But I have the crankcase mod..?! I have had it for awhile now and I've

got/had alot of oil back there. Seriously man, it's alot of oil. Kawi. is takin'

care of me though.

Stupid hurts.</p>

man I have been tring to figure that problem out for awhile now. I had just chalked it up to too many wheelies. It has been to long since I have been on here. I am glad that I have got back on. I am going to check my connections in the morning. But I bet that there is oil in there because I have an ass load of oil that comes from the tail. It is not a drop or two it is way more than that.

</p>

checked my '02 faster Black/gold model, and the connector is dry as a bone. I noticed a drop of some kind of hot melt type substance on the wires where they came out of the loom to the connecter so I wonder if Kaw started sealing the harness on newer bikes?

'00 ZRX1100 E.L.R.
'02 ZX12R Black/Gold

"When all else fails... get a bigger hammer!!"</p>

This has been going on longer then you think!!!and they do know about it, why do you think the thing is mounted way up high in the back!

</p>

I just filled out the NHTSA Form regarding my front fender welding itself on my front tire. Here's the ODI Number: 764662



Gentlemen - I mentioned this once before. On www.badweatherbikers.com, which is a popular Buell site, they have a stickie topic called, "Buell Company, Are You Listening?" Individuals post concerns and problems. Buell has assigned an individual to review these posts. The results aren't always pleasing, but, many times they do get responses and help. If we get enough traffic on this site, it just makes common sense that Kawasaki will at least take note of what we are saying.

Not just a barbarian, a great barbarian!</p>

Tenn, but didn't you have the problem before doing the CC Mod?

"Green Mamba" - Feeds mostly on Birds, almost flourescent green in color, can strike violently with extrodinary speed.
</p>

Dealer called me today ........He said the mechanic took out the stator....and harness and it was filled with oil(harness)....The mechanic who never saw this before called Kawi and spoke to a tech and the tech informed him that Kawasaki is completely aware of such problems. They state it is not a recall( no duh) and it is fully warranteed..(stator,rectifierand harness) ..He further stated that the new stator and harness are different Have a silicone plug in it and will not happen again......The catch was the parts will take 1 week to get .......Unless I Blue Label it......(overnight-2nd night).....that will cost me about $40.....for shipping......then I can have bike back by Fri or Sat.........Brian

"Be Nice to the Police Officer.......Ya Never Know When He Owns 12!!!!</p>

Do you have any part#'s for the new kit or anything that will help an unbelieving dealer make the call and get it fixed?

Will they fix it even if it hasn't started leaking yet? (can I go in and get the updated harness/stator before I run into problems?)

easyrider@zx-12r.org
*
www.ZX-12R.org</font>
*
Top 100 Bike Sites</font></p>

I'lll ask and find out in the AM Easy.....

"Be Nice to the Police Officer.......Ya Never Know When He Owns 12!!!!</p>

I feel the same way as easy, Mine is not leaking........YET! But I have a feeling if I were to cut into my harness at the stator in would be full of oil. I would bet allot of others have oil in their wiring but it hasn't gotten to the connector yet. I would also like to know if I can get the "new" harness with the plug in it before I run into problems, so a part # would go a long way with my dealer.

Either way I'm gonna fix/prevent this from being a major pain in my arse.



BigJ12

</p>

The way I see it , is the regulator generates alot of heat and with the wires inside of the plastic harness and mostly the wires going into the motor do NOT have any silicone, the hot wires are like a straw sucking oil up and out through the connector. Comments?

</p>

Uuuuuuum, maybe a recall would cost alot for the big Kawi co., but there sure seems to be enough people experiencing this little oil problemo. What or how many people does it take before it's a recall?? I would think this would clasify as a saftey issue seen as though my damn bike almost cought on fire.

Living life on two wheels
and living wild
on one</p>

Under warrantee? What about the guys whose warrantees have expired?

Not just a barbarian, a great barbarian!</p>

if its expired then I am sure it would take a recall..........unless you have a really kool dealer and he finagles it for you......

"Be Nice to the Police Officer.......Ya Never Know When He Owns 12!!!!</p>

Then I'm hosed!

Not just a barbarian, a great barbarian!</p>

I'll ask MY Dealer when I go there.............maybe he'll call kawi and ask

"Be Nice to the Police Officer.......Ya Never Know When He Owns 12!!!!</p>

I say..... RECALL EM ALL!!! Quit jerking around!!!

Living life on two wheels
and living wild
on one</p>

Thanks for keeping us updated Epstein...it sounds like what I'll have to do is take my bike down, let them verify there's a problem, then have them reassemble it so I can ride it while I wait for the parts to arrive. <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/happy.gif ALT=":D">



Tim

</p>

Ok heres the Deal......Got My Baby back today ......the part # is the same but it has been modified... ....Kawasaki knows about the problem and will warrantee any machine with same problem....the stator wire harness and rectifier have been replaced...the dealer was truly amazed at the problem and has kept the parts to show the Kawi rep when he comes to the dealer.....As for the shipping.... My dealer called Kawi and has asked for a full reimbursement on my blue label shipping...I am one truly satified customer!!!Way to step up to the plate .......as for those who are out of warrantee call kawi and demand the part be fixed ..... If enough of us call the dealer said they will make it a recall!

"Never wrote a ticket to a showboating squid.....I just scoop em off the pavement!!!"</p>

Glad you got your bike fixed so quickly Epstein.





I am going on vacation tomorrow, Saturday 07/27, and will be gone for seven days.



Just in case anybody tries to e-mail or ping me I will be

internet free <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/laugh.gif ALT=":lol"> <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/laugh.gif ALT=":lol">





"I'll be your huckleberry"</p>

I don't really see a correlation between oil being found in the wire wrap and connector vs the overheated rectifier and over-heated wiring.



Sounds like 2 unrelated problems to me.



Anyone care to shed some light?? <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/smile.gif ALT=":)">





by the way, for what it's worth, I've had my crankcase breather connected to the exhaust reed-valve area for a long, long time. (w/Kleen Air removed)

Maybe, like Y2KZX12R says and has also done, that's why I have no oil anywhere on my wire-wrap or connector.





</p>

Red 2000, all's dry in there.



Jeff

</p>

The oil was causing a short in the plug and made the wires hot thus cracking the insulation ...All one in the same BA.....Brian

"Never wrote a ticket to a showboating squid.....I just scoop em off the pavement!!!"</p>

I'm dry! I'm just wondering if the oil in connector issue is related to the PCIII. After what happened to Mark-PMB, I'm wondering if his PCIII actually slightly failed before, not enough to cause a catastrophic failure. But, maybe it had previously failed enough to cause high pressure in the crankcase which forced oil through his stator wiring. Has anyone had this problem (i.e., oil excretion) that has not installed a PCIII?

Not just a barbarian, a great barbarian!</p>

Markus...my el problems happen prior to installing the Yosh EMS.

Living life on two wheels
and living wild
on one</p>

So much for my theorem.

Not just a barbarian, a great barbarian!</p>

Checked mine out. Nothing at 5500 miles.

</p>

and i still got the oil leak..later...reddawg<img src=http://www.ezboard.com/intl/aenglish/images/emoticons/embarassed.gif ALT=":o">

</p>

Well, you can add me to the list of "OILERS" I just took mine apart today, and had to do an "oil change" on the connections under the seat!!! seriously....a lot of oil in there. I cleaned it all out with contact cleaner, then dried it with compressed air. I guess i'll need to do something to prevent it from happening again, but it should be okay for a while now. My bike is a 2000 model, bone stock, with just under 6K miles on it. Yes, I drive it hard occaisonally, but no vertical wheelies or anything drastic like that.

</p>

hey jadegreen,just cause you dried it out and blew dry it does not mean it will stat dry, i did the same thing and a week later it was wet again..later..reddawg<img src=http://www.ezboard.com/intl/aenglish/images/emoticons/embarassed.gif ALT=":o">

</p>

Checked mine and its ok.Blue 2001/3.5k mls.

</p>

My friend who also has a 2000 with Full Muzzy, PCIIIR and K&N's has had oil under his tail section now for quite sometime, but didn't know what was going on until I told him last night.

</p>

I've been giving this problem a wee bit of thought and one possible solution is that the oil is travelling between the strands of the wire inside the insulative sleeve of either one or more of the wires from the generator housing.

Has anyone seen the inside of the generator and if so, are the ends exposed within that would allow the oil to get inside the individual wires??

