installing a clutch cover window

[Deano]

For those of you that have brought a clutch cover insert from me and are planning to install it your self i have put this together for you as a guide i how I install the windows.


http://www.streetfighters.com.au/forum/upload/910219109135688.jpg

firstly take the cover off the bike and remove the oil sight glass. you do this by cutting away the silicone on the inside of the cover and them pressing it out. It can be a little tricky. I use a socket that was the correct dia and covered it with a rag. remember that it could be quite easily broken so don't impact it. you could use a g clamp and slowly close it to press out the glass.

then you need to sit the window on the cover in the corret position and i used a scribe to mark the postion on the cover.

you are better off cutting the hole smaller rather than larger as you cant make the hole smaller once it is cutt out.

the pic shows the window on the cover ready to be scribed around for cutting.

[Deano]

http://www.streetfighters.com.au/forum/upload/910219109137676.jpg

this is the cover that has been marked and ready to be cut.

to cut out i drill a 10mm hole to allow the jigsaw blade a starting point

[Deano]

http://www.streetfighters.com.au/forum/upload/910219109166490.jpg

once it is cut out check the fittment of the window.

you can just see the line that i scribed out. it is a bit larger in dia than the hole i have cut.

[Deano]

http://www.streetfighters.com.au/forum/upload/910219109153880.jpg

i then use a flap disc on the 4" grinder to slowly make the hole in the cover bigger to fit the window.

remeber - easy does it. this is also the time to correct the position that the window will sit in if you marked it slightly off centre

[Deano]

http://www.streetfighters.com.au/forum/upload/910219109161595.jpg

i then use that same flap when to grind away the webbing on the inside of the cover. you will have to leave about 6mm clear from the edge of the hole for the bead of weld that the welder will lay.

[Deano]

then paint strip the area around the weld. get it welded and then fit the sight glass and seal it with the gasket maker that was supplied with your window and your nearly done.

as a precaution i have a large piece of 240g emery paper that i put down on a flat surface and lapp a new sealing surface on the cover. The cover may warp during the welding process and therefore leak around the gasket were it is bolted to the motor.

before putting on the cover on you motor i would assemble the window and fill the unit with water and leaver overnight to check for leaks around the weld and sight glass. if you put it on you motor before checking for leaks and it then does leak your welder may have trouble rewelding the effected area if the weld recesses are filled with oil. whereas the water can be evaporated away before welding.

when you put the oring in the grove you will notice that it seems a little to small and keeps jumping out of the grove. i recommend given the oring a little strech before placing it in the grove. the oring will slowly contract back to it original size but you should be able to place the polycarbonate window on and tighten the bolts before this becomes a problem.

when tightening the bolts keep in mind that the boly is made from alloy and only needs to be tighened firm to give a good seal between the oring and window.

keep an eye on the bolts and check there tightness every couple of months as the oring can flatten slightly.

hope this helps you all just let me no if you need any extra info.