Hi guys, need some advice about replacing/repairing a cracked rev counter window on my xt660z Tenere. Any advice will be appreciated, I�ll be getting on with the repair soon and whatever happens I�ll post up here.


The problem. See pics below, top left of the rev counter plexi window is cracked as a result of a drop onto some rocks in Morocco.










My options:

1. Buy OEM replacement meter assembly for �360 from local dealer.

2. Buy replacement meter assembly from breakers for �180 with various ODO readings.

3. Repair myself using new (flat) plexi-glass disc from ebay for �5 and doing either of the following:

a. Break apart the meter assembly to insert new plexi-glass window from inside the assembly. Pro: new window can be hand filed to fit snuggly in the assembly and no glue will be visible. Con: The difficulty with this is that the two parts are glued together in the factory and there is risk of messing it up or making it look awful afterwards.

b. Knock in the old window from the front and insert a new one but with filed edges in order to slide in sideways. Pro: Means I don�t have to break apart the assembly and risk damaging internals/circuit boards etc. Con: there will be visible gaps where the new glass edges are filed though I will use clear epoxy to water proof it.


Currently I�m tending towards option 3.b. Depending what people say here, this is what I will commit to in the coming days once I receive the new plexi-glass. I will add pics and records for others� information.

thanks guys!

Contact Ashley Pople. He's fixed, repaired or reconditioned several Japanese and British speedos and rev counters over the years for me. He's forgotten more than most people will ever know about repairing motorcycle gauges.

TEL/FAX: +44 (0)1252 329826
MOBILE: +44 (0)7824 884434
email: a.pople@btconnect.com
A.E. Pople, Speedo Repairs,
C/O A & E Coachworks,
The Vehicle Centre
Ashchurch Road,
Aldershot,
Hants,
GU12 6LX

If you worried about doing it yourself, but don't want to get new or secondhand, or want some advice from an expert, then Ashley Pople is your man. If you're not too far from Aldershot then pop round to the workshop, show him the problem and have a chat.

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Brilliant, thanks Pleiades! Just sent him an email for a quote. Really appreciate your help!

just a quick update to anyone following/interested.

I've decided not to risk bodge-jobbing the repair, if I mess up (which is a possibility e.g. accidental fingerprints, sloppy glueing round edges etc.) then I'll have to fork out loads for a replacement.

What I have done is apply some araldite around the crack and fill the small hole to strengthen the crack and stop water ingress. A bit lazy but the clock is fully functional and a repair would only be for aesthetics. I'm looking to sell my trusty Ten and migrate to my "new" 1200 GS ('05 plate!). So this repair was only to improve the value of the sale... I guess I'll just bite the bullet on price.

Oh and I didn't get a response from Ashley from Speedo Repairs, via email or phone, guess he's on holiday....

FYI: If anyone comes across a similar problem with their clocks, bare in mind that you cannot open the clocks to gain access to the internals. It is fully sealed shut in the factory. This means you cannot access the plexi window from inside, which would be more ideal. This also means there is no point removing the clock from the bike (which is a heck of a job) and you might as well work it in situ.

If you wanted to open it up you would need a stanley knife and the hands of a brain surgeon to cut along the bonding line to separate the parts, after which the assembly may end up looking a lot worse. So ask yourself if it is worth the risk?

Anyway, hopefully that's some useful info for the next casualty.

case closed.