Repairing a Kawasaki Ninja ZX-10R’s motor and cooling systems requires removal of the intricate arrangement of the motorcycle’s aerodynamic fairing panels. Getting beneath its plastic skin can appear overly complex, thanks to the numerous bolts and fasteners attaching each panel to the motorcycle’s frame. While it is fairly straightforward and can be accomplished with only a few tools, removing the fairings from a ZX-10R is more time-consuming than anything else. Expect to spend a minimum of one hour on this task.
1. Unscrew the bolt from the side panels below the rider’s seat, using a 4 mm Allen wrench. Pull the side cover’s mounting pins out of the rubber grommets on the motorcycle’s frame.
2. Unscrew the bolts on the sides of the rider’s seat, near the gas tank, using a 5 mm Allen wrench. Slide the seat toward the tail fairing and lift it away from the frame.
3. Loosen the plastic rivets from the lower fairing, using a flat screwdriver to lift the center piece out of the rivet. Pull the loosened rivets out of the lower fairing. Unscrew the bolts along the top and bottom of the lower fairings, using a 4 mm Allen wrench. Lower the fairing to the ground and slide it out from under the motorcycle.
4. Unscrew the bolts on the ends of the upper inner fairing panels, positioned on with side of the gas tank, using a 4 mm Allen wrench. Pull the panels to the rear of the motorcycle until the mounting tabs on the front of the panel are freed from the upper fairing.
5. Unscrew the bolts securing the middle fairings to the upper fairing and frame, using a 4 mm and a 5 mm Allen wrench. Unscrew the bolts on the inner portion of the middle fairings, near the front wheel, using a 4 mm Allen wrench.
6. Pull the middle fairings away from the frame slightly. Reach behind the fairing and unplug the front turn signals from the motorcycle’s wiring harness. Set the middle fairings aside.
7. Unscrew the bolts from the perimeter of the windscreen on the upper fairing, using a 3 mm Allen wrench. Pull the windscreen away from the upper fairing and toward the rear of the motorcycle.
8. Reach into the upper fairing and behind the speedometer assembly. Unplug the speedometer from the motorcycle’s wiring harness. Unscrew the pair of bolts on either side of the speedometer’s wiring, using a 10 mm socket.
9. Reach around the upper fairing and headlight assembly. Unplug the headlight bulbs from the wiring harness. Pull the entire upper fairing and headlight away from the motorcycle.