• Disconnect:
Headlight Lead Connector [A]
•
•

City Light Lead Connector [B]
Open the clamp [C].
Remove:
Bolt [D] and Clamp [E]

• Open the clamp [A].

15-16 FRAME
Fairings

• Disconnect the hoses [A].

the rear part of the upper fairing assembly outward to
• Pull
clear the projection [A] from the grommet on both sides.
• Remove the upper fairing assembly forward.

Upper Fairing Assembly Installation

the upper fairing assembly in the reverse of re• Install
moval.
the leads, harness and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
that the upper fairing assembly is installed without
• Check
a gap [A] to the air intake duct.

Upper Fairing Disassembly

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
•

Removal)
Windshield (see Windshield Removal)
For other than US and CA models, remove the followings
if necessary.
Nut [A]
Purge Valve [B]
Screws [C]
Quick Rivet [D]
Brackets [E]
Canister [F]

FRAME 15-17
Fairings

• Remove:
Screws [A]
Bolts [B]
Headlight Unit [C]

• Remove:
Screws [A]
City Light Unit [B]
Center Cover [C]

• Remove:
Screws [A] (Both Sides)
Front Upper Fairing [B]
Rear Upper Fairing [C] (Both Sides)

Upper Fairing Assembly

that the following parts are in place on the front
• Check
upper fairing.
Pads [A]

that the following parts are in place on the center
• Check
cover.
Wellnuts [A]
Pads [B]

15-18 FRAME
Fairings
that the following parts are in place on the left rear
• Check
upper fairings.
Pad [A]
Wellnuts [B]
Clip Nut [C]
Brackets [D]
Clamps [E]
Grommets [F]

that the following parts are in place on the right
• Check
rear upper fairings.

•

Pad [A]
Wellnuts [B]
Clip Nut [C]
Bracket [D]
Grommet [E]
Clamp [F]
For other than US and CA models, install the followings if
necessary.
Canister [G]
Bracket [H]
Bracket with Purge Valve [I]
Quick Rivet [J]

• Check that the pad [A] is in place on the city light.

followings in the reverse of disassembly.
• Assemble
Upper Fairings
Center Cover
City Light Unit
Headlight Unit
○Insert the tabs [A] into the slots [B].

FRAME 15-19
Fairings
Inner Cover Removal

• Remove:
Quick Rivet [A]

Bolt [B] and Washer
Inner Cover [C]

Inner Cover Installation

adhesive to the trims [A], and install them as shown.
• Apply
Left Inner Cover [B]

•

Right Inner Cover [C]
Front [D]
Install the inner cover in the reverse of removal.

Inner Fairing Removal

• Remove:
Quick Rivets [A] (Both Sides)

• Remove:
Quick Rivets [A]
•

Screw [B]
Bring the inner fairing [C] backward to clear the front edge
while lift up the upper fairing edges lightly.

15-20 FRAME
Fairings
Inner Fairing Installation

installing the pad [A], fit its rear end to the corner
• When
of the inner fairing [B].

is the reverse of removal. Note the following.
• Installation
Insert
the
hook
portion [A] of the center inner fairing above
• the headlight unit
[B].

Fuel Tank Cover Removal
Fasteners [A]
Slot [B]
Projections [C]
Claws [D]
Hook [E]
Grommets [F]
Tab [G]

FRAME 15-21
Fairings

• Remove:
Rear Seat (ZX1000R/S, see Rear Seat Removal)
Single Seat Cover (ZX1000Z, see Single Seat Cover Removal)
Front Seat (see Front Seat Removal)
Bolt [A] and Washer
Bolt [B]

the front end [A] of the left fuel tank cover outward to
• Pull
clear the hook and the claws [B].
the left fuel tank cover outward to clear the projections
• Pull
[C] and fastener [D].
the left fuel tank cover forward to clear the tab [E]
• Slide
and remove it.
• Remove the right fuel tank cover in the same way.

the bolt [A] on both sides.
• Remove
Pull
the
upper
cover [B] upward to clear the pro• jections [C] fromfuelthetankgrommets.
• Remove the upper fuel tank cover.

Fuel Tank Cover Installation

that the wellnut [A] and the grommet [B] are in
• Check
place on both sides.

• Check that the pad [A] and the grommets [B] are in place.

