedogbikes – Yes, we measured the damn thing!
Rock oil for the servicing info
ZRX1200 article on Wikipedia
If you’ve got any questions, comments or suggestions please feel free to leave them below 🙂
Disclaimer: The information on this page is correct to the best of our knowledge. But the info should NOT be taken as 100% accurate as we can, occasionally make mistakes!
Leave a Reply