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Stator Lead Bung Failure

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Guest

Guest
Who has any ideas on this.

Flying up the coast highway today I discovered my left boot covered in oil. Traced the leak to the starter motor compartment and replaced the starter O'ring as there was some seepage there. Went out for another pound but still my boot was getting a shower.

Pulled the 300 degree starter out and Oh, I see, oil dripping from the exit hole for the stator wires. Pulled the stator covder and oil was pooled on the wrong side of the rubber bung.

I am using an aftermarket stator so had to cut the old bung off the OEM to reuse. This has worked for about 10,000k.

Before anyone suggests high heat sillycone, are there any rubber solutions outside of me making one? They are molded onto the Oem stator so..... who has tackled this and won?
 
If the old rubber is hard and shrunk you have no choice but to replace it. I've reused the grommet on every bike I've worked on up to this point and will continue to keep my fingers crossed. One thing which may help is to degrease the grommet and mating case area really well with brake cleaner and let dry, then coat the curved portion with ThreeBond sealer before installing the grommet into the cover. Install the cover while the sealer is still wet and then let dry before starting engine.
 
Or...you can degrease it well with brake or parts cleaner spray and squish it full of ULTRA BLACK RTV around the wire pass thru hole, then let it harden up. Then when installing it in the cover, apply a liberal smear and again let it set up for about 15 minutes or so and reassemble.
 
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