Theres a pic at the top of page 9 of the inside of the stator

2002 Pearl Mystic Bullet

</p>

Add me to the list. Mine sprung a leak a couple of weeks ago and I didn't know what it was until I saw this thread. (Once again you guys are all over it! I love this site!) My plug was also 1/3 full of oil. I drained it out and wiped clean hoping it was just some dialectric jelly from the factory that had liquified from the summer heat and hot tempered 12. I was dissappointed to again see the oil dripping on my hugger/chain guard after my next ride of about an hour.

Okay, now I'm worried. Time to call the dealer. By the way this happened with 7k on the clock.

</p>

Okay, I just finished replacing my generator cover. When I put the coil and wires into the new cover, here is what I found:



There are ~4 white wires that are not used in the cover. Their ends are covered with a black cloth tape. Due to their being in the cover the tape does not seal the ends from the rest of the case, instead the tape acts as a little tunnel directly to the exposed wires inside.



These wires are in the top half of the case but obviously oil does get in there. This is motor oil we're talking about here, not some grease or anything else.



Thus the oil does infact travel up the wires on the inside, not in the wire loom cover. I currently do not have the problem you guys are describing, though I can very easily see how I might in the future.



Incidentally, my bike is a 2002 model. Hope this helps to explain what you are finding.

</p>

I have an 02 model and it has 6,000 miles on it. I am running Mobil 1 and I use the 12 to get me to and from work mostly. Only a couple of first gear power weelies and no high speed runs and I too have the small electrical connector addressed here leaking oil. I didn't have to pull it apart to notice it, as it has a motor oil pond on top of the connector. How often does Kawasaki recommend changing the oil in this connector? I have not changed the oil in this connector since the bike was new? This better not void my warranty as my manual has nothing about changing the oil in the connector. LOL!

I am calling my dealer tomorrow.

Thanks a bunch guys/gals.

Elbo

</p>

Elbo, thats too funny <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"> <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/laugh.gif ALT=":lol">

Official BAM Club Member

</p>

Please see my post for the solution for this problem.

Regards

Ted

</p>

Here's a link to Ted's thread........



One Possible Solution

Official BAM Club Member

</p>

Here's Ted's thread in full, Im afraid it will drop off the board if I do not copy here.......



Author Comment

Ted Edwards

Expert

Posts: 956

(8/14/02 1:56:05 pm)

Reply Possible solution to oil in connector problem

--------------------------------------------------------------------------------

Guys,

This is for the guys that are out of warranty and can't get a replacement from Kawasaki.

Having thought long and hard about this very unusual problem, I think I may have come up with a viable solution.

Those in the aviation industry will be fully aware of what I am talking about, basically I would be inserting a "Plug break" in series with the wires that are allowing the oil to travel through them.

This sounds drastic, but please read the whole post before you make a decision.

Basically, you cut your wires somewhere just above the generator casing and before the frame gets in the way, I guess about 4 to 8 inches away from the generator casing.

You then get a plug and socket with the requistite number of pins, preferably an aircraft spec or something similar from a radio shack or whatever.

Some names as follows, Plessey, Hellerman Deusch, Cannon. The important thing is that they must be SOLDER type pins and sockets, I don't think crimp type will do.

You then "tin" the wire ends, (basically, bare a part of the inner wire, heat the wire and apply some solder to meltonto the wires. It helps if you put a slight twist on the wires to keep it tight and easier to apply the solder to) fill the male and female pin sockets with solder. Heat the pin and insert the bare "Tinned"wire into the socket. This should seal the wire end into the socket of the male or female pin. You can then "lightly" apply some glue/varnish etc over the end of the plastic insulation on the wire to seal it against the socket end of the pin.

DO NOT put the glue on the whole pin as it will insulate the connection.

Using the supplied insertion tool assemble the pins into the plug/socket.

Aircraft spec plugs and sockets are hermetically sealed to prevent moisture ingress, therefore it will be difficult for any oil to escape. They are also generally easy to do and undo (half twist or screw together)

The end results are as follows;



1) You have sealed the ends of the wires at a point just above the casing by soldering the wires and inserting them inside a pin. Therefore there is nowhere for the oil to go as you have disconnected the internal path through the wires.

2) You have sealed the plastic insulation to the pin.

3) You have sealed the pins inside a hermetically sealed plug/socket (connector).

4) You also have easy access to see if you have any problems with the repair.

5) You can also gain access to carry out any electrical testing without taking the seat unit apart.

