Leak from Stator cover

Hello KZ riders! I have just bought my first bike a 77 kz 1000. it has a drip from the wires in the stator cover, there was no gasket on the cover just gasket sealer. I dont have manual so i dont know if there is supposed to be oil in there or if it is a crank seal that is leaking. It is coming out of the grommit and if it is supposed to have oil i suppose i can just seal up the grommit and put the gasket on. The gasket looks like it is for holding oil so i assume its a wet alternator. Can anybody help me out on this one? Thanks!

Yes oil is supposed to be in the stator cover, there are new gromets available or you can try sealing yours up as well

kz kev wrote: Hello KZ riders! I have just bought my first bike a 77 kz 1000. it has a drip from the wires in the stator cover, there was no gasket on the cover just gasket sealer. I dont have manual so i dont know if there is supposed to be oil in there or if it is a crank seal that is leaking. It is coming out of the grommit and if it is supposed to have oil i suppose i can just seal up the grommit and put the gasket on. The gasket looks like it is for holding oil so i assume its a wet alternator. Can anybody help me out on this one? Thanks!

Hello, kz kev, and WELCOME to KZr!

Click here > www.z1enterprises.com/ItemDetails.aspx?i...+1100&item=RIGROMMET

Good Fortune!

Your grommet is rock hard buy a replacement from Z1 Enterprieses install then fill cavity void full of sealer let set up for 1 day install good to go for another 20 yrs.

cool i will just order new grommet. Thanks for the help guys it is much appreciated!

If a new gasket is also needed ---

www.z1enterprises.com/ItemDetails.aspx?i...00&item=KS72-2002I-1

Good Fortune!

I had to cut the wires to install the new grommet and then solder it back with a couple layers of heat shrink. Maybe someone here has a better way of doing it. Maybe taking off the connector to do it.

The best way is cut outside the cover and stagger the connections. Heat shrink is good and I used the out side insulator of some irrigation wires. You could just re use the woven one if you can push it back and it"s still in good shape. Mine was not.
Steve

When replacing the grommet, other considerations will also include whether to cut and reconnect the wires, or remove and replace the terminals at the connector ends of the wires, or other methods to help assure a leak-free result. There are numerous KZr topics and forum posts about this particular repair.

For example:

Cardin wrote: When I replaced the grommet, I put sealer up between the grommet and the case AND I put some through the wire holes... still leaked... the problem for me was the braided fabric wire insulation. Oil was wicking through it.

Once I yanked that and put in new wire, not single drop.

That being, it confuses me that they aren't born leaky. I suppose that insulator is a lot more supple when it's new... now here, 30 years later...

There is definitely just a few ounces of oil flow to the case there. And if you have the case open and you put the bike on it's side stand, there's more than a few ounces of oil on your driveway.

Patton wrote:

650ed wrote: I'm not familiar with the seal, but if it is all rubber (no metal ring) you may want to make a slice from the center to the outer edge, slip it over the wires, then superglue the slice back together making the seal whole again. Ed

Have always wanted to try that. Just not positive that superglue would be the best adhesive.

And why not --- as the grommet is relatively inexpensive should another be needed due to leakage through the re-joined area.

Good Fortune!

Here are many more KZr articles about replacing the grommet in the alternator cover.
Click here > kzrider.com/forum/search?query=new%20alt...te=all&childforums=1

KZr's FORUM > SEARCH feature USING keywords NEW ALTERNATOR GROMMET produced the above link.
Variations of keywords may be used to find additional information in KZr.

Good Fortune!

For reference, here's the lubrication diagram as shown in the FSM (Factory Service Manual.)

Some models, such as large Kawasaki fours, have a little oil inside the alternator cover, as shown by the lubrication diagram in the FSM, such as:




Good Fortune!