No photo of this model in the library yet.

Have this bike? Send a photo or the manual's service chart

Kawasaki · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, shaft drive

Voyager XII (1196 cc)

Library entry covers 1998-2001

35 factory 29 guideline

Published source

Kawasaki 2003 Voyager XII ZG1200-B17 Owner's Manual 99987-1105 (US, English), Periodic Maintenance Chart pp.88-90

Factory owner's handbook. Covers ZG1200-B17 Voyager XII; 2003 US owner's manual 99987-1105, English. Chart columns 800/5,000/10,000/15,000/20,000/25,000/30,000 km (500/3,000/6,000/9,000/12,000/15,000/18,000 mi) plus 'Every' column, whichever comes first; for higher odometer readings repeat at the frequency interval established. K = should be serviced by an authorized Kawasaki dealer; dagger = replace, add, adjust, or torque if necessary; (C) = California model only. Chart is split into Emission Related and Non-Emission Related sections. Catalog row 1998-2001; the 2003 ZG1200-B17 manual is the same ZG1200B model family (the 2001 ZG1200-B15 manual 99920-1983-01 is refused by the viewer). Liquid cooled, carbureted, shaft final drive.

64 items for a 2001 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Shaft
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2001 Kawasaki Voyager XII (1196 cc)

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 5,000 km or 1 month

1 item

Brake/clutch fluid level - check

Brakes

Factory

Factory: Every: month; Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary (p.89)

Every 5,000 km or 12 months

5 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km

13 items

Air suction valve - check

Engine

Factory

Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
General lubrication - perform

Engine

Factory

Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial (p.89)
Idle speed - check

Engine

Factory

Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug - clean and gap. Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart; no replacement interval printed (p.88)
Air cleaner oil drain reservoir - check

Fuel and air

Factory

Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi) (p.90)
Fuel hoses connections - check

Fuel and air

Factory

Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; dagger: replace, add, adjust, or torque if necessary; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.88)
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor synchronization - check. Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering - check. Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.89)
Brake light switch - check

Brakes

Factory

Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary (p.88)
Brake/clutch hoses connections - check

Brakes

Factory

Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; no dagger mark; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.88)
Check brake pads and discs

Brakes

Factory

Manual: Brake pad wear - check. Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; dagger: replace, add, adjust, or torque if necessary (p.88)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire wear - check. Factory: Marked 5000-30000 km (3000-18000 mi); not at 800 km initial; dagger: replace, add, adjust, or torque if necessary (p.89)
Evaporative emission control system - check (California model only)

Controls and cables

Factory

Factory: Every column incl. 800 km (500 mi) initial, then every 5000 km (3000 mi); dagger: replace, add, adjust, or torque if necessary; (c) California model only; in the Emission Related section of the chart (p.88)

Every 6,500 km or 12 months

1 item

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 9,500 km or 12 months

7 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check final drive for leaks and bearing play

Final drive

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km or 12 months

2 items

Change engine oil

Engine

Factory

Manual: Engine oil - change. Factory: Every: year; Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi) (p.89)
Inspect coolant hoses and clamps

Engine

Factory

Manual: Radiator hoses, connections - check. Factory: Every: year; Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); dagger: replace, add, adjust, or torque if necessary (p.89)

Every 10,000 km

8 items

Check cylinder head bolt torque

Engine

Factory

Manual: Cylinder head bolt tightness - check. Factory: Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
Final gear case oil level - check

Engine

Factory

Factory: Marked at 10000, 20000, 30000 km (6000, 12000, 18000 mi); not at 800 km; dagger: replace, add, adjust, or torque if necessary (p.89)
Nut, bolt, and fastener tightness - check

Engine

Factory

Factory: Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); dagger: replace, add, adjust, or torque if necessary (p.89)
Replace oil filter

Engine

Factory

Manual: Oil filter - replace. Factory: Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); no K mark; no Every entry (p.89)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip play - check. Factory: Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - clean. Factory: Marked at 800, 10000, 20000, 30000 km (500, 6000, 12000, 18000 mi); no dagger mark; in the Emission Related section of the chart; no air cleaner replacement row printed (p.88)
Fuel system - check

Fuel and air

Factory

Factory: Marked at 10000, 20000, 30000 km (6000, 12000, 18000 mi); not at 800 km; dagger: replace, add, adjust, or torque if necessary; in the Emission Related section of the chart (p.88)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm pivot - lubricate. Factory: Marked at 10000, 20000, 30000 km (6000, 12000, 18000 mi); not at 800 km; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.89)

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 20,000 km or 2 years

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearing - lubricate. Factory: Every: 2 years; single mark at 20000 km (12000 mi); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)
Replace brake fluid

Brakes

Factory

Manual: Brake/clutch fluid - change. Factory: Every: 2 years; single mark at 20000 km (12000 mi); covers brake and clutch fluid; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.89)

Every 20,000 km

1 item

Lubricate drive shaft splines / check U-joint

Final drive

Factory

Manual: Propeller shaft joint - lubricate. Factory: Marked at 10000 and 30000 km (6000 and 18000 mi); spacing 20000 km (12000 mi); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.89)

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 30,000 km or 2 years

1 item

Replace coolant

Engine

Factory

Manual: Coolant - change. Factory: Every: 2 years; single mark at 30000 km (18000 mi); not a K item (p.89)

Every 30,000 km

2 items

Change final drive (rear drive) oil

Final drive

Factory

Manual: Final gear case oil - change. Factory: Marked at 800 km (500 mi) initial and 30000 km (18000 mi) (p.89)
Change fork oil

Front end

Factory

Manual: Front fork oil - change. Factory: Single mark at 30000 km (18000 mi); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.89)

Every 32,000 km or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

5 items

Caliper piston seal and dust seal - replace

Engine

Factory

Factory: Every: 2 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)
Caliper slave cylinder piston seal - replace

Engine

Factory

Factory: Every: 2 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake/clutch master cylinder cup and dust seal - replace

Brakes

Factory

Factory: Every: 2 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)

Every 4 years

3 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose - replace. Factory: Every: 4 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake/clutch hose and pipe - replace. Factory: Every: 4 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.90)
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.