Sight glass broke, oiled my right boot then my brake. Parts ordered will see how much of a pain it turns out to be. Lost my manual might have to wing~it.

Pointers

 

Not a hard job at all. You'll have to just remove that case side cover.

Going by memory so might forget something..
Order new side case gasket
Pull the brake pedal, detach clutch cable on the low side
remove water pump cover, water pump impeller (careful with the seal)

Then pull the side case. There's like 12-15 8mm cap bolts that hold it on.
PROTIP: some are different lengths. To not get messed up, take a piece of cardboard and sketch the case cover and put dots for each bolt. Then as you take off the bolts, stick them into your cardboard sketch in the right spots.

Once you have the case cover off, the sight glass is held on by one bolt I believe. Swap, put it back together and ride.

Someone verify I haven't missed a step, I forget things often

 

Trail fix ideas for this one? Never thought about that little bugger...

 

turnsleft:
check my 351 thread https://www.kawasakiforums.com/forum...351-0-a-36944/ for pics of the other side of the site glass. I looked at that when I had it apart and just figured it would be a press out / press in fit. PM me your private email if you want a copy of the manual. Let us know how this one turns out.

edit - here's one pic:

 

try to clean it up best as possible and duct tape ?

 

Or, you can cut your own gasket, which I prefer. Get a sheet or two of good fiber gasket material (instead of the cheapo OE crap.) Place side cover over and trace around, "dot" the holes. Hold the gasket up to your case and "indent" the inner edge, making sure the gasket doesn't slip or move. Cut the inside. Use paper punch for the bolt holes. Use gasket sealer of your choice. (Use alcohol or naptha to ENSURE the edges are oil free.) Apply to both case edge and cover edge. Allow to tack about 15-20 min. Gently place the gasket on the case edge while you insert bolts through cover. Finger tighten to snug (ONLY!) Allow another 20 min for gasket/sealer to begin to cure. Tighten to "more snug" and don't squeeze out the goo. Allow another 10-15 min, then torque to spec.

 

Yep good call, that's what I did when I installed the kick starter on the wife's bike.

 

Yep, that's what I do. NAPA sells rolls of it in like 5ft sections for $5. I've made hundreds of gaskets, saved a lot of money. I didn't mention it to OP though because to most people it's easier to just buy the gasket.

My wife has lots of craft supplies including some nice scissors and hole punches of different sizes.

This is the last gasket I made:


If you can get the old one off in decent condition, just trace it. If not, lay the material over the new surface and use rubber mallet to tap it on and "trace" the edges.

Good stuff!

 

+1^ The home-made type just seem to work better for me.

 

Just curious, how did you guys break it.