5) It will also be a damn sight less expensive than replacing the generator. (Which could conceivable leak in the future).

6) You can also for "super safety" put in insulative "putty" or potting compound to further seal the connector.



OK Guys, the pain in my head has now gone away!! By the way, my bike is 7,000 miles and dry! (Faster 00 silver)

Sorry it was so long!

Anyone got any other ideas?

Regards

Ted



VinnieZX12R

Expert

Posts: 772

(8/14/02 6:02:54 pm)

Reply Re: Possible solution to oil in connector problem

--------------------------------------------------------------------------------

Not a bad idea Ted! Along those same lines, wonder if you could just cut a half inch of insulation off each wire, seal the wires with solder as you suggested, then cover the uninsulated areas with the glue/varnish? Just a thought.

"Take two beers and call me in the morning"



ZXLNT

Street Pro

Posts: 478

(8/14/02 6:08:40 pm)

Reply Re: Possible solution to oil in connector problem

--------------------------------------------------------------------------------

That might be a damn good idea. U have to take the freaking motor mount bolt space out anyway to get the fucking wiring harness of the bike. Major pain in the ass...

It's True The Way I Feel

Promised By Your Face

The Sound Of Your Voice

Painted On My Memories

Even If Your Not With Me

I'm With You



Ted Edwards

Expert

Posts: 963

(8/15/02 2:56:58 pm)

Reply Re: Possible solution to oil in connector problem

--------------------------------------------------------------------------------

Vinnie,

That might just do the trick if you are careful to ensure that the solder has penetrated ALL the strands of the wire. Would also be cheaper than buying a plug/socket! Nice one!

Any more news on your possible trip over the pond?

Regards

Ted



VinnieZX12R

Expert

Posts: 774

(8/15/02 4:37:09 pm)

Reply Re: Possible solution to oil in connector problem

--------------------------------------------------------------------------------

Still waiting to hear back from some contacts in London. I'm really hoping I get the chance, I'd love to visit London! I will try to touch base with them tomorrow, so hopefully I'll know something. I'll definitely let you know when I find out for sure.

"Take two beers and call me in the morning"



Ted Edwards

Expert

Posts: 966

(8/16/02 9:45:05 am)

Reply Re: Possible solution to oil in connector problem

--------------------------------------------------------------------------------

OK Vinnie,

Regards

Ted





Official BAM Club Member

</p>

Ok, so has anybody tried VinnieZX12R's suggested method of preventing the oil from traveling up the wires? I'd like to hear a few success stories before "novice me" goes cutting into the wires of my charging system!

</p>

Roy (Slver12) and I have solutions to ours. The local dealer contacted Kawasaki, and they are replacing ours completely. I will drop mine off probally next week to have the warranty work performed.

Official BAM Club Member

</p>

okay fella's,i tried the RTV fix on my 12 at the beggining of this thread, before i went up to VIR thinking it would work...WELL IT DID NOT WORK...so i guess i will try TEDS fix next..it sounds more of a solid fix than the RTV fix..i had a feeling it would not work but i figured i would give it the old reddawg<img src=http://www.ezboard.com/intl/aenglish/images/emoticons/embarassed.gif ALT=":o"> try..i will keep you posted..later...reddawg<img src=http://www.ezboard.com/intl/aenglish/images/emoticons/embarassed.gif ALT=":o">



</p>

<blockquote>Quote:<hr> Author Comment

EPSTEIN

Street Pro

Posts: 330

(8/24/02 8:42:49 am)

Reply ANOTHER OIL LEAK In Harness

--------------------------------------------------------------------------------

OK It happened again.......less than 1000 miles since repair......and yes my connector is FILLED with oil again....When we met Todd and stopped for lunch I asked him if he had checked his connector...he said no so I showed him the plug on mine .....a lil voice said "Pull It LUKE...Feel The Force" and F*&K it was filled with oil ....AGAIN.......New stator New Harness ...and i know its new cause the dealer (who I know personally) replaced it and saved my old part.......Dunno Any suggestions???..Brian



<hr></blockquote>





Official BAM Club Member

</p>

I too have experienced this oil leak....I ahve yet to have an elecrical problem caused by it, but the harness was full of oil...enough where I could pour it out. I have conacted kawasaki about it, and as of yet have had no reply. The oil is not seeping through the wire bundle, but actually through the wires themselves. I discovered this by finding a hole in the bundle further up the line where another wire is coming out and finding that it was completely dry. I have never before seen anything like this. The dealer seemed stumped on how this could happen(big surprise there) But I also know others who have experienced this problem and had electrical problems because of it. Guess I will wait and see what Kawasaki has to say about it (if anything)

</p>

I called my dealer yesterday and told them I'm bringing it in on Friday because "we" need to get this fixed. He's calling Kawasaki to see what he needs to do to warranty the work. These guys are friends of mine so we'll see how Kawasaki plays it. I'll let you know what happens. I also printed out much of this thread for the dealer so he can forward it onto Kawi if neccesary. They need to know we are having this problem and that "they" ned to fix it before one catches fire.

