Broken gauge glass replacement, pics
#1
04-16-2010, 10:13 PM
Join Date: Mar 2008
Location: N. Illinois
Posts: 3,406
Broken gauge glass replacement, pics
I guess I'm kind of rough on the ol' KLX 
It's fun to push my own limits. Exceeding my limits results in broken stuff. During the Leaf River D/S ride (ride report here https://www.kawasakiforums.com/forum...ad.php?t=32160 ) I laid the bike over into a tree. I basically lost my balance in a slow spot, and leaned it over into the tree. The hit must have put too much pressure on the gauge cluster causing the glass to shatter. Not cool.
The gauge housing itself was fairly easy to remove. The glass is permanently installed in the housing. At the factory, the glass inserts are placed inside the housing and then a plastic backing ring is glued in behind them. I used pliers to pull the glass and the rubber seal out, and then went around the inside of the opening with a Dremel to cut out the glued in backing ring. I then measured the diameter of the openings and made a cardboard pattern that fit the opening. Next I traced around the patterns on some Plexiglas and cut them out on the band saw. To hold the plexi in place I ran a small bead of silicone around the inside of the opening. Laid the the replacements into the silicone and added another small bead on the other side of the plexi. I think it turned out well. I'm also thinking that the plastic will hold up better than glass.
Dan
It's fun to push my own limits. Exceeding my limits results in broken stuff. During the Leaf River D/S ride (ride report here https://www.kawasakiforums.com/forum...ad.php?t=32160 ) I laid the bike over into a tree. I basically lost my balance in a slow spot, and leaned it over into the tree. The hit must have put too much pressure on the gauge cluster causing the glass to shatter. Not cool. The gauge housing itself was fairly easy to remove. The glass is permanently installed in the housing. At the factory, the glass inserts are placed inside the housing and then a plastic backing ring is glued in behind them. I used pliers to pull the glass and the rubber seal out, and then went around the inside of the opening with a Dremel to cut out the glued in backing ring. I then measured the diameter of the openings and made a cardboard pattern that fit the opening. Next I traced around the patterns on some Plexiglas and cut them out on the band saw. To hold the plexi in place I ran a small bead of silicone around the inside of the opening. Laid the the replacements into the silicone and added another small bead on the other side of the plexi. I think it turned out well. I'm also thinking that the plastic will hold up better than glass.
Dan
#3
04-16-2010, 11:08 PM
Join Date: May 2007
Location: Oklahoma City, OK
Posts: 1,102
Awasome job!!!
#5
04-17-2010, 01:54 AM
Join Date: Mar 2008
Location: N. Illinois
Posts: 3,406
@canklx , your right I will have to watch it when wiping it off. If it gets too bad I can always re-replace it.
Dan
#6
04-17-2010, 02:17 AM
Good as new!! Good job!
I would have definitely backed the ODO a couple-two-tree thousand! hahhaa
I would have definitely backed the ODO a couple-two-tree thousand! hahhaa
#9
04-17-2010, 09:38 AM
Join Date: May 2006
Location: Pittsburgh, PA
Posts: 12,584
Weird...
But you know why they are glass right? So they dont scratch, i replaced mine with plexi too... but dont try to clean it off with your fingers if they are all muddy, it will scratch.
But you know why they are glass right? So they dont scratch, i replaced mine with plexi too... but dont try to clean it off with your fingers if they are all muddy, it will scratch.
#10
04-18-2010, 10:27 PM
Join Date: Mar 2008
Location: N. Illinois
Posts: 3,406
Dan