Kawasaki Z1000SX - Service manual > Upper Fairing Removal

• Remove:
  Lower Fairing (see Lower Fairing Removal)
  Windshield (see Windshield Removal)
  Bolts [A] with Washers
  Meter Cover [B]

• Remove:
  Bolts [A] with Washers
  Windshield Bracket Cover [B]

• Remove:
  Nuts [A] (Both Sides)
  Rear View Mirror [B] (Both Sides)

• Remove:
  Bolt [A] (Both Sides)
  Clamp [B] (Left Side only)

• Disconnect:
  Headlight Lead Connectors [A]
  City Light Lead Connectors [B]
• Remove the upper fairing with the headlight.

Upper Fairing Installation

• Installation is the reverse of removal.

Upper Fairing Disassembly

• Remove:
  Upper Fairing (see Upper Fairing Removal)
  Screws [A]
  Clamp [B]
  Headlights [C]

• Remove:
  Screw [A]
• Separate the upper fairing.

Upper Fairing Assembly

• Fit the projections [A] into the slots [B].

Windshield Bracket Disassembly

• Remove:
  Upper Fairing (see Upper Fairing Removal)
  Meter Unit (see Meter Unit Removal in the Electrical System chapter)
• Remove the springs [A].

• Remove:
  Stay Assembly Mounting Bolt [A] and Collars (Both Sides)
  Bolt [B], Damper, Collar and Washers (Both Sides)
  Stay Assembly [C]
  Adjust Knob Assembly [D]

• Remove:
  Bolts [A]
  Adjust Knob [B]
  Adjust Knob Bracket [C]

• Remove:
  Bolts [A]
  Stay Shaft [B]
  Lower Stays [C]
  Upper Stays [D]
  Stoppers [E]

Windshield Bracket Assembly

• Confirm that the upper fairing bracket has been firmly installed by the mounting bolts [A].

• Assemble the adjust knob assembly as shown in the figure.

  Adjust Knob Bracket [A]
  Adjust Knob [B]
  Bolts [C]

• Apply a non-permanent locking agent to the threads of the stay shaft mounting bolts [A].
• Assemble the stay assembly as shown in the figure.

  Upper Stay [B]
  Stopper [C]
  Stay Shaft [D]
  Stay Shaft Mounting Bolts
  Stopper Mounting Bolts [E]

  • Do not tighten firmly the stopper mounting bolts at this time.

• Apply grease to the dampers [A] and washers [B].
• Apply a non-permanent locking agent to the threads of the adjust knob assembly bolts [C].
• Install:
  Adjust Knob Assembly [D]
  Washers
  Dampers
  Collars [E]

• Install the stay assembly [A].
  • Fit the pis [B] of the adjust knob assembly into the grooves [C] of the stopper (Both Sides).

• Install:
  Stay Assembly Mounting Bolts [A] and Collars
• Tighten the following bolts while the pins fit in the stoppers.

  Torque -
   Stay Assembly Mounting Bolts: 6.9 N*m (0.70 kgf*m, 61 in*lb)  
   Stopper Mounting Bolts [B]: 4.2 N*m (0.42 kgf*m, 37 in*lb)

• Install:
  Lower Stay [A]
  Bolts [B]

• Install:
  Springs [A]
• Confirm that the position of the windshield stoppers [B] change smoothly and surely.
  • Push the adjust knob [C] and change the positions of the windshield stoppers.

If the windshield stoppers do not move smoothly reassemble the windshield bracket.

Windshield Bracket Assembly Removal

• Remove:
  Upper Fairing (see Upper Fairing Assembly Removal)
  Meter Unit (see Meter Unit Removal in the Electrical System chapter)
  Horn Lead Connectors [A]
  Turn Signal Relay [B]
  Clamp [C] (Main Harness)
  Bolt [D]

• Remove:
  Bolts [A]
  Windshield Bracket Assembly [B]

Windshield Bracket Assembly Installation

• Installation is the reverse of removal, note the following.
  • Run the cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

See also: