09/10 ZX-6R Fairing Removal Tutorial : KawiForums.com Kawasaki Forums: Kawasaki motorcycle forums

Thrash1982 · 11-29-2009, 09:01 PM

Fairing removal on a 2009 ZX6R

Side panels (p.15-16)
• Side panels can be popped out by hand in order to remove the front seat without completely removing the side panels.

• To completely remove the panels, remove the front bolt and pull straight out.

Front seat (p.15-8)
• After popping out the rear of the side panels or removing them completely, remove the two bolts holding the seat on. (one per side)

• Lift front of seat up and remove.

Rear seat (p.15-8)
• Insert ignition key into seat lock and turn to disengage the seat latch.

• Pull up on the front of the seat to remove.

Lower fairings (p.15-9)
• Remove the three bolts at the front and one at the rear.

• Pry out center of lower front pop rivet and remove the small pop rivet joining the lower fairing to the lower center fairing.

• Separate top clips from center fairing.

• Repeat on other side.

Lower inner fairing (p.15-9)
• Separate top of fairing from rubber grommet on radiator.
• Separate sides of fairing from center fairings making sure not to loose the rubber nuts.

Upper inner fairings (p.15-13)
• Remove the two pop rivets and front and rear bolts

• Separate top of fairing from the rubber nut attached to the windshield

• Clear rear projections from the frame.

Windshield (p.15-23)
• Remove remaining bolts from windshield

• Lift up and slide it off.

. . . Continued . . .

Thrash1982 · 11-29-2009, 09:06 PM

Upper fairing assy (p.15-10)
• Disconnect the headlight and city light lead connectors (and canister on California models)

• Disconnect turn signal leads.

• Disconnect alternator and regulator/rectifier lead connectors.

• Remove mirrors

• Remove inner bolt with a 10mm socket.

• Remove pop rivet at bottom of air duct.

• Remove bolt and pull sides of center fairing out to clear projections.

• The top black plastic section along with the headlight assembly will be removed with the fairings.
• Rotate the side pieces down slightly to help remove them.
• Be sure to clear the projections from both segments of fairing.

Fairing covers (p.15-15)
• Remove the bolts holding the fairing cover to the frame.

• Pull away to remove.

• Repeat on opposite side.

Headlight removal (p.16-50)
• Remove four remaining headlight bolts. Make sure you don’t loose the wiring harness clips on the lower two bolts.

• Remove pop rivet underneath the center inner fairing.

• Pull headlight straight back and out.

. . . Continued . . .

Thrash1982 · 11-29-2009, 09:09 PM

Center fairing removal (p.15-11)
• Remove three pop rivets and one turn signal bolt per side.

• Separate from upper inner fairing.

• To separate the rest of the fairing sections remove the remaining fasteners.

Seat covers (p.15-17)
• Remove two bolts

• Pull back, lift up and remove

• Remove 4 pop rivets on the undertail.

• And the two pop rivets under the front seat.

• Remove the 2 rear bolts.

• Pull sides out clearing the clips along the bottom edge.

When you’re all done, this is what you end up with.

Thrash1982 · 11-29-2009, 09:19 PM

I tried to follow the service manual's order of removal but they tend to jump around. For those of you that have the service manual I've included the page number after each heading.

A couple final comments and a question.

First of all. DO NOT FORCE ANYTHING!! The last thing you want is to crack a fairing. Be careful. You will have to bend the side fairings out a bit to get them off but do it carefully.

Make sure your fairings are in a safe place. Don't want them getting scratched up in the garage.

And can someone tell me why the hell they made these fairings so damn hard to get off !??

UPDATE
For your convenience I have created a PDF of the tutorial for you to download. It can be downloaded here:

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