Hey guys and girls, I have a leaking site glass in my 1993 zzr250, can anyone tell me how easy it is to change it out? Cheers Graham
Without seeing it, I would think that you would have to remove the sidecase to access the back of the glass to unscrew it. Maybe have a look at the manuals section. At least STs don't have this problem.
A pain in the bum but not that complicated. Did it on my old '94 ZZR once. They're about $20 by memory. 1. Drain the oil 2. Take the cover off, chuck the cover gasket. (buy a new gasket too. You could attempt it without removing the cover but I wouldn't recommend it as the glass could end up in your engine which wouldn't be very nice) 3. Remove the existing site glass (this is the annoying part, by memory they're pressfit in with a little o-ring type seal) so you may need some minor mechanical intervention or a good soak with something slightly acidic (eg a degreaser) to get it out. Be careful not to damage the hole though - you want a good seal at the end. 4. Insert the new site glass. I recommend putting it in the freezer for a few hours first, hardens it up and shrinks it a bit so you can put it in place easier. You'll need to wait for it to get back to room temp before you put your oil back in though, but it will expand as it warms up to form a seal. Don't hit it with anything directly like a hammer or a mallet. I'd get a bit of wood or something, place it over the glass and tap that gently with a mallet if you need to. You can always check your seal integrity by putting it under some running water or something before you put the cover back on. Just dry the cover before re installing it. 5. Put new gasket on cover 6. Install cover 7. Put oil back in (or may be a good opportunity for new oil & filter while you're at it). Not too hard.
Yeh you could do that too. The reason I suggested water is because it has a much lower viscosity than oil. It's a quick way to test the integrity of the seal. You could do it with oil too, but may need to wait a little longer just to be sure it doesn't have a very minor/slow leak somewhere.
