How do I replace the sight glass?

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  • Buy the part (get the part number from buykawasaki or Ron Ayers).
  • Put new glass in the freezer for several hours.
  • Note the relative position of your old glass before you remove it.
  • Don't forget to drain the oil. The sight glass is literally the only thing holding the oil in.
  • Take a small screwdriver and carefully remove all the remaining bits of glass.
  • Using the same screwdriver, remove the metal ring that held the old glass in.
  • Remove glass from freezer, completely coat it with fresh oil, and VERY CAREFULLY, drive it into the case, using a small socket to spread the force of the impact(s) onto the metal rim of the glass.

Caveats

  • Be VERY careful, otherwise the new glass will crack, too. Very soft, light taps should get it in there.
  • Don't push too hard on the clutch cover; it's cast aluminium.
  • It might not be a bad idea to have a piece of pine or other soft wood around for impact absorption. (ie... to tap on)
  • If this is done during cold weather, you should consider leaving the bike overnight in a heated garage before trying to install. This, along with freezing the new glass, will help make the fit less stubborn. It's a simple compression fit; there are no bolts holding it on. Warming up the engine in the garage will help expand the metal and make the fit easier.