tuusinii
Pro
Posts: 1031
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posted July 24, 2006 09:09 AM
The stator wire oil problem
Hello!
Doing regular maintenance after a little Europe trip and noticed that my stator connector looked little bit oily from the outside so opened it up and it was all oily inside! So now asking how have people addressed the problem because the factory "fix" don't work. My bike had the KHI fix done some 3 years ago even if there wasn't oil - maybe the connector was little damp. But now after 6 and half Years and 95k km the problem has daunted my bike. Good thing is it hasn't melted anything so everything is still working. But I'm asking has anybode found a real FIX to the problem. Don't remember reading a lot about this problem lately...
  
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rundog
Parking Attendant
Posts: 10
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posted July 24, 2006 11:14 AM
Cut, solder, vent the insulation you apply..........
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slug
Pro
Out in search of my mind...
Posts: 1433
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posted July 24, 2006 02:21 PM
there are a few threads around here for that problem, several really good fixes are described. try a quick search, this isn't new by any stretch.
(and i am really not trying to be a butthole, i just know there are several threads adderssing this issue  )
   
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tuusinii
Pro
Posts: 1031
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posted July 25, 2006 12:11 AM
OK after doing the search found these cures:
Zip tie all the individual wires near stator - no other word about this working???
Use RTV and splice the individual wires and inject the RTV to the inside of the wires. - seemed to cure the thing???
Open the stator cover and put RTV to the wire ends - many reports that it started leak after a while.
Separating the crankcase vent from the air box and adding a filter to let it breath to air - no word how it worked?
And now the rundogs advice about cutting and soldering - I could have a little advice how You vented the insulation after that? To me that sunds like the best/easiest solution. Because of the solder the oil would not get past anymore and the RTV around it would do the rest of preventing oil going trough the wires.
Are there any other "solution" that have been found or someone can recommend?
And on question about the filter for the crankcase vent? What kind should it be - remember reading someone using fuel filter and it working nicely? And someone speaking about k&n filter? The fuelfilter would be much easier to my to get - if it works...
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Wideout
Expert Class
Posts: 300
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posted July 25, 2006 03:19 AM
Many opt for soldering. Some I've heard have problems with it heating up / smoking, but I guess if you do it right...
Another option is to install the '04+ stator harness. Not sure what all is involved in needing to be replaced, the dealer put that on my '02. He replaced the voltage regulator on mine as well, but I don't recall whether it was because of connectors or showed signs of failing.
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rundog
Parking Attendant
Posts: 10
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posted July 26, 2006 04:56 PM
t., after reviewing all those threads, I decided to cut & solder because it seemed to be the best way to make sure there was no way the oil was going to make it up those wires, without disturbing my alt. cover. Plus, some of the threads seemed to say there was a recurrence of the problem after attempts to seal the wires at the source.
Oil flows between the strands of the wires, and will find the smallest gap. Now I'm not very knowledgeable about soldering, but it seems to be working out pretty well.
I cut the wires, skinned them back about 3/4" filled them with solder, and then joined them by soldering a short piece of wire 'on top of' each cut piece that contacted the entire bare length of each cut piece. I did it this way because it seemed to be the best way to both cut off the flow of oil & give a long conductive path to minimize the increase in resistance. I used flux & silver-bearing solder. When I heated the heat shrink insulation, I left a very small hole at each end, so that if the oil somehow got through, it would run out instead of continuing up the wire.
Haven't seen anymore oil................
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tuusinii
Pro
Posts: 1031
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posted July 27, 2006 12:34 AM
I think I'm going to opt for the soldering too. Just bought me so more heatshrink because I was running out of it. That extra piece of wire to solder to the joint sounds like a good idea too - think I'm going to do the same today. Hope it finally solves this problem...
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Hells Dark Lord
Needs a life
living life, and loving it.
Posts: 7981
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posted July 29, 2006 11:43 PM
tusinii....get a hold of crashtech.....our buddy Roger fixed his mine and his own, with never an issue afterwards....he can tell you how to do it.....
____________
When in doubt, lean farther and go faster....
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