</p>

I feel like I am being left out... I didnt find any oil

yet.



2000 6k+ miles

Never Ride Faster Than Your Guardian Angel Can Fly!!</p>

Cross your fingers.

Hello, My name is OutsiderZX12R, and I am a ZX-12R.org addict.</p>

I have dealt with this problem for 2 years now! I figured it was something you had to live with! 00-green, and 00-black(used to be red)....every time I have the seat off, I unplug the connector and route it down low and let it drain for about 20 minutes....pita....is KWAK gonna' take care of this????

</p>

"Is KWAK going to take care of this?" <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/roll.gif ALT=":rollin">

Hello, My name is OutsiderZX12R, and I am a ZX-12R.org addict.</p>

The dealer in Pensacola Florida. (P.M.S.) Claims they contacted Kawasaki and followed their instructions. They replace the alternator cover gasket and resealed the wiring harness. A week later and I don't have any oil dripping off of the conector but when opening up the conector I found it full of oil. I don't know if this is just residue from the problem before or not. We shall see.

Anybody want to put bets on that fixing the problem?



Now 2weeks after cleaning out the conector and just a little bit of oil in conector when I took it apart. Not enough to poor any out. Looks like maybe it is fixed for now.



</p>Edited by: <A HREF=http://pub56.ezboard.com/uelboman.showPublicProfile?language=EN>Elboman</A> at: 9/15/02 4:46:42 pm

I'm betting it won't. I did that when I changed stator covers. Still leaks.

Hello, My name is OutsiderZX12R, and I am a ZX-12R.org addict.</p>

Kawi is warrantying my repairs on my '01 which is far out of its' original warranty. I spoke with the shop manager and explained the problems others have had with simply replacing the loop and he said they would fix it all the way so it won't occur again. Made my day. Can't wait to get the beast back. I like my new R1 but I love my 12.

</p>

My dealer ordered the parts for my 02 today. Going to replace the stator and wiring assembly. The mechanic thought I was joking about it. I assured him I was serious.

We pulled my seat off and it was obvious. My connector, and the wiring harness in both directions was covered in oil.

I told him before he pulled the connector apart to get a few rags. He said "really?" Yep, we poured oil out of mine, on both sides. They claim they have never seen anything like that. I said "really?" <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/laugh.gif ALT=":lol">

Mechanic cleaned my connectors real good, reassembled the bike, and we ordered some parts. I'll take it in next week for repairs.

Is that a Bam?



</p>

First off I'd like to say thanks for the very usefull information, I'm new to the site and have put it to the top of my list for zx12r sites. GREAT JOB! by EPSTEIN's reply it sounds like the warranty fix did not cure the problem. Am I understanding this correctly? If so, the great idea of ZXLNT in Ted Edwards thread on how to fix the problem is probably the best approach. This is where ZXLNT mentioned striping back some of the insulation on each of the wires and wicking solder into the bear wire and then reinsulating it. Just remember the wire will probably already have oil on it so you will want to use some electrical cleaner to clean the wire before soldering it.



what do ya think?? (and thanks again, great group)





</p>

My 02 is at the dealer now to have repairs made.

I'll let you know if it is a successful surgery <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/smile.gif ALT=":)">

Is that a Buell?



</p>Edited by: <A HREF=http://pub56.ezboard.com/umwrzx12.showPublicProfile?language=EN>mwrzx12</A>* at: 9/11/02 6:07:11 am

Well, it looks like Kawi is using my bike as a case study to figure out what is happening here. They asked the dealer to send the stator, cover, gasket and wiring loop back as one unit so they can examine the whole assembly. Looks like they are going to replace the entire assembly under warranty but they aren't paying for for labor! I'll let you know how this turns out. Peace.