15-22 FRAME
Fairings
the projections [A] of the upper fuel tank cover into
• Insert
the grommets [B] on the fuel tank.
the bolts on both sides of the upper fuel tank
• Tighten
cover.

that the damper [A] and the fastener [B] are in
• Check
place.

the front end [A] of the fuel tank cover to the front end
• Fit
of the upper fuel tank cover.
• Fit the claws [B] to the edge of the upper fuel tank cover.

the slot [A] of the left fuel tank cover to the tab [B]
• Insert
on the fuel tank.
• Insert the projections [C] into the grommets [D].

• Tighten:
Bolt [A] and Washer
•
•
•

Bolt [B]
Push the fastener portion [C] of the left fuel tank cover to
fix the fastener.
Install the right fuel tank cover in the same way.
Install the removed parts (see appropriate chapters).

FRAME 15-23
Seat Covers
Seat Cover Removal
Upper Seat Cover
Hooks [A] (Both Sides)
Slots [B] (Both Sides)
Hook [C] (Both Sides)

• Remove:
Rear Seat (ZX1000R/S, see Rear Seat Removal)
•
•

Single Seat Cover (ZX1000Z, see Single Seat Cover Removal)
Bolts [A] and Washers
Slide the upper seat cover [B] rearward to clear the hooks
[C] on both sides.
Remove the upper seat cover.

15-24 FRAME
Seat Covers
Lower Seat Covers
Hooks [A]
Slots [B]

• Remove:
Front Seat (see Front Seat Removal)
Battery (see Battery Removal in the Electrical System
chapter)
Bolts [A]
Bolt [B] and Washer
Quick Rivet [C]

the lower seat cover [A] rearward to clear the hooks
• Slide
[B].

FRAME 15-25
Seat Covers
the left side, free the seat lock cable [A] from the seat
• On
lock [B].
• Remove the lower seat cover.

Seat Cover Installation
Lower Seat Covers
On the left side, install the seat lock cable [A] to the seat
lock [B].

•

the hooks [A] of the lower seat cover into the slots
• Insert
[B] on the rear fender.

NOTE

○In this photo, the seat lock cable does not connect for
clarity.
the quick rivet.
• Install
• Tighten the bolts.

Upper Seat Cover
When installing the pad [A], note the followings.
○Fit the corner [B] of the pad and the corner of the upper
seat cover.
○Wrap the pad.
Viewed from Top [C]
When installing the pad [D], fit the corner [E] of the pad
and the corner of the upper seat cover.
When installing the pads [F], align them to the guide lines.

•
•
•

15-26 FRAME
Seat Covers
the hooks [A] of the lower seat cover into the hook
• Insert
[B] and slots [C] on the rear fender on both sides.
the bolts and washers.
• Tighten
Install
the
removed parts (see appropriate chapters).
•

FRAME 15-27
Fenders
Front Fender Removal

• Remove:
Front Wheel
•
•

(see Front Wheel Removal in the
Wheels/Tires chapter)
Free the brake hoses and the front wheel rotation sensor
lead from the clamps [A].
Remove:
Reflectors (Equipped Models)
Bolts [B] and Washers [C]
Front Fender [D]

Front Fender Installation

a non-permanent locking agent to the front fender
• Apply
bolts.
the front fender.
• Install
Tighten:
•
Torque - Front Fender Mounting Bolts: 4.0 N·m (0.41 kgf·m,
35 in·lb)
Front Reflectors (Equipped Models): 3.4 N·m (0.35
kgf·m, 30 in·lb)

the leads and hoses correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).

Flap Removal

• Remove:
Rear Seat (ZX1000R/S, see Rear Seat Removal)
•
•

Single Seat Cover (ZX1000Z, see Single Set Cover Removal)
Left Lower Seat Cover (see Seat Cover Removal)
Disconnect:
Rear Turn Signal Light Lead Connectors [A]
License Plate Light Lead Connector [B]
Remove the ECU cover bolts [C] to free the ECU cover
[D].

