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[longlast]

Has any one had a leak from the were the stator wires come out of the casing? I spoke with HD they say the seal is on the inside of the casing and that the hole thing will need to be replaced (stator with harness) as the seal is part of the harness.
Surely there must be a way of sealing it externally ? It's enough it's making a mess on the under carriage and the primary was low.
Suggestions to over come this without having to fork out £200.00 that HD wants for the part not to mention the work of removing and refitting. Thanks.   

[Twolanerider]

Many stator replaced for this.  No external fix.  I have fixed a couple without buying a stator though.  Remove the stator.  Carefully fill the rubber sealing "teeth" of the plug with a good oil resistant sealant  (I like Permatex brands but there are many) then carefully reassemble.   Dealership would never do it that way though.  Stator has gone through revisions just for that seal.

[Beak Boater]

Use some brakekleen, get all the oil off the plug and wires, then wash it with soap and water and dry the area around the wires and plug. The apply a silicone sealant of choice. Its a band aid, some last for years with out leaking, some only a month.

[longlast]

Thanks Don, I was afraid of that but not surprised. I don't have a repair manual just an owners. Any recommendations on a good repair manual. I think I'll be needing one. I'd like one that will cover it all, from motor rebuild to the tail light if pos. do you know of one?

[longlast]

Use some brakekleen, get all the oil off the plug and wires, then wash it with soap and water and dry the area around the wires and plug. The apply a silicone sealant of choice. Its a band aid, some last for years with out leaking, some only a month.

Thanks any thing is worth a try other than a strip down

[Twolanerider]

 Any recommendations on a good repair manual.

Look at it as the optimist would; you've got the garage now so you can screw with just exactly this kind of problem at your own pace and to your heart's content  .

There aren't a lot of options for service manuals.  The Harley manual really is good.  The Clymer manuals are out there and, for most things, actually don't suck.  They even include some areas of electrical diagnostics that the Harley manual does not.  Their wiring schematics are a little easier to read too.

This is not a terribly difficult nor delicate job.  Even dealing with that plug that seals through the engine block isn't that big a deal.  The first time you do it will seem tedious but it's a survivable task.  It's something you can likely sort with the insights gained from just looking at the exploded view in the parts manual if you're at all familiar.  You'll need some tools for the clutch and primary if such aren't already in your toolbox though.

[longlast]

Look at it as the optimist would; you've got the garage now so you can screw with just exactly this kind of problem at your own pace and to your heart's content  .

There aren't a lot of options for service manuals.  The Harley manual really is good.  The Clymer manuals are out there and, for most things, actually don't suck.  They even include some areas of electrical diagnostics that the Harley manual does not.  Their wiring schematics are a little easier to read too.

This is not a terribly difficult nor delicate job.  Even dealing with that plug that seals through the engine block isn't that big a deal.  The first time you do it will seem tedious but it's a survivable task.  It's something you can likely sort with the insights gained from just looking at the exploded view in the parts manual if you're at all familiar.  You'll need some tools for the clutch and primary if such aren't already in your toolbox though.

Your bang on about the garage I can tinker till the wee AM if I so desire.
 I'll look at the Clymer manual I got mechanical insight but do need a manual for guidance, tools I'm slowly getting as I'm needing them all my others are metric. AF tools are not so handy to get over here got to online order them as I need them the tool shops are 99% metric. It is a hassle, I have to sort out what tools are needed before anything, hell it took 2 weeks waiting for the tools just to do the oil change. Thanks for the help Don I'll have one or two for yeas

[Twolanerider]

Your bang on about the garage I can tinker till the wee AM if I so desire.
 I'll look at the Clymer manual I got mechanical insight but do need a manual for guidance, tools I'm slowly getting as I'm needing them all my others are metric. AF tools are not so handy to get over here got to online order them as I need them the tool shops are 99% metric. It is a hassle, I have to sort out what tools are needed before anything, hell it took 2 weeks waiting for the tools just to do the oil change. Thanks for the help Don I'll have one or two for yeas

That's a plan  !

[longlast]

Since my post and weighing the options from all the good advice. I had also taken the bike into the HD shop and got it on the table lift with mechanic he also said an external fix is would be a slim chance of susses. With that in mind I thought,... what the hay I'll give it ago.
I thought I'd share on how I went about it, it may help some one else with this.

I removed the foot board for easier access   

[longlast]

tie back the shifter or remove for easier access

[longlast]

      Clean off the area and dry. prop a spanner (wrench) in jiffy stand and with a pear of long nose pull back the rubber dust boot, it will not pull back very far as in pic   

[longlast]

I used this sealer,..sorry pic s not so good

[longlast]

It's fiddly to do, but you need to get the sealer in the inside of the rubber cup lip. I used a paper clip opened it up and got the sealer in and around the cup.

[longlast]

  let it set up a bit and smooth it off the best you can. I had used grey couldn't get any black sealer after it had a 3 hr set I gave it a brush of heat resistant black paint.

Hope this helps. The leak has stopped all good it's been a two days. It saved me a tear down and waiting for the sealer to set took most the time.   

[Twolanerider]

Very good luck on that being a long term fix  .