</p>

I just finished checking my Blue '02 and it is as dry as a bone inside the rear cowling. Not even the slightest residue of oil, only some road or brake dust. <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/smile.gif ALT=":)">



I have 3500 km. on it, but I will check it everytime I do a oil change just to be on the safe side.

</p>

Happy camper, Did you disconect and check inside the small conector on the left side under the front seat? That conector has a rubber O ring or seal to seal water out and it also works good for sealing the oil inside the conector keeping your cowling dry and hiding the problem.

Just a thought.

</p>

Spoke to my dealer again and he stated just bring it back and they will replace the stator and harness yet again.........Now I had a very wierd experience ......I rode the bike for at least 30 miles.....and stopped ...and it was as dead as Elvis Presley.......jumped it ran it ...and didnt have that problem again.......hmmm scratch it as just a freak battery problem or is oil the culprit.......hmm shoudl I push for a new battery as well?....

Going to pick the 12 up at lunch. We'll see it it stays leak free :?

I have mine back. Seems ok right now, I'll keep a check on it...

Add me to the list. Went on a 200 mile afternoon ride. Stopped for a late lunch. Dammit, I seen oil dripping on the swingarm. 7700 miles. Talked to my dealer, said bring it in tomorrow. And that they would call Kawi.

Dealer called Kawi service. Told them to order a stator which comes with the harness and send my old one back in. They said they know they have a problem but are trying to figure it out.

:( Add me to the "Oil In 3 Pin connector" group. I have 34,000k's on my toy and there has never been a sign of oil around the offending area. I pulled the connector apart for piece of mind - BUMMER - there was about half a teaspoon on the inside of the 3 pin connector.

Took my 01 pearl white 12 to the dealer today here in Tx. They had never heard of this problem. I gave them some threads to read and the web to look at. Wish me luck.

Sounds like the dealers in Central Kansas. Two of them haven't heard of it, so they say. :shock:

i guess i better check mine. :x

You haven't looked yet :?: :shock:

G to busy being a ripped green ho :P :P :P

:P

I understand now!

relaxxxxx man... its cool.... :)

I've had the 12 back for a couple of weeks now and have put about 500 miles on her since parts were replaced with no sign of oil in narness yet. Kawi picked up the whole she-bang, parts labor and all even though my warranty expired in March. I hope they treat everyone else the same. Good luck. I'll post here if the problem returns. Peace.

is that only on the 2002 model

This is a recall. Contact Kawasaki for more information.
I have not received my recall in the mail, but it is on the way.

I now have 11,000 miles on said bike. I took the connector apart and only a small trace of oil was noticabel inside the conector. Not even enough to poor out, unlike before. I believe it was a small enough amount to have been left over in the wiring harnes from before fix was preformed at 6,000 miles. So now I am a happy camper.
The reciept says that the parts used was a "generator cover gasket" and labor was "remove alternator and reseal"
Looks like it worked.

G'day,
Just recieved my recall notice via snail mail. Dark down here now so I'll check it out on the morrow. Let ya know what I find.

My battery went dead on me the other day and I was checking it out. I took the connecter apart for my stator and it was full of oil. And now I'm not getting any voltage from my stator to charge my battery. but my lights and stuff r working. Because I read about people losing there lights. I can put it on the charger and then ride it for a bit and shut it off and it is dead. does that sound like the cause and problem. I'm glad to see someong doing more checking on it. I noticed the oil there before and couldn't find anything out.

Could it be that the oil that is wicked up through the harness is creating resistance in that harness? Cuz I've done the soldering fix and removed the connectors that fill with oil. I'm still getting dead battery problems and the wires I've soldered are now browning, they will eventually get brittle and fry. I was thinking of doing this.... Make the solder near or even in the stator casing to prevent the wicking of oil all the way to the tail section.Of course that would be done after a new stator, harness and rectifier/voltage regulator. Any thoughts?

Or.... replace the wires themselves with solid copper wire. All the way from where they connect to the stator. There are only three wires coming from the stator right? https://www.regulatorrectifier.com/c...ges/21-216.jpg Because from what I've read the wicking of the oil into the wires is within the wire strands themselves, not the insulation.

yo, that problem you described about the mysterious oil will lead to one of the two regulator connectors becoming saturated in oil. this will lead to the connector becoming ONE connection! big problem! pull them apart and inspect.

i know this because i just removed the connector, it had melted together causing a serious charging issue...

ROFLMAO talk about reviving a dead thread.. this is from 2002.. I believe there is a recall on it and the dealers fix is super glue.. member's here have found multiple better ways to rectify the situation.