• Remove:
Flap Mounting Bolts [A]
Flap Assembly [B]

15-28 FRAME
Fenders
Flap Installation

the flap assembly.
• Install
the rear turn signal light leads and license plate light
• Run
lead through the rear fender.
a non-permanent locking agent to the flap mounting
• Apply
bolts.
• Tighten:
Torque - Flap Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

a non-permanent locking agent to the ECU cover
• Apply
bolts.
the ECU cover.
• Install
Tighten:
•
Torque - ECU Cover Bolts: 3.0 N·m (0.31 kgf·m, 27 in·lb)

• Install the removed parts (see appropriate chapters).
Flap Disassembly

• Remove:
Flap Assembly (see Flap Removal)
Bolts [A] (Equipped Models)
Side Reflector Assembly [B] (Equipped Models)
Screws [C]
Bolt and Washer [D]
Flap Cover [E]

• Remove:
Bolts [A]
Flap Bracket [B]
Flap [C]

FRAME 15-29
Fenders

• Remove:
License Plate Light Screws [A]
Washers [B]
Dampers [C]
License Plate Light [D]
Rear Turn Signal Light Mounting Screw [E] (Both Sides)
Washers [F] (Both Sides)
Turn Signal Light [G] (Both Sides)
License Plate Bracket Bolts [H] (Equipped Models)
License Plate Bracket [I] (Equipped Models)
Tail Reflector Nut [J]
Tail Reflector [K]

Flap Assembly

the equipped models, apply a non-permanent locking
• On
agent to the license plate bracket bolts [A].
the license plate bracket [B].
• Install
Tighten:
•
Torque - License Plate Bracket Bolts (Equipped Models):
4.0 N·m (0.41 kgf·m, 35 in·lb)

the tail reflector [C].
• Install
Tighten:
•
Torque - Tail Reflector Nuts [D]: 3.4 N·m (0.35 kgf·m, 30
in·lb)

• Install:
Dampers [A]
Washers [B]
License Plate Light [C]
○Be sure to install the groove of the damper to the hole
edge of the flap [D] completely.
Tighten:

•

Torque - License Plate Light Mounting Screws [E]: 1.2 N·m
(0.12 kgf·m, 11 in·lb)

• Install:
Turn Signal Lights [A]
Washers [B]

○Be sure to install the groove of the turn signal light to the

•

hole edge of the flap completely.
Tighten:
Torque - Rear Turn Signal Light Mounting Screws [C]: 1.2
N·m (0.12 kgf·m, 11 in·lb)

the leads correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).

15-30 FRAME
Fenders
installing the pads [A] to the flap bracket [B], note
• When
the followings.

○Align the pads with the corner lines [C].
○Fit the pads to the end of the ribs [D].

installing the damper [E] to the flap cover [F], note
• When
the following.

○Align the damper with the guide lines [G].

a non-permanent locking agent to the bolts [A].
• Apply
Install:
• Flap Bracket [B]

•

Flap [C]
Flap Cover [D]
Rear Reflector Assembly [E] (Equipped Models)
Washers [F]
Tighten:
Screw [G]
Bolts
Torque - Rear Reflector Bracket Bolts [H] (Equipped Models): 8.0 N·m (0.82 kgf·m, 71 in·lb)

Rear Fender Removal

• Remove:
Rear Seat (ZX1000R/S, see Rear Seat Removal)
Single Seat Cover (ZX1000Z, see Single Seat Cover Removal)
Front Seat (see Front Seat Removal)
Seat Covers (see Seat Cover Removal)
Flap (see Flap Removal)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Vehicle-down Sensor Connector [A]
Relays [B]
ECU Cover Bolts [C]
ECU Cover [D]

FRAME 15-31
Fenders

• Disconnect:
Tail/Brake Light Lead Connector [A]
• Remove:
Screws [B]

the front part of the tail/brake light [A] to free it from
• Raise
the rear fender.

the tail/brake light [A] rearward to free it from the tab
• Slide
[B] of the rear frame rear.
• Remove the tail/brake light and damper [C].

the screws [A], washers and clamp [B] to free
• Remove
the exhaust butterfly valve actuator.
the starter relay [C] and he fuse box [D] from the
• Remove
rear fender.

• Remove:
Clamps [A]
Quick Rivets [B]

15-32 FRAME
Fenders

• Remove:
Bolt [A] (Both Sides)
Clamp [B]
Screw [C]
Rear Fender

Rear Fender Installation

the cut bands and clamps with new ones.
• Replace
that the following parts are in place.
• Check
Clamp [A]
Dampers [B]
Pad [C]
Dampers [D]
Pad [E]