Kawasaki Z400 - Service manual > Fairings

Lower Fairing Removal

• Remove: Quick Rivet [A] Bob and Washers [B] Bolt and Collar [C]
• Pull the lower part of lower fairing to out side, and clear the tabs [D].
• Remove the lower fairing.

Lower Fairing Installation

• Insert the tabs [A] on the lower fairing into the slots [B] on the middle fairing.

• Lift up the rear part of the lower fairing while installing the removed parts.
• Tighten the bolts following the tightening sequence [1~3]
• Install the quick rivet [A]

Lower Inner Fairing Removal

• Remove the bolts [A].

• Remove the quick rivets [A] (both sides).

• Pull the lower inner fairing to dear the tabs [B] on both sides, and remove the lower inner fairing.

Lower Inner Fairing Installation

• Installation is the reverse of removal.
• Insert the lower inner fairing to the tabs [A] on the middle fairing.

Middle Fairing Removal

• Remove: Lower Fairings (see Lower Fairing Removal)

Lower Inner Fairing (see Lower Inner Fairing Removal)

Side Covers (Side Cover Removal)

Fuse Boxes [A] (Left Side Only)

• Disconnect the front turn signal light lead connector [A].
• Remove the bolt [A].

Remove: Bolt [A] and Washer Quick  Rivet [B]

• Remove the bolts [A] rand washers.
• Pull the middle fairing outward to dear the projections [B] and tab [C].
• Remove the middle fairing.

Middle Fairing Installation

• Installation is the reverse of removal.
• Check that the dip nut [A] and grommets [B] are in place.

• Insert the tabs [A] into the slots [B].
• Insert the projections [C] into the grommets [D].

• Push the front part [A] of the middle fairing while installing the bolt [B].

• Tighten the lower bolt [A] first, and then tighten the upper bolts [B].
•  Install the removed parts (see appropriate chapters

Middle Fairing Disassembly/Assembly

• Open the damps [A].
• Remove:

Screws [B]

Brackets [C] (Left Side Only)

Bolt and Nut [D]

Lower Middle Fairing [E]

Fin [F]

Pad [G] (Left Side Only)

Bracket [H]

Turn Signal Light [I]

Turn Signal Light Cover [J]

Upper Middle Fairing [K]

• Installation is the reverse of removal.

Upper Fairing Removal

• Remove: Middle Fairings (see Middle Fairing Removal)
• Disconnect the headlight lead connector [A].
• Open the damp [B].

• Remove: Quick Rivet [A] (Both Sides) Saw [B] (Both Sides) Bolt and Washer [C] (Both Sides) Headlight Mounting Bolt [D] (Both Sides)
• Move the upper fairing forward to remove it from the grommet [E] (both sides).

Upper Fairing Installation

• Installation is the reverse of removal.
• Check that the grommets [A] are in place.

• Insert the projection [A] into the grommet [B] (both sides).
• Tighten the bolts and screws following the tightening sequence [1~3]

Headlight Mounting Bolt [1] (Both Sides ) Bolt and Washer [2] (Both Sides) Screw [3] (Both Sides)

• Run the cable, leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

Windshield Removal/ Installation

• Remove: Rear View Mirror Bolts [A] Rear View Mirrors [B] Windshield [C]
• Installation is the  reverse of removal.
• Tighten:

Torque - Rear View Mirror Bolts: 8.8 N*m (0.90 kgf*m, 78 in-lb)

Upper Inner Fairing Removal

• Remove: Windshield (seee Windshield Removal/Installation) Upper Fairing (see Upper Fairing Removal)
• For accessory socket equipped models, disconnect the accessory socket connectors [A ].

Slide the dust cover [A], and disconnect the meter connector [B]

• Remove the bolt [A] and washer (both sides).
• Pull up the upper inner fairing to dear the projection [B ] (both sides).

• Pull the upper inner fairing to dear the projections [A].
• Clear the holes [B] from the windshield mounting portions.
• Pull the upper inner fairing to dear the projection [C].

  Remove the upper inner fairing.

Upper Inner Fairing Installation

• Installation is the reverse of removal.
• Check that the grommets [A] are in place.
• Check that the grommet [A] is in place.
• Insert the grommet to the projection [B].
• Fit the holes [C] to the windshield mounting portions [D].
• Insert the projections [E] to the grommet [F].

• Insert the projection [A] to the grommet [B] (both rider).

Upper Inner Fairing Installation

Remove: Upper Inner Fairing (see Upper Inner Fairing Removal) Turn Signal Relay [A] Accessory Relay [B] (Equipped Models) Regulator/Rectifier [C] (see Regulator/Rectifier Removal in the Electrical System chapter) Vehicle-down Sensor [D] (see Vehicle-down Sensor Removal in the Electrical System chapter) Turn Signal Light Lead Connectors [E] Coolant Reserve Tank [F] (see Coolant Reserve Tank Removal) Head Light Lead Connector [G]

• Open the damps [H].
• Remove: Upper Fairing Bracket Bolt [I] (Both Sides) Upper Fairing Bracket Nut [J], Bolt and Spacer Upper Fairing Bracket

Upper Fairing Bracket Installation

• Replace the upper fairing bracket nut [1]with a new one.
• Install:  Upper Fairing Bracket [A] , Spacer [B] Bolt [C]
• Tighten the upper Wing bracket nut and bolts following the specified tightening sequence [1 - 3].

Torque - Upper Fairing Bracket Nut: 34 Nm (33 kgf*m, 25 ft*lb)

Upper Fairing Bracket Bolts: 34 N*m (3.5 kgf-m, 25 ft*lb)

• Install the removed parts (see appropriate chapters).

Covers

Side Cover Removal

• Remove: Front Seat (see Front Seat Removal) Bolt [A] Bolt [B] and Washer
• Pull the side cover outward to clear the projections [C].

Side Cover Installation

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

Insert the projections [A] into the grommets [B].

Insert the projection [C] into the hole [D]

• Tighten the bolts following the specified tightening sequence [1 - 2].

See also: