rotor plug leaking from INSIDE plug
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Novice
Joined: Sep 2012
Posts: 15
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From: Texas Hillcountry
rotor plug leaking from INSIDE plug
I am having an issue with my rotor plug in the front of the primary case.
I know it is fairly common to have a leak from around the plug, but in my case, it seems like the leak is coming from INSIDE the plug.
No primary fluid leaks out from around the plug.
When I unplug it, INSIDE the male and female halves of the plug is leaked primary lube.
It is not enough lube to drip, but it IS enough to allowed the plug to become loose once or twice.
I don't see any way to RTV the leak without having to do it from the inside.
I've already ordered the spring to secure the plug in closed position.
So far, condition of the metal male and female plug halves inside the rubber plugs is good.
Any ideas on how to remedy this minor issue ? ... short of stator replace.
The previous owner of the bike said the stator had been replaced once before.
-CLC
I know it is fairly common to have a leak from around the plug, but in my case, it seems like the leak is coming from INSIDE the plug.
No primary fluid leaks out from around the plug.
When I unplug it, INSIDE the male and female halves of the plug is leaked primary lube.
It is not enough lube to drip, but it IS enough to allowed the plug to become loose once or twice.
I don't see any way to RTV the leak without having to do it from the inside.
I've already ordered the spring to secure the plug in closed position.
So far, condition of the metal male and female plug halves inside the rubber plugs is good.
Any ideas on how to remedy this minor issue ? ... short of stator replace.
The previous owner of the bike said the stator had been replaced once before.
-CLC
Seasoned HDF Member
Joined: Mar 2007
Posts: 66,948
Likes: 4,573
From: TOAK western branch
I am having an issue with my rotor plug in the front of the primary case.
I know it is fairly common to have a leak from around the plug, but in my case, it seems like the leak is coming from INSIDE the plug.
No primary fluid leaks out from around the plug.
When I unplug it, INSIDE the male and female halves of the plug is leaked primary lube.
It is not enough lube to drip, but it IS enough to allowed the plug to become loose once or twice.
I don't see any way to RTV the leak without having to do it from the inside.
I've already ordered the spring to secure the plug in closed position.
So far, condition of the metal male and female plug halves inside the rubber plugs is good.
Any ideas on how to remedy this minor issue ? ... short of stator replace.
The previous owner of the bike said the stator had been replaced once before.
-CLC
I know it is fairly common to have a leak from around the plug, but in my case, it seems like the leak is coming from INSIDE the plug.
No primary fluid leaks out from around the plug.
When I unplug it, INSIDE the male and female halves of the plug is leaked primary lube.
It is not enough lube to drip, but it IS enough to allowed the plug to become loose once or twice.
I don't see any way to RTV the leak without having to do it from the inside.
I've already ordered the spring to secure the plug in closed position.
So far, condition of the metal male and female plug halves inside the rubber plugs is good.
Any ideas on how to remedy this minor issue ? ... short of stator replace.
The previous owner of the bike said the stator had been replaced once before.
-CLC
Maybe someone gots a better idea.
Road Master
Joined: Apr 2009
Posts: 1,123
Likes: 43
From: NJ
I fixed mine with a zip tie as seen above, just enough preasure to pinch the rubber around the metal posts, still dry. This seems to happen as the rubber gets older and in my case, kind of soft or spongy. I think people might flex it too much when changing the filter, I'm real carefull now. Just make sure the regulator plug fits all the way on when you are done.
There is a thread here that describes all this..
Ds
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Novice
Joined: Sep 2012
Posts: 15
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From: Texas Hillcountry
thanks Doug S...
I was thinking along these lines earlier, but hadn't thought of using the ziptie, although I have a million of them and use them all the time.
Great info !
My leak is actually more of a light seep, and I bet this would make a difference.
Cool.
I fixed mine with a zip tie as seen above, just enough preasure to pinch the rubber around the metal posts, still dry. This seems to happen as the rubber gets older and in my case, kind of soft or spongy. I think people might flex it too much when changing the filter, I'm real carefull now. Just make sure the regulator plug fits all the way on when you are done.
There is a thread here that describes all this..
Ds
Great info !
My leak is actually more of a light seep, and I bet this would make a difference.
Cool.
I fixed mine with a zip tie as seen above, just enough preasure to pinch the rubber around the metal posts, still dry. This seems to happen as the rubber gets older and in my case, kind of soft or spongy. I think people might flex it too much when changing the filter, I'm real carefull now. Just make sure the regulator plug fits all the way on when you are done.
There is a thread here that describes all this..
Ds
Seasoned HDF Member
Joined: Jun 2010
Posts: 9,324
Likes: 3,869
From: Upstate New York
My first stator developed this problem. Fluid wicks up the wire and contacts inside the plug and gets in between the mating surfaces. My current stator has the entire lengths of the two wires overmolded with rubber in one piece with the plug to try to prevent this. It hasn't leaked on the inside yet, but started leaking around the outside after two weeks.
Seasoned HDF Member
Joined: Jun 2010
Posts: 9,324
Likes: 3,869
From: Upstate New York
I fixed mine with a zip tie as seen above, just enough preasure to pinch the rubber around the metal posts, still dry. This seems to happen as the rubber gets older and in my case, kind of soft or spongy. I think people might flex it too much when changing the filter, I'm real carefull now. Just make sure the regulator plug fits all the way on when you are done.
There is a thread here that describes all this..
Ds
Thread Starter
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Novice
Joined: Sep 2012
Posts: 15
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From: Texas Hillcountry
Damn Uncle G ! It still leaked !
If I have to replace stator, I guess I will do what you did, but also black ultra rtv around the outside of the plug where it goes through case, AND ziptie around plug outside of case...
With all this AND one of those bolt on to the engine mount retainer clips, I should be OK... haha.
If I have to replace stator, I guess I will do what you did, but also black ultra rtv around the outside of the plug where it goes through case, AND ziptie around plug outside of case...
With all this AND one of those bolt on to the engine mount retainer clips, I should be OK... haha.
My first stator developed this problem. Fluid wicks up the wire and contacts inside the plug and gets in between the mating surfaces. My current stator has the entire lengths of the two wires overmolded with rubber in one piece with the plug to try to prevent this. It hasn't leaked on the inside yet, but started leaking around the outside after two weeks.
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Road Master
Joined: May 2009
Posts: 1,232
Likes: 8
From: Powder Springs, GA
Mine did the same thing and drove me nuts. I ended up having so many problems with my primary with the clutch basket and leaks that I went with a dry BDL set up. No more leaks or problems.
I did put a bit of RTV sealant on the inside where the wires meet the plug and this helped to slow it down.
I did put a bit of RTV sealant on the inside where the wires meet the plug and this helped to slow it down.
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Seasoned HDF Member
Joined: Jun 2010
Posts: 9,324
Likes: 3,869
From: Upstate New York
On my current (there's that pun again) stator, I tightened up the fit between the plug and the case by installing some o-rings in the molded "grooves" in the stator plug, then using some RTV. It held for about 2 weeks then started to seep when it was cold. It stops seeping when the motor is fully warmed up. This was an improvement over the original installation, so I left it for five years.
A week or so ago, I was doing an unrelated sealing job and using some "flowable" RTV (made to "wick" into cracks to seal windshield leaks). I had some left in the syringe, so, on a whim, I cleaned up the stator plug and case with electrical contact cleaner and laid a bead of flowable RTV around the junction of the plug and the case. I didn't expect anything to come of it, but the stator plug has been dry for 800 miles now.
A week or so ago, I was doing an unrelated sealing job and using some "flowable" RTV (made to "wick" into cracks to seal windshield leaks). I had some left in the syringe, so, on a whim, I cleaned up the stator plug and case with electrical contact cleaner and laid a bead of flowable RTV around the junction of the plug and the case. I didn't expect anything to come of it, but the stator plug has been dry for 800 miles now.
Last edited by Uncle G.; Sep 29, 2012 at 08:39 AM.
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