How To: Install 13'-15' ZX-6R fairings on a 09'-12' ZX-6R - ZX6R Forum
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post #1 of 32 Old 07-11-2015, 04:01 PM Thread Starter
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How To: Install 13'-15' ZX-6R fairings on a 09'-12' ZX-6R

Hello this is a guide or more so what you need guide on how to install 13'-15' ZX-6R fairings on an 09'-12' ZX-6R. The forum wouldnt let me post this on the guide section for some reason. Be aware this guide is not near to being perfect and there will be some kinks that will need to be fixed. However I will update it and answer questions as much as I can. Note there is a lot of reading on this topic so bear with me.

Alittle history of my I have always loved the new styling of 636 ever since they were released in 2013. I wasnt able to afford the new 2013 model at the time, so I purchased a 2009 ZX-6R in 2013.

I LOVE my 09 ZX-6R no doubt, however I have always in the back of my mind wanted the look of a 13'-15' ZX-6R.

When I started seeing threads about being able to put 13' fairings on an 09' ZX-6R i was instantly interested.

But I never really found a straight to the point guide or complete list of what you needed. So this is what this thread is for. Enough nonsense onto the good stuff.

Heres a list of what you NEED: (I put the item number on parts that someone may not be familiar with and the price I paid)

Fairings (DUH)
Headlights
Front Turning Signal Housing and Bulb
Front Turning Signal Fairing Brackets (11056-2187 and 11056-2186)
Brake Light
Rear Fender (35023-0351)
Air Duct (39045-0057)
Meter Bracket *Holds Cluster in place* (11056-1959)
Fuel Tank Covers Right and Left (14092-1087 and 14092-1088)
Main Frame Side Brackets (11056-1961 and 11056-2390)

NOTE: This is a list for a COMPLETE OVERHAUL OF THE 09' Fairings.


This picture does not show all of the parts I listed



While reading on threads about this topic, I would read other peoples comments about being able to use just certain fairings from the 13'-15' on there own without the use of the rest of the fairings. From my experience, its a possible.

You can just use the 2009-12 Tail Fairing and not have to worry about purchasing the rear fender, the fuel tank covers, and the side covers.

But in my opinion the bike just looks out of sync with the 09' tail section.
They look similar but the 13'-15' tail fairings are wider and look more aggressive.

You can basically use everything else from your 2009-2012 ZX-6R including but not limited to:

Tail Section (if you are not using 13'-15' Tail Section), Gauge Cluster, Battery, Wheels, Seats, Driving Lights, Rear view Mirrors, anything I did not list on the what you need list (Unless I forgot something)
__________________________________________________ __________

One thing I will mention and is important as well is that I purchased aftermarket 13'-15' ZX-6R Fairings on eBay. These are very, VERY cost friendly and will save you tons of money instead of having to buy the OEM ones which can be expensive.

However I will advise you on this, sometimes its a gamble to purchase Chinese aftermarket fairings as they will not always fit perfectly. The ones I purchased did fit very well but I had to use a dremel to cut some of the fairings inserts that connect fairing to fairing. It was very minimal cutting and they just needed to be alittle thinner in order to fit in the holes.

Here is a picture of the ones I purchased and they come with every 13'-15' fairing you need




and the Link: White Painted Fairing Bodywork Body Kit for Kawasaki Ninja zx6r 2013 2014 AC | eBay

I bought those fairings to save money and because they came painted. However the paint is very fragile and is not anywhere near perfect. So I would advise you to purchase non painted fairings and paint them yourself. It will also save you a couple hundred dollars.

Like these:
HPST New ABS Injection Unpainted Bodywork Fairing for 2013 Ninja ZX 6R 636 | eBay



You will also need some some extra rivets, nuts, bolts, dampers. Here is a list of parts I purchased from Partszilla that you will need to help you install the fairings. It will cost you about 250$. This price also includes the Meter Bracket, the Fuel Tank Covers, and Rear Fender.




Procedure (You cane skip all the tail section portion if you are not installing the 13'-15' tail section)

1. Start by removing your fairings of course. If you cannot do this on your own then I would probably advise against you doing this project. You dont have to remove the wheels like I did, I just had them removed to get them powdercoated and new rubber installed Like so.



2. You do not have to remove the Fuel Tank entirely like I did, I had it powder coated so I removed it. Tilt the fuel tank up and the install the the Fuel Tank Covers onto the Fuel Tank like so (You will need extra dampers that are included on the Partszilla List).




3. Put the Fuel Tank back into place then proceed to put the middle fairings together. I added foam onto the fairing to simulate the OEM foam. I did this because the OEM foam is ridiculously expensive. Connect the rectifier onto the right side middle fairing as well as the turning signal housings and brackets (use the partszilla diagram to guide you on how to place these parts).



4. Heres where I ran into my first issue. The bulb from the 09' turning signal is too fat to fit into the 13'-15' turning signal housing. So you must use the 13'-15' bulb. You can decide for yourself if you want to use the 13' Bulb Socket as well but it will not plug in play and you will have to splice the wires. So I used the 09 bulb socket as it fits but its need to be cut on the sides so I used a dremel to cut around the socket and cut it to fit.





5. Since we used the 13' bulb, it does not the match the wattage of the 09' relay. So we need to add a resistor to the socket wiring like the picture below. You can buy resistors online on amazon for 8$.



6. Next connect the nose cowling onto the middle cowling as well as the headlights. You can use alot of the OEM screws again and bolts for this. But ordering extra like what I listed on the Partszilla list is very helpful and is in opinion needed.



7. Gather your meter bracket, gauge cluster, and air duct. Use the old dampers from your 09' meter bracket and switch them over onto your 13' meter bracket. Install the air duct onto the frame air duct hole. Then proceed to install the meter bracket onto the air duct. (This is where you will NEED some bolts on the Partszilla list) You can then place the gauge cluster onto the meter bracket like so:





8. Install the nose cowling and middle fairing assembly onto the air duct. Insert it well onto the air duct as this will be the only thing holding into place while you install the other fairings into place. Put the lowering fairings together (There is a small piece that bolts onto the lower fairing) then install it onto the middle fairing, this small piece comes with the kit I listed). You should have something like this now:



9. Install the rear fender and remove the starter relay and the plastic it sits on from the 09' rear fender. Move it onto the 13' rear fender. Also the ecu and fuse box does not fit onto the 13' rear fender slots properly, so you have to dremel here as well. Cut in the middle of the fuse slot plastic and cut the plastic that hits the relay on the ecu slot plastic. Then they will fit like a charm. I will post photos later on this.







10. Another issue I ran into is that the 09 brake light main harness connecter and 13' brake light connect do not fit together. So I had to splice the wires together or you can grab your 09 bracket light connecter, cut it off and splice the connector onto the 13' brake light wires if that makes sense lol. Just match color with color.



11. From here its simple, simply fit the tail section together. You can use alot of the oem bolts that you removed from the old fairings. But you will need some bolts and dampers I listed on the Partszilla list.



12. We're almost DONE If you have done so already connect the main frame brackets onto the main frame using the bolts you removed from the 09' fairings however do not fully tighten the bolt as you will need to move around the bracket to adjust the fairings. Connect the V shapped looking cowling onto the middle cowling. Line it up well so it connects onto the main frame brackets. Then you can tighten the main frame brackets.




13. Put the necessary hooks and other velcro relates parts onto the side cover and install it onto the sides of the fuel tank. Oh and dont forget that on the very lower part of the tail section, there is a hole that needs a damper installed in it so the side cover can fit into it. You can remove this damper from one of the 09' V shaped fairing. The side cover should look something like this.



14. This part is alittle tricky, install the inner cowling that goes behind the nose fairing and above the middle faring. You have the line up all the holes from the inner cowling, middle faring, and the side cover fairings then start bolting the fairings up. Dont forget to put the 5mm nut wells on as well .



15. Use rivets to install air duct fairing into the middle fairing and the nose cowling. 2 rivets go into the turning signal brackets that is why its crucial that you purchase those brackets or else the fairing will be flying all over the place.

16. AND........... You're done Start putting everything back together. Tighten any bolts that you havent tighten yet like the one near the side stand for the lower cowling. Lol Put your rearview mirrors back on and your windshield etc...


Now for the final product. Here is my before and after pictures of my bike

BEFORE



AFTER









FINAL THOUGHTS:

This was a very time consuming project. Long, humid nights in my garage trying to figure things out. But overall I LOVE my New(ish) bike lol

I ended up spending about a total of 800$ (not including the price I spent on powder coating, and the new slip on exhaust).

Was it worth it? Yes. Some people told me why not just buy a new 2015 bike if you really what the look? Bills. I have 2014 Evo to pay for, my house, tuition to pay for, my kids, you get the memo.

Lastly PARTSZILLA is your FRIEND. Use it, the diagrams helped me so much when figuring out what size bolt to use, what spots need nut wells, what parts go where, where rivets go ETC.... Also BUY MORE RIVETS, i broke like 50% of the old ones I removed. And I would also suggest you buy non painted 13'-15' fairings if you decide to use aftermarket Chinese ones. Also before painting them, check to see how they fit. Put them together and dremel cut them before you paint them so then you wont ruin the paint.

This guide is no where near perfect and I will be updating it if any questions or comments are brought up. I also might have forgotten a step or two. I hope this pushes someone who may have thoughts about doing this and havent done so or someone who wants to do this after reading this thread. It was an awesome project with amazing results.

Thank you for reading folks Let me know what you think.
MrZ, ilotek, AlexZX6R and 8 others like this.

[U]2009 Kawasaki ZX-6R 2013 Fairings Conversion/U]
-8k Miles
-M4 Exhaust
-Servo Buddy

Last edited by ticaaal70; 07-11-2015 at 04:13 PM.
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post #2 of 32 Old 07-11-2015, 04:10 PM
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Nice Job. Looks awesome.
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post #3 of 32 Old 07-11-2015, 04:23 PM
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That's awesome pure dedication right here.
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post #4 of 32 Old 07-11-2015, 05:13 PM
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Very nice, the red looks good with it.
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post #5 of 32 Old 07-11-2015, 05:33 PM
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This could have helped:

09-12 & 13+ Parts Compatibility Thread

It's not a how-to, it was meant to be updated as others found what was interchangeable. I started the thread when I was converting my 13 to a track bike and was using various 09-12 parts for the project.

Very informative post, you should fit in nicely around here!
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post #6 of 32 Old 07-11-2015, 06:12 PM
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Looks good man.
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post #7 of 32 Old 07-13-2015, 03:05 PM Thread Starter
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Thanks guys I appreciate the input Red does look good with the white

And Schooley I did actually use the thread as a starting point to what I needed. Thanks alot man
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[U]2009 Kawasaki ZX-6R 2013 Fairings Conversion/U]
-8k Miles
-M4 Exhaust
-Servo Buddy
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post #8 of 32 Old 07-13-2015, 03:05 PM Thread Starter
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Oh and can I get this thread moved to the How To section. Please? Thanks

[U]2009 Kawasaki ZX-6R 2013 Fairings Conversion/U]
-8k Miles
-M4 Exhaust
-Servo Buddy
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post #9 of 32 Old 07-13-2015, 03:43 PM
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It's nice. But I bet you'll be that dude on CL selling it as a 2013. No title. Lost. Only bill of sale. Good thing for engine codes.
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post #10 of 32 Old 07-13-2015, 04:40 PM Thread Starter
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No way. I'm not that kind of guy to screw someone over. If I would sell it, I would specifically state that it's an 09, with 13 fairings. You're welcome

[U]2009 Kawasaki ZX-6R 2013 Fairings Conversion/U]
-8k Miles
-M4 Exhaust
-Servo Buddy
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post #11 of 32 Old 07-13-2015, 06:14 PM
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This is a good time to mention I have almost everything you need for sale. Mint from a 2013 Green.
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post #12 of 32 Old 07-13-2015, 06:28 PM
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Quote:
Originally Posted by sdiver68 View Post
This is a good time to mention I have almost everything you need for sale. Mint from a 2013 Green.
Cool, way to try and hijack an otherwise useful thread and trying to turn it into your own classifieds ad

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post #13 of 32 Old 07-13-2015, 06:39 PM
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Cool, way to try and hijack an otherwise useful thread and trying to turn it into your own classifieds ad

Or 1 stop shopping convenience for OEM quality and the pleasure of helping to get another ZX6R to the podium. Thanks for the free pub.

Last edited by sdiver68; 07-13-2015 at 06:42 PM.
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post #14 of 32 Old 09-24-2015, 01:15 AM
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Good job and a really good thread with detail and photos.
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post #15 of 32 Old 09-24-2015, 02:16 AM
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Nice write up and it came out great.
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