wannabe
Pro
Posts: 1931
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posted August 10, 2003 03:34 PM
 Edited By: wannabe on 10 Aug 2003 16:37
Bike ('01) leaking oil. Need reminder of fix.
I was wiping down my bike for some work before next week's race. I noticed that there is some oil under the tail section. I know that this is coming from the oil wicking up the wiring harness from the stator.
Can someone remind me how to fix this?
I remember someone saying something about silicone on the wiring harness. Where do you put the silicone? On the side of the harness under the seat or the side of the harness inside the stator cover?
edit: yes, I still have the recall paperwork, but I don't want the dealer touching my bike.
  
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted August 10, 2003 03:38 PM
just take a ziptie and pull it tight around the wiring harness down near the stator cover
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wannabe
Pro
Posts: 1931
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posted August 10, 2003 04:40 PM
Thanks, Bergie. That's a nice simple (and clean) answer. I'll try that first.
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted August 10, 2003 06:17 PM
If that doesn't work (it should) you'll need to pull the stator cover itself. Inside is a wiring harness bracket with two screws. Loosen the bracket and clean the area around the rubber grommet then apply RTV. Let it tack up then reinstall. The zip tie method seems to work just as well though.
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magzx12r
Expert Class
Posts: 252
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posted August 10, 2003 07:55 PM
Oil Leak
This was a recall item. You should take the bike to your dealer and let them repair it.
____________
Mark
'03 ZX-12R
'12 1199S
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wannabe
Pro
Posts: 1931
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posted August 10, 2003 08:14 PM
Thanks again, Bergie. I've got my fingers crossed about the tie wrap. Thanks for the backup plan if that doesn't work.
magzx12r: Please see my first post. I don't trust anyone else to touch my bike especially now that I am racing it. Doing it all myself is the only way I know 100% in my mind that everything was done right.
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Hells Dark Lord
Needs a life
living life, and loving it.
Posts: 7981
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posted August 11, 2003 09:53 AM
let us know how it turns out there Wanna.....
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When in doubt, lean farther and go faster....
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k bryant
Needs a job
Sponsor
Posts: 2911
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posted August 11, 2003 12:47 PM
I got the same recall notice for my '03. Have not had any leakage, so I'm just keeping my eye on it.
RAC4IT has it right. Best way is silicone. This same deal used to happen on early model Z1(s) in 1973 - 75. Pretty pathetic. We're talking 30 years ago and they still have the same problem surfacing!
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redelk
Moderator
Please... speak to the hand.
Posts: 3212
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posted August 11, 2003 05:55 PM
Below is the "official method" for the "fix". If you do this yourself, PLEASE notify your dealer so they can send in the proper paperwork showing that the service has been done. Unlike a "in house" recall, this one is a federally mandated recall from the NHTSA. There is required paperwork KMC has to submit to the NHTSA.
Kawasaki and it's representitives (the dealers) have to prove that bikes (that are still operating on public roads) falling under this recall have been serviced. It's also why step #16 has to be performed. No 12R can be resold by a dealer unless they perform the repair or there is a "Repair Verification" mark on frame. To do so would be a federal offense as well as open the dealer, KMC and KHI up to all sorts of legal problems.
This is what I posted this on a previous post about this recall.
I just made a copy of my dealer's SIX PAGE "instruction" sheet (Bulletin MC 02-11) that came with the "Official KHI Recall Repair Kit". What a hoot! There are SIXTEEN pictures and FOUR diagrams.
They are instructed to "Replace the harness clamp if the harness clamp is soaked with engine oil" (PN 92171-1255). They are also instructed to make a small punch mark on the frame directly above the top rivet holding the ID plate, indicating that the recall service has been done.
The kit consists of a large bottle of "crazy glue" (supposedly enough to do 20 bikes), a roll of electrical tape (more than enough fro 20 bikes) and a small flat blade jeweler's screwdriver (to get the wires out of the plug). Oops! Sorry, it's called a "Terminal Removing Tool".
In a nutshell, here's what is supposed to be done...
1. Remove rear seat, front seat and side panel.
2. Disconnect the alternator lead connector.
3. Remove the vinyl (black) tape from the harness, approximatly 100mm from the connector.
4. Remove the plastic lead tube (so THAT's what they call that plastic wire cover!)
5. Remove vinyl tape that covers intermediate connection (where the two wires go into one before the plug)
6. Remove terminals from the plug.
7. Clean terminals with contact cleaner (SEVEN steps and must be repeated THREE times!)
8. Apply "quick curing adhesive" where the wire is crimped to the terminal to seal the wire (FIVE steps!).
9. Apply adhesive to the top and bottom of the intermediate connection (Three steps!)
10. Insert terminals into plug (the same position they were in).
11. Wind 4 to 5 turns of tape around the intermediate connnection.
12. Put plastic tube over wires.
13. Wind tape 2 to 3 times around the end of the tube (by the plug) and continue to wrap the tube until you overlap the original tape wrap (approx. 100 mm).
14. Clean the regulator connector and the area around the connector with contact cleaner.
15. Reinstall the removed parts in reverse order.
16. Make "Repair Verification" mark on frame.
17. Fill out "Warranty Claim" documentation (REQUIRED by Federal Law - NHTSA Law 49 U.S.C. Section 30210(i) or they will keep sending the customers notices).
Repair time: 0.5 hour.
Other Recalls and/or Bulletins
I think I got this right in the right order, this time. As far as I know this is the complete list of all official Service/Technical Bulletins and Recall Notices that has issued by KHI/KMC for the ZX-12R.
NOTE: some bulletins and recalls do not apply to all models.
MC 00-02 (A1) - Rear seat cover adjustment (service bulletin/A&P sheet addendum)
MC 00-04 (ALL) - Proper spacing of front wheel (service bulletin/A&P sheet and service manual addendum)
MC 00-06 (ALL) - Break-in mileage change (service bulletin/owner's and service manual addendum)
MC 00-07 (A1) - Cracked winglets (service bulletin)
MC 00-08 (ALL) - Proper clutch release lubrication procedures (service bulletin/service manual addendum)
MC 00-09 (A1,A2) - High altitude ECU replacement (service bulletin)
MC 00-13 (A1,A2) - Fuel tank leak and fuel gauge (NHTSA recall)
MC 01-07 (A1, A2, B1) - Wheel valve stem locking nut (NHTSA recall)
MC 02-11 (ALL) - Oil seepage from alterator lead connector (NHTSA recall)
NHTSA - National Highway & Transportation Safety Administration
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There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely games.
-Ernest Hemingway
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