Reason being that as the strands are round there will be gaps all the way up through the wires to the connector in the tail unit. If there is crankcase pressure, it is conceivable that given time, the oil may work it's way up there via the inside of the individual wires.

It's only an idea, but if someone can confirm if the ends in the generator casing are open then it seems feasible???

Regards

Ted

</p>

You say you would like to see what the inside of the generator cover looks like. Well, here's a picture. Someone please take this picture, save it, and host it as my earthlink acc't will die very quickly. I will leave this pic up for 1 day, and then delete it.



The reason that I have this pic is because, in case you hadn't noticed, I have a 2 inch crack in my cover. Hopefully this week I will have the replacement cover.



PICTURE

</p>

Pulled mine tonight. Bone dry. 2k w/Akra.

"Never play leapfrog with a unicorn."</p>

Charlie, I saved the picture. I'll put it out on my website as a link when I get time. P.S. - Nice resolution on the pic.



I was going to move this thread to the archives, unless you guys want to keep it here a while longer.



Let me know any opinions.

"Never play leapfrog with a unicorn."</p>

I called Kawasaki this afternoon and was told by somebody (I didn't get a name) that they were not aware of it. Either he is lying or HE has not heard about it. Basically told me that it was my problem. I emailed the NHTSB using the link mentioned earlier in this thread.



BTW: I would keep this thread here a little longer if it was me. There are more leakers out there and as we get new members, they can find this thread and can look at their machines.

</p>

Actually, that picture was a shrunk version of the original. The original resolution was 2448x1632. That's just a little bit too big to be reasonable for the board.

</p>

It's good for new members too see this, but I feel most of the regulars here have checked this out. I would think that Easy may want to save this one on the main site possibly under the potential problems area. That is up to you. Thanks for keeping this here for as long as you have, I belive it has helped several members here.

2002 Pearl Mystic Bullet

</p>

Thanks for the pic Charlietuna,

I have spoken to a few of my associates at work and they also seem to think that although it is very unusual it is feasible that some sort of capiliary action might be causing this fault. As you can see with the pic (hope it comes out) the ends are open. This is not to say that I am correct as I am always willing to accept that I might be wrong and always willing to learn new things.

{image}file:///C:/My%20Documents/My%20Pictures/DCP_0440-1%5B1%5D.jpg{image}

Regards

Ted

</p>

Pic???



{image}photo.msn.s8.com/MS8zLzAv...jpg{image}



Regards

Ted

</p>

<img src="http://photo.msn.s8.com/MS8zLzAvMS8xMDI5LzE1NS8zMi9aaHcxZXhqdGYtdjRDWkFEcD RhOUJ3/e66650cac7ba6f663cd98997acb29b77/clbk=HcZNnT9kkUgTyAlRNNqMyu60tYfXPi5ndBQzALAGTnWCE nI7i79WQ6WhmD3L7ibZ0hpeVjGPgTs$/jpg.jpgEzCode Parsing Error:

">

</p>

Finally got the damn picture through!!

LOL I still cannot see clearly if the conductors are exposed to the oil directly, but I would guess that they are.

Anyone else got any other ideas??

Regards

Ted

</p>

It's pretty simple.



I don't have oil in my connectors, but if you do, just check the loom for oil if there is oil in the plastic loom then that's where it's traveling up, if the loom is dry then the oil is travaling up the actual wire insulation between the copper wire and the plastic insulation. I find that very hard to believe......BUT ya never know!



So can someone with oil in there connector help us out and either cut a slit in the loom or take off some of the black tape that wraps the loom and check for oil.



Thanks



BigJ12

</p>

Ok Its traveling up the wires and inside of the insulation.......I know this because I illustrated it to the dealer by "pin pricking" the wire and showing him the oil "oooze" out of the wire.......The wire is exposed at the stator and this is fixed by encasing it in silicone.......or a new style harness as the dealer put it......Brian

"Never wrote a ticket to a showboating squid.....I just scoop em off the pavement!!!"</p>

Mystery solved!

Now what is Kasasaki going to do about it??? Anyone got any feedback??

Regards

Ted

</p>

Ok, now that I am back from vaca. (yuck) When I was down at Mid-Ohio a few weeks ago Jolt and I spoke with a guy at the Kawi booth about this, mind you he was not a tech tho ( no techs were there )....He said that HE has never heard about any thing like this but does knows about this website. (said he owned a 12 at one time and was on here alot, no I didnt get his screen name tho) He said Kawi DOES frequent this site and that he will definatley make a report about this situation and let Kawi know about this. Now, "if" he did make that report and "if" Kawi does frequent this site I dont know for sure.....

</p>

Epstein,



If I read your post right, the oil is traveling up the actual wire insulation and not the loom? How many wires are in the loom at least 4 or 5 so was the oil in every wire. If this is the case then sealing the loom does nothing to prevent the leak. You will have to seal each wire at the point where the insulation ends and the bare wire starts inside the stator.



This still may not solve the problem because I believe the wires are made up of many little strands and not solid (like the wires in a house) so unless you get sealer into the stands the oil may still find a way up the wire?



Are you sure the oil was in the wire insulation and not the loom? The loom was bone dry but the connectors were full of oil?



Thanks for the help.



BigJ12

</p>

Yes each individual wire (not loom)...Dealer replaced enitire harness stator and rectifier.......Stated Kawi knows about problem and has made a new harness with same part # to fix problem....Fully Warranteed......silicone fixes will require each wire being done correct... Brian

"Never wrote a ticket to a showboating squid.....I just scoop em off the pavement!!!"</p>

been on vacay and just seen this thread. been noticing some oil on my chainguard before i left. just pulled mine apart. full of oil everywhere. inside & outside. even has blown allover the tool box. it's a mess in there. so any word from kawasaki on this yet. noticed epstein's post. did they replace your system. not gonna be riding this thing until i get it rectified. i'd have to say whole thing needs to be replaced top to bottom. it definitely ain't my problem but theirs. these bikes have just had to many recalls. i've got less problems with my old kawasaki triples. at least i have some other bikes to ride

</p>

Sorry...mis-info, I posted from work and when I got home and looked at the service manual I was wrong.

Do unto others before they do unto you!</p>Edited by: <A HREF=http://pub56.ezboard.com/unebraska12r.showPublicProfile?language=EN>Nebrask a12R</A> at: 8/12/02 12:01:10 am

Epstein,



Thanks for the post I thought it was going up the loom! this explaines alot! like how oil gets into the connector without it being on the outside of the connector.



Now I know what to do to try to prevent this from happening to my bike. At least I will give it a shot. Anything to keep it from having to be brought to the dealer!





I will keep checking my connectors until the winter, then If it's still dry I will go into it and take a look at how the wires are positioned in the stator and how they can be better sealed.



Thanks again.



BigJ12

</p>

I now know it fills up quickly with oil. Cleaned mine up, rode the bike about 300 miles and checked it again, it was full of oil.....

2002 Pearl Mystic Bullet

</p>

is this a 01 or 02 problem?



Is there going to be a recall??????

Eddie, 02 ZX12 (RED) 2bros pipe...96 Z-28
CAMARO....

I don't have a speeding problem, I have a police problem
</p>

Eddie, it's a problem with all model years. Mine is an 02 and I had less than 2000 miles when I first noticed it....



I doubt they do a recall, but you can never tell....



Check yours, if it has oil in it, go to your dealer, and they should correct it for, looks like you may still be under warranty....

2002 Pearl Mystic Bullet

</p>

Even the 2002's have the problem?

</p>

Outsider, that is correct...

2002 Pearl Mystic Bullet

</p>

Add me to the list also. I noticed a nice streak of oil along the left side of the bike while looking inside my trunk. I have an '01 model with 2400 miles on it.

</p>

I'll update the list tomorrow....



We have added several more new people to the list.....



Hopefully as people find differnet solutions they will post here...



So far the best two I have heard is blockinf off at the stator or removing the connector all together and soldering the wires directly together.



Our local dealer told a 12 owner to clean out the connector, fill it full of silicone, and close it back up...



I am still researching, all input is appreciated.....



2002 Pearl Mystic Bullet

</p>

This may be far fetched, but here it goes.......

Ok, we now know the oil is traveling up the individual wires and not the harness.



So I wonder if you can "pinch" the individual wires from inside the stator before they go into the harness or maybe kink them in a way where the oil would have to make a sharp angle to get by?



This way the connection will still be good but it would make it harder for the oil to start it's way up?



Somebody who has had the cover off please tell me if there is room in there to do this.



Thanks,



BigJ12

</p>