fairing bolts

[chrisw]

well were fixing up the missus ZZR250 (fallen_angel) and weve gotten it to a nice point, but need to hang the fairings back up. they were always held on by a mishmash of bolts and allen bolts.... and dont want / need genuine flat top bolts from kawasaki.

does anyone know what the size/thread type of the bolts are? its not in the service manual.

[Slow and wobbly]

Generally m5.
Before you duck down to your hardware store though go and check out your local dealer for genuine items. Three reasons.
1. The pic above shows you have put in a fair effort and it seems worthy.
2. The real McCoy is made from stainless and thus wont look tatty in 6 months time
3. Nothing says Dodgy like zinc plated machine screws

Most bike shops have a collection of used screws and fasteners that they have acquired through crash repairs, modifications or have just plain forgotten to replace. Failing that then all of these fasteners can now be gotten aftermarket as a kit or individually through the spares counter.

[robracer]

Size wise they will be M5 & M6 metric

[Marty ZZR rider]

I have the fairings off my son's bike at the moment:

There are six M5 x 0.8 x 20 long phillips head screws in each of the side fairing panels. Three of these attach it to the front fairing, two attach it to the vee panel and one fits it to a bracket on the frame just below the tank on the side of bike about where your knee rides. There is a small flat nylon washer under each screw to prevent rubbing. The original screw has a small point on it to help line up the fairing panels but I think you will get away with standard screws.

There are four of the same M5 x 0.8 x 20 long phillips head screws in the surround that acts as an infill around the instruments.

There are five of the same M5 x 0.8 x 20 long phillips head screws in the front fairing to hold the screen. These 21 screws are all mushroom head.

There are also two M6 x 1 x 20mm long Socket button head screws on each side panel. They have a special washer about 25 mm in diameter that is countersunk to suit the screw and they have a spigot about 10 mm diameter that fits into a rubber grommet in the panel.

There are three screws in each of the side panels, that run under the seat to the ducktail. These are: two M6 x 1 x 14mm long and one M6 x 1 x 18 long Phillips head screws. They have a large panhead about 15.5 mm in diameter. The longer ones fit under the seat and holds the duck tail centre piece and the side panels to the frame. The other two go; one under the ducktail and one through the side panel.

There are also two M8 x 1.25 x 20mm long socket head screws that hold the grab rail to the frame. But these are under the seat and can't be seen until the seat is removed.

There is one screw missing on our bike it holds the two side panels together. It is evident by a hole and moulding for it in the base of the left panel but the bracket is missing on the right panel. As the screw can't be fitted I don't know what it was.

There are some shops on Ebay that do fairing screws you can even order your preferred colour:
http://cgi.ebay.com/ebaymotors/WINDSCRE ... enameZWDVW

Good luck finishing the bike.

[robracer]

Legendary effort there Marty