Xitomer Motorcycle Fairing Bolt Kit Installation Manual

1. Product Overview

This Xitomer complete fairing bolt kit is designed to replace or upgrade the fasteners for your Yamaha YZF-R6 (2003-2005) or YZF-R6S (2006-2009) motorcycle bodywork. The kit includes a comprehensive set of bolts, washers, nuts, clips, and grommets required for various fairing components, featuring a durable titanium electroplated finish.

2. Package Contents

The complete fairing bolt kit includes fasteners for the following areas:

• Upper Fairing
• Windscreen
• Tank Cover
• Side Fairings
• Lower Fairings
• Tail Fairing
• Trims
• Inner Panels
• Fenders

The kit typically includes the following types of components:

• Screws: 10.9 Grade Iron, heat-treated, titanium electroplated finish.
• Washers: Various types including flat washers and plastic washers.
• Nuts: Including lock nuts and U-nuts.
• Clips: Plastic push rivets and metal clips.
• Grommets: Rubber grommets with metal inserts and well nuts.

Image: Titanium-finished fairing screws. These are the primary bolts for securing fairing panels.

Image: Black flat washers. Used to distribute the load of a threaded fastener, such as a screw or nut.

Image: Metal lock nuts with blue insert. These nuts provide a secure fastening that resists loosening due to vibration.

Image: Black U-nuts or speed clips. These are often used to provide a threaded receptacle for screws in sheet metal or plastic panels.

Image: Black plastic spacers or bushings. Used to create distance between components or to protect surfaces.

Image: Rubber grommets with metal inserts. These provide vibration dampening and a secure mounting point for screws.

Image: Black rubber well nuts. Used to secure components in blind holes, expanding to create a tight fit.

Image: Black plastic push rivets or clips. Used for quick and easy fastening of lightweight panels.

3. Specifications

4. Installation (Setup)

Before beginning installation, ensure you have the necessary tools, including a torque wrench, appropriate hex keys, and a clean workspace. Refer to your motorcycle's service manual for specific fairing removal and installation procedures.

4.1. Preparation

1. Review Parts List: An installation drawing and parts list are included with your package or available via email. Compare the received components with this list to ensure all parts are present.
2. Identify Fasteners: Match each fastener from the kit to its corresponding location on the motorcycle fairing.
3. Clean Mounting Surfaces: Ensure all mounting points on the motorcycle frame and fairing panels are clean and free of debris or old threadlocker residue.

4.2. Installation Steps

1. Remove Old Fasteners: Carefully remove the existing fairing bolts and components. Keep track of their original locations for reference.
2. Position Fairing Panels: Align the fairing panels correctly on the motorcycle.
3. Insert New Fasteners: Insert the appropriate Xitomer bolts, washers, nuts, clips, or grommets into their designated positions.
4. Hand Tighten: Initially, hand-tighten all fasteners to ensure proper alignment and engagement of threads. Do not overtighten.
5. Torque to Specification: Using a torque wrench, tighten all M5 bolts to a minimum of 7 NM and all M6 bolts to a minimum of 9 NM. Refer to your motorcycle's service manual for any specific torque values for critical components. Do not exceed recommended torque values to prevent damage to fasteners or fairing.
6. Final Check: After installation, visually inspect all fasteners to ensure they are securely in place and the fairing panels are properly seated.

5. Usage and Maintenance

5.1. General Usage

Once installed, the fairing bolt kit provides secure fastening for your motorcycle's bodywork. These fasteners are designed for durability and a clean aesthetic.

5.2. Maintenance

• Regular Inspection: Periodically check all fairing bolts for tightness, especially after riding on rough terrain or after any maintenance involving fairing removal.
• Cleaning: Clean the fasteners with a mild soap and water solution. Avoid harsh chemicals or abrasive cleaners that could damage the titanium finish.
• Corrosion Check: While the titanium finish is designed to resist corrosion, regularly inspect for any signs of rust or wear, particularly in areas exposed to moisture and road salt.
• Re-torque: If any bolts feel loose, re-torque them to the specified values (M5 > 7 NM, M6 > 9 NM).

6. Troubleshooting

• Bolt Does Not Fit: Double-check the parts list and installation drawing to ensure you are using the correct bolt for the specific location. Motorcycle fairings can have various bolt sizes and types.
• Fairing Panel Not Seating Properly: Ensure all underlying brackets and mounting points are correctly aligned. Do not force panels into place, as this can cause damage. Verify that all spacers and grommets are correctly positioned.
• Fasteners Rusting Prematurely: While the product features a titanium electroplated finish, exposure to harsh environmental conditions (e.g., road salt, extreme humidity) without proper cleaning can accelerate wear. Ensure regular cleaning and inspection. If significant rusting occurs within the warranty period, contact Xitomer support.
• Missing or Incorrect Parts: If your kit arrived with missing or incorrect components, refer to the contact information in the Warranty & Support section to request replacements.

7. Warranty & Support

Xitomer provides a 1-year quality guarantee for this fairing bolt kit. This warranty covers manufacturing defects and material failures under normal use.

For warranty claims, technical assistance, or inquiries regarding installation drawings and parts lists, please contact Xitomer customer support through the retailer where the product was purchased or via the official Xitomer website. Please have your purchase details and model number (FBT00415TI-X) available when contacting support.