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I was wondering if anybody has step-by-step instructions for installing new turn signals on the front of a 00-02 ZX6R or a 05-up ZZR600? The lights I bought have no instructions at all and I don't want to break any tabs or spend 5 hours doing a one-hour job.

I was able to find a nice writeup on a 636 but not the 00-02 zx6r. Any help, hints, suggestions would be great!
 

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Just go carefully and don't lose any hardware. I removed the front fairing pretty easily. You don't have to disassemble the ram air cowl, it can stay attached. It makes it easier removing the lower fairings as you have more room to work up front. I kept all my hardware in zip-lock bags and labled the bags with a permanent marker. Don't force anything and you should figure it out rather easily.
 

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This was posted by FLASH, I found that it worked a treat:

1. Remove the ram air duct covers from the left and right sides. 1 screw in each to the rear and a pressure hole mount (just lift up) in the front.

2. Use a screwdriver to lift up the spring rings on the rubber ram air tube from the plastic ducts, one on each side. Don't take the spring ring off, just slide it up towards the front of the bike. With the screwdriver under the ring as a fulcrum, work your way around the ring with your fingers until the whole spring ring is out of the rubber holding channel. Once it's off the rubber tube and plastic duct line will slide right apart.

3. Remove the left and right lower fairing bolts (1 on each side) that are slightly behind where the ram air duct covers were.

4. Remove the left and right upper fairing bolts (1 on each side) on the sides of the instrument cluster. Be ready to catch washer as bolts are removed.

5. Remove both mirrors.

6. Remove 3 fairing screws on outside of fairing and 1 fairing screw on inside of fairing (near small hole) adjacent to where the front signal is. Repeat for each side. 8 screws total.

Here's where you need a helper.

7. ''Slightly'' lift fairing up off of bike.

8. Disconnect electrical lead wire, from the front of the bike from the fairing. This lead wire goes to the headlight and turn signal lights. There is only about 8 inches slack in this wire. Connect is tough to pull apart.

Almost done. (Here is where my instructions will differ from Reds)

9. Reach down right near the center of the triple arm and squeeze a pinch clamp on a rubber hose connecting a hose coming straight out of the frame to the plastic air duct lead that connects to the front fairing. Leave the pinch clamp on the rubber wire, only need to move it about 3/4 an inch. Slide the rubber hose off the plastic air duct lead.

10. Remove fairing from bike.

Now, on my bike (2002 California Model) it was not necessary to remove the single screw under the fairing nose, NOR remove the two screws under the front of the fairing (as if you were looking up from the forks) that connect through the bottom of the front fairing into the air intake ducts.

I did that when I removed mine, later I found out that you didn't need to. (My initial try I didn't do steps 2 and 9 above) It was a bitch to try and put the fairing back on with the air ducts connected to the bike. Finally I installed the ducts into the fairing first, then it was a lot easier to but the front fairing back on.

One screw on each front turn signals removes a mounting plate and then use a screw driver to remove the second mounting plate and rubber grommet. Cut the stock harness wire closer to the signal end (not the connector end) so you have plenty of slack to work with the wires on the new turn signals.



And here's a cut and paste from the other thread:

A few words of advice to others tackling the project.

1. Don't forget to plug your electric harness back in before you mount everything back on.

2. Set a chair or table or something in front of your bike, put the front fairing on that, plug it in, and TEST THE SIGNALS to make sure they work before you mount everything back on. If there is anything wrong with the wiring, you get a fast blink. Test both the left and right turn signals (front and rear) and test the hazards. NOTE: On both my front and rears the hot wire was a yellow wire with a stripe on it and the ground wire was solid green. On the short stalks they had all black wires, one with a stripe (hot) and one solid (ground) so that make it easy, the fronts hooked up the same way as the rears.

3. While all that stuff is off of there, not a bad time to do some cleaning, so I did.

4. REAL IMPORTANT Thread the adapters, washers and bolt and any heat shrink over the wire BEFORE you splice it into the existing stock wire. (Like Red mentioned, the stock wire connector is too big to run thru any holes) Also for the 02's that wire plug is behind the headlights, not down in the side of the fairing.

5. Might want to have a helper to get the fairing on and off so you don't drop/bump/scratch it.

6. To reattach, might want to start by threading the upper fairing back onto the mounting holes for the mirrors. Starting there, you know you got it lined up right.

7. Pay close attention to where the front fairing will connect to the engine fairing. There is an alignment tab, which goes in the back, not the front, so make sure you got that lined up as you thread stuff back on.

And to reattach the fairing basically follow a reverse order of the first set of instructions above. I'd say get everything (bolts and screws) just partially hand tightened to make sure everything is on and lined up properly before you go and do the final tightening down.


Good luck, any problems post and let us know, happy to help.
 

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I left my fairings on....and just removed my ram air ducts....and worked from the top, it gave me lots of room to work and ive got fat hands and arms.

I used the same mounting system that the big honkin signals came stock with. Just pop the plate that the screw turns into out of the stock signal, and two sided tape it to the back of your new signals. Make sure to use good quality tape. then use the stock fastening plate and bolt, to fasten the new signals in place, looks clean, no cutting required, and mine have been on for over 8000km now without any problems. I have the cheap LP V flushmounts by the way......

good luck

jonny

 

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I have a 2007 ninja 500r and having issues figuring out the front signal lights... there's 4 wires coming from the bike and not sure which wire is for the daytime running...wire colors are ..red with blue stripe..green..blk with yellow stripe and grey

Sent from my SM-A500W using Tapatalk
 
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