Handlebar Removal

• Remove:
Steering Damper (see Steering Damper Removal)
Clutch Lever Clamp Bolts [A]
Clutch Lever Assembly [B]
Left Switch Housing [C]
Handlebar Weight [D]
Left Handlebar Grip [E]

• Remove:
Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter)
Right Switch Housing [B]
Throttle Case [C]
Handlebar Weight [D]
Throttle Grip [E]

• Loosen:
Front Fork Clamp Bolt (Upper) [A] (Both Sides)
Handlebar Clamp Bolt [B] (Both Sides)

• Remove:
Steering Stem Head Nut [A] and Washer [B]
Steering Stem Head [C] with Handlebars

• Remove:
Handlebar Positioning Bolts [A]
Handlebars [B]

STEERING 14-15
Handlebar
Handlebar Installation

a non-permanent locking agent to the threads of
• Apply
the handlebar positioning bolts and tighten them.
Torque - Handlebar Positioning Bolts: 10 N·m (1.0 kgf·m,
89 in·lb)

the leads correctly (see Cable, wire, and Hose Rout• Run
ing section in the Appendix chapter).
the steering stem head with handlebars.
• Install
the washer [A] and steering stem head nut [B].
• Install
Tighten:
•
Torque - Steering Stem Head Nut: 80 N·m (8.2 kgf·m, 59
ft·lb)
Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

NOTE

○Tighten the steering stem head nut before tightening the
upper front fork clamp bolts and handlebar clamp bolts.

WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables, harnesses and hoses are routed
properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
adhesive cement to the inside of the left handlebar
• Apply
grip.
the left handlebar grip, throttle grip and left/right
• Install
handlebar weight.

○Align the end of the left handlebar with the end of left

•

handlebar grip.
Apply a non-permanent locking agent to the threads of
the handlebar weight bolts, and tighten them.

the left and right switch housings.
•○Install
Fit the projection [A] into a hole [B] in the handlebar.

○For left switch housing, tighten the upper screw first, and
then the lower screw. There will be a gap at the lower part
of the left switch housing after tightening.
○For right switch housing, tighten the rear screw first, and
then the front screw. There will be a gap at the front part
of the right switch housing after tightening.
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)

14-16 STEERING
Handlebar
the throttle cable tips.
• Install
Install
throttle case.
•○Fit the the
projection [A] into a hole [B] in the handlebar.
Tighten:
•
Torque - Throttle Case Bolts: 3.5 N·m (0.36 kgf·m, 31 in·lb)

• Install:
Clutch Lever Assembly (see Clutch Lever Installation in
the Clutch chapter)
Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter)
Electronic Steering Damper (see Electronic Steering
Damper Installation)

FRAME 15-1

Frame
Table of Contents
Exploded View...................................
Seats .................................................
Front Seat Removal .....................
Front Seat Installation ..................
Rear Seat Removal (ZX1000R/S)
Rear Seat Installation
(ZX1000R/S) .............................
Single Seat Cover Removal
(ZX1000Z) .................................
Single Seat Cover Installation
(ZX1000Z) .................................
Single Seat Cover Assembly
(ZX1000Z) .................................
Fairings..............................................
Lower Fairing Removal ................
Lower Fairing Installation .............
Upper Fairing Assembly Removal
Upper Fairing Assembly
Installation .................................
Upper Fairing Disassembly..........
Upper Fairing Assembly...............
Inner Cover Removal ...................
Inner Cover Installation ................
Inner Fairing Removal..................
Inner Fairing Installation...............
Fuel Tank Cover Removal............
Fuel Tank Cover Installation.........
Seat Covers.......................................
Seat Cover Removal....................

15-2
15-10
15-10
15-10
15-10
15-10
15-11
15-11
15-11
15-13
15-13
15-14
15-15
15-16
15-16
15-17
15-19
15-19
15-19
15-20
15-20
15-21
15-23
15-23

Seat Cover Installation.................
Fenders .............................................
Front Fender Removal .................
Front Fender Installation ..............
Flap Removal...............................
Flap Installation............................
Flap Disassembly.........................
Flap Assembly .............................
Rear Fender Removal..................
Rear Fender Installation...............
Frame ................................................
Rear Frame Rear Removal..........
Rear Frame Rear Installation.......
Rear Frame Front Removal .........
Rear Frame Front Installation ......
Frame Inspection .........................
Windshield .........................................
Windshield Removal ....................
Windshield Installation .................
Guard.................................................
Mud Guard Removal....................
Mud Guard Installation.................
Rear View Mirrors..............................
Rear View Mirror Removal...........
Rear View Mirror Installation........
Side Stand .........................................
Side Stand Removal ....................
Side Stand Installation .................

15-25
15-27
15-27
15-27
15-27
15-28
15-28
15-29
15-30
15-32
15-34
15-34
15-34
15-34
15-34
15-35
15-36
15-36
15-36
15-37
15-37
15-37
15-38
15-38
15-38
15-39
15-39
15-40

15

15-2 FRAME
Exploded View

FRAME 15-3
Exploded View
No.
1
2
3
4
5
6

Fastener
Front Fender Mounting Bolts
Front Reflectors
Front Footpeg Bracket Bolts
Side Stand Bolt
Side Stand Bracket Bolts
Side Stand Switch Bolt

7. US and CA Models
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

N·m
4.0
3.4
25
45
50
9.0

Torque
kgf·m
0.41
0.35
2.5
4.6
5.1
0.92

ft·lb
35 in·lb
30 in·lb
18
33
37
80 in·lb

Remarks
L

L
L
L

15-4 FRAME
Exploded View

FRAME 15-5
Exploded View
No.

