Kawasaki · Modern chain-drive motorcycle (2000-)

Z 800

Library entry covers 2013-2017

33 factory 24 guideline

Published source

Factory owner's handbook. Covers 2013 (ZR800A/B owner's manual, July 2012 printing).

Open the source

57 items for a 2016 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: Fuel injection
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: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2016 Kawasaki Z 800

On the road: every 200 mi

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 300 mi

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 400 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain lubrication condition - inspect. Factory: Every 600 km (400 mile); more often in severe conditions

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain slack - inspect. Factory: Every 1 000 km (600 mile)

Every 3,000 mi or 12 months

4 items

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
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

Every 3,800 mi or 6 months

1 item

Brake fluid level - inspect

Brakes

Factory

Factory: Every column from 1,000 km, or every 0.5 year

Every 3,800 mi or 12 months

1 item

Brake system - inspect

Brakes

Factory

Factory: Every column from 1,000 km, or yearly

Every 3,800 mi

1 item

Check brake pads and discs

Brakes

Factory

Manual: Brake pad wear - inspect. Factory: Columns 6/12/18/24 x1000 km

Every 4,000 mi or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 6,000 mi or 12 months

3 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

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

Every 7,600 mi or 12 months

11 items

Change engine oil

Engine

Factory

Manual: Engine Oil and Oil filter - change. Factory: Initial 1 (0.6) x1000 km; columns 1/6/12/18/24 x1000 km; repeat beyond chart
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system - inspect. Factory: Initial 1,000 km; then 12/24 x1000 km or yearly
Replace oil filter

Engine

Factory

Manual: Engine Oil and Oil filter - change. Factory: Changed with engine oil; initial 1,000 km (600 mi)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle control system (play, smooth return, no drag) - inspect. Factory: Initial 1,000 km; then 12/24 x1000 km or yearly
Fuel system - inspect

Fuel and air

Factory

Factory: Initial 1,000 km; then 12/24 x1000 km or yearly
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Factory

Manual: Electrical system - inspect. Factory: Marked at 12 and 24 x1000 km or yearly
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play - inspect. Factory: Initial 1,000 km; then 12/24 x1000 km or yearly
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Suspension system - inspect. Factory: Marked at 12 and 24 x1000 km or yearly
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearing damage - inspect. Factory: Marked at 12 and 24 x1000 km or yearly
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Wheels and tires - inspect. Factory: Tire air pressure also yearly, 12/24 x1000 km
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Chassis parts - lubricate. Factory: Marked at 12 and 24 x1000 km or yearly

Every 7,600 mi

8 items

Air suction system - inspect

Engine

Factory

Factory: Marked at 12 and 24 x1000 km columns
Condition of bolts, nuts and fasteners - inspect

Engine

Factory

Factory: Initial 1,000 km; then 12 and 24 x1000 km
Coolant level - inspect

Engine

Factory

Factory: Initial 1,000 km; then 12 and 24 x1000 km
Idle speed - inspect

Engine

Factory

Factory: Initial 1,000 km; then 12 and 24 x1000 km
Replace spark plugs

Engine

Factory

Manual: Spark plugs - change. Factory: Marked at 12 and 24 x1000 km columns
Synchronize throttle bodies

Fuel and air

Factory

Manual: Engine vacuum synchronization - inspect. Factory: Marked at 12 and 24 x1000 km columns
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch operation (play, engagement, disengagement) - inspect. Factory: Initial 1,000 km; then 12 and 24 x1000 km
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear - inspect. Factory: Marked at 12 and 24 x1000 km; drive chain guide wear same

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 11,400 mi

1 item

Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - inspect. Factory: Inspection marked at 18 (11.4) x1000 km column

Every 12,000 mi or 2 years

2 items

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,200 mi or 2 years

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearings - lubricate. Factory: Marked at 24 x1000 km column or 2 years
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (front and rear) - change. Factory: Marked at 24 x1000 km column or 2 years

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi 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 22,500 mi or 3 years

1 item

Replace coolant

Engine

Factory

Manual: Coolant, water hose and O-ring - change. Factory: Every 36 000 km (22 500 mile) or 3 years

Every 22,500 mi

1 item

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element - change. Factory: Every 36 000 km (22 500 mile)

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 26,250 mi

1 item

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Valve clearance - inspect. Factory: Every 42 000 km (26 250 mile), dealer item

Every 30,000 mi or 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose/rubber parts of brake master cylinder and caliper - change. Factory: Every 48 000 km (30 000 mile) or 4 years
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Brake hose/rubber parts of brake master cylinder and caliper - change. Factory: Every 48 000 km (30 000 mile) or 4 years

Every 30,000 mi 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

1 item

Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 5 years

1 item

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hoses - change. Factory: Every 5 years

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.