Question about 2000 Harley Davidson FLHR-FLHRI Road king

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I have an oil leak from where the stator wires come out of the primary cover. Is there a way other than changing the whole stator to fix it?

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  • Anonymous Mar 05, 2009

    I had the same problem the only fix is to replace the stator this is a common problem

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  • 48 Answers

You have some seals that are leaking from around the crankshaft the stator is supposed to be sealed from the oil you wont have to change the stator just the crank seal

Posted on Feb 27, 2009

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Hi Anonymous, if you are going to work on your bike your going to need tools, and the first and best tool you will ever buy is a service manual. It has step by step instructions, how too's, pictures, special tools you will need, torque specs, special products (loc-tite, sealants, cleaners ect.) and wiring diagrams, along with trouble shooting tips. That being said here is the short version: Drain primary oil, remove primary cover, clutch pak, primary chain, compensating sproket, and alternator rotor to access stator. Good luck

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1 Answer

Oil has gotten to my stater and has ran out of the stater plug, How can I fix it


If it is just leaking a little, remove the primary cover. Push the stator plug into the primary housing. Clean the plug and hole it goes into with brake cleaner. Apply black silicone to the outside of the stator plug and push back into the hole. Replace the primary cover, and after the silicone is dry, refill the primary. If oil is leaking alot, and the bike is a Twin Cam, check to make sure vent hose on the trans top cover isn't plugged. Twin Cam primaries vent through the trans and if the vent hose is plugged, oil will be under pressure in the primary and force itself out around the stator plug.

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1 Answer

Need to know how to change 85 lowrider alternator. Fxr. And help would begreat


Instructions
  1. Replacing the Alternator
    • 1 Remove the drain plug located under the clutch area of the primary chaincase and drain the chaincase lubricant into a catch pan. Remove all mounting bolts from the primary cover and slide the cover from its locating studs. Loosen the primary chain tensioner and inspect it for wear (this is a logical time to replace the tensioner shoe, since you are in the case).
    • 2 Lock the primary chain where it enters the bottom of the clutch drum. Remove the engine sprocket nut and slide the compensator/sprocket assembly from the engine sprocket shaft. Slide the reluctor bowl off the engine sprocket shaft. Push the stator plug through the hole into the inner primary case. Remove the stator mounting bolts and slide the stator from its support boss. Remove the stator from the case.
    • 3 Slide the new stator onto the support boss and orient it so that the stator wires are closest to the stator plug hole in the case. Install and torque the new stator bolts to factory specification (refer to manufacturer's torque sheet). Do not re-use the old bolts. The bolts come pre-treated with Loctite and are designed for one-time use. Insert the stator plug into the plug hole and snap it into place.
    • 4 Slide the reluctor bowl onto the sprocket shaft and bottom it onto the shaft shoulder. Align the splines on the shaft and the compensator/sprocket assembly and slide the assembly into position. Install the engine sprocket nut and torque to factory specification for your model of Harley. Adjust the primary chain tensioner to factory specification.
    • 5 Scrape the old primary gasket from the case. Harley Davidson gaskets are produced with a print-o-seal feature that melts and '"cooks" onto the case surface. Insure that all of the old gasket is removed from the machined surfaces. Use caution when scraping the gasket, as the cast-aluminum cases are easily gouged, leading to poor sealing and leaks. Install the fresh gasket onto the locating studs, followed by the primary chaincase cover. Torque the primary cover to the proper torque and in the recommended pattern according to the specification sheet for your model of Harley. Remove the inspection plate and add new chaