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The ZZR600 Service Manual says you need to remove the lower and upper fairing to replace the headlight bulb. It lies. This is how you do it, takes 15 minutes and all you need is a #2 Phillips Head screwdriver and a 10mm open-ender.
Remove the 4xPhillips head screws and remove the 'Cover-Head Lamp' from under the fairing (between the fork legs). It's easier if you turn the front wheel left and right so you can get at them.
Pull off the lower spade connector on the horn. Leave the other one on, that way you can't mix them up. Remove the 10mm bolt from the RHS of the 'Joint-Brake' (where the hose from the master cylinder comes down and splits in two to go to each caliper). The bolt is 35mm long, hence the requirement to remove the spade connector off the horn. It's easier if you turn the bars to full lock to get maximum clearance.
Loosen the 10mm bolt on the LHS. Swing the horn out of the way. Pull off the electrical connector on the back of the bulb. Pull off the protective boot, and undo the retaining clip. Remove the bulb.
Tuck the electrical connector and the retaining clip out of the way. Put in the new bulb and clip it in. Put everything back in reverse order...Voila!
Things to be careful of...
1. Don't scratch the fork legs with the screwdriver or the open-ender.
2. Don't loosen the LHS horn bolt too far and remember the two bolts that hold the horn on also hold your brake hoses rigid at the joiner, and the joiner to the fork mounts. BE CAREFUL while one bolt is off as they are movable and you may damage the hoses or the joins.
3. Don't touch the bulb glass.
BTW, the standard bulb is 60/55W. IMHO this is too weak for country riding. I've been using a Narva H4 12V 100/55W bulb (Part #48911BL) since I picked up the bike 18 months ago with no problems.
Mick
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