Okay first of all I am stripping down my 97 FXSTC I just picked up. I will post some good pics when I am done. I am very excited. But here is my question. I noticed a leak at my stator plug and I know this is not uncommon but here is the odd part. The leak is coming from the actual round plug holes and not from the edge. In other words when I had the regulator unplugged and the bike was on the side stand I could see a very slight amount primary fluid coming out the two round plug holes. When on the jack it stopped (obviously due to the fluid shifting). And now finally the question. Do you guys think a some simple silicone up in the plug itself or should I just take a few hours and pull the cover?

 

As you already know this is common problem and there's no easy fix other than taking the time to pull the stator.
I think I would try giving the hole a shot of brake cleaner first, can't really say I've heard of oil coming up through the 2 pins. Couple years back my buddy's 87 fxr quit charging 3 hours from home and we found that the pins lost contact with the regulator connections because the rubber in the stator plug and around the pins broke down and became gummy. We did change his out with an entire ultima 32 amp kit. I just changed mine out with a cyclelectric 38 amp kit. Still early into the season so you will probably want to fix it up correctly.
By the way the cyclelectric stator has an advanced design for the connection from stator to regulator, no more chinsey plugin at inner cover.

 

Yeah it is bugging me so I may just pull it. But since I have messed with the plug I can put it on a load and see if it is charging as well. Both ends of the plugs looked to be in excelent shape.

Do you think putting silicone up in the regulator side of the plug would be a bad idea? To basically seal off those holes.

 

Can't hurt as long as you don't loose the contact.

 

It's been done plenty of times. It needs to be cleaned up really good. That plug starts off soft new and hardens with age and starts leaking.

 

Thanks a guys. One thing that is good is I will know if it is leaking just from sitting on the side stand. So if it starts again I am pulling it off and replacing the stator.

 

Another thing I will mention is the guy I bought it from swears there were never any leaks (of course) but he also said he just changed the primary fluid. Hmmmm. I wonder if he overfilled it.

 

It's a possibility.

 

Oil should be right at bottom of spring plate with bike standing straight up.

 

Isn't that stator plug on the left side engine case? If it's leaking doesn't that mean a bad oil seal on the crank and oil getting on the rotor/stator where it should be dry? If I'm recalling correctly that fitting is not on the inner primary case is it? That rotor/stator assy. is dry isn't it and not bathed in hot oil? And that rubber fitting to the voltage regulator is just to keep dirt/dust out and insulate; not an oil seal.

Correct me if I'm wrong but I've seen pics of that area being disassembled and don't recall that stator being covered in any kind of oil?