Fastener

1
2
3
4
5
6
7
8
9
10

Muffler Stay Bolts
Rear Footpeg Bracket Bolts
ECU Cover Bolts
Rear Frame Front Bolts
Rear Frame Rear Bolts
Flap Mounting Bolts
Tail Reflector Nut
Chain Cover Mounting Bolt
Rear Side Reflector Nuts
Rear Frame Front Plugs

11. US and CA Models (ZX1000RG  RH/SG  SH)
12. Other than ID, PH and TH Models
13. ZX1000Z
14. ZX1000R/S
G: Apply grease.
L: Apply a non-permanent locking agent.
R. Replacement Parts

N·m
25
25
3.0
45
25
10
3.4
3.0
3.4
25

Torque
kgf·m
2.5
2.5
0.31
4.6
2.5
1.0
0.35
0.31
0.35
2.5

ft·lb
18
18
27 in·lb
33
18
89 in·lb
30 in·lb
27 in·lb
30 in·lb
18

Remarks
L
L
L
L
L
L

15-6 FRAME
Exploded View

FRAME 15-7
Exploded View
No.
1
2

Fastener
Windshield Mounting Bolts
Bracket Mounting Screw

3. ID Model
AD: Apply adhesive.
L: Apply a non-permanent locking agent.

N·m
0.40
2.5

Torque
kgf·m
0.04
0.25

ft·lb
3.5 in·lb
22 in·lb

Remarks

15-8 FRAME
Exploded View

FRAME 15-9
Exploded View
1.  JKAZXT00SSA010017

15-10 FRAME
Seats
Front Seat Removal

• Remove:
Rear Seat (see Rear Seat Removal)
•
•

Upper Seat Cover (see Seat Cover Removal)
Remove the front seat bolts [A].
Remove the front seat backward to clear the seat hooks
[B].

Front Seat Installation

• Install:
Dampers [A]

Collars [B]
When installing the dampers [C], note the followings.
○Place them to the inside of the seat frame.
○Place them to the front of the guide line [D].

•

the seat hooks [A] under the fuel tank bracket [B].
• Insert
Tighten
bolts.
• Install thetheremoved
parts (see appropriate chapters).
•

Rear Seat Removal (ZX1000R/S)

the ignition key [A] into the seat lock.
• Insert
While
turning the key clockwise, pull the front part of the
• rear seat
upward to clear the seat latches [B].
Pull
the
rear
seat forward to remove it.
•

Rear Seat Installation (ZX1000R/S)

the rear seat hook [A] under the rear frame rear [B].
• Insert
Insert
the seat latches [C] into the latch holes [D].
• Push down
the seat until the lock clicks.
•

FRAME 15-11
Seats
Single Seat Cover Removal (ZX1000Z)

the ignition key [A] into the seat lock.
• Insert
turning the key clockwise, pull the front part of the
• While
single seat cover upward to clear the latches [B].
• Pull the single seat cover forward to remove it.

Single Seat Cover Installation (ZX1000Z)

the hook [A] under the rear frame rear [B].
• Insert
the latches [C] into the latch holes [D].
• Insert
Push
down
the single seat cover until the lock clicks.
•

Single Seat Cover Assembly (ZX1000Z)

the seat cover [A] upside down.
• Put
the dampers [B] as shown.
•○Insert
Pinch the projection tip [C] by fingers and pull it until the

•

stopper portion [D] comes through the hole on the seat
cover.
Insert the damper [E] into the holes of the single seat
cover.

the clip nuts [A] on the single seat cover [B] as
• Install
shown.

○The thread side of the nut faces the single seat cover.

the damper [A] to the bracket [B].
• Fit
the dampers [C] to the bracket so that the metal
• Install
side [D] faces upward.

15-12 FRAME
Seats
the bracket [A] on to the single seat cover [B] with
• Install
the bolts [C].

FRAME 15-13
Fairings
Lower Fairing Removal
Hooks [A]
Slots [B]

• Remove the quick rivets [A].

• Remove:
Quick Rivets [A]
Bolt [B] and Washer

15-14 FRAME
Fairings

• Remove:
Bolts [A] and Washers
Bolt [B] and Collar

the rear part of the lower fairing downward to clear
• Pull
the hooks [A] from the upper fairing [B].

the lower fairing rearward to clear the hook [A] from
• Pull
the upper fairing.

the followings if necessary.
• Remove
Quick Rivet [A]
Screws [B]

Lower Fairing Installation
Right Side
When installing the pad [A], align it along the marked line.
When installing the pad [B], align it along the edge [C] and
boss [D] of the fairing.

•
•

Left and Right Side
Install the lower fairing in the reverse of removal.

•

FRAME 15-15
Fairings
Upper Fairing Assembly Removal

• Remove:
Lower Fairings (see Lower Fairing Removal)
Inner Fairing (see Inner Fairing Removal)
Inner Covers (see Inner Cover Removal)
Rear View Mirrors (see Rear View Mirror Removal)
the regulator/rectifier connectors [A].
• Disconnect
Remove:
• Bolt [B]

•

Nut [C]
Regulator/Rectifier [D] with Bracket
Open the clamps [E].

the fuse box [A] and connectors from the bracket
• Remove
on the upper fairing.
• Remove:
Bolt [B] and Clamp [C]
Disconnect:
• Headlight Lead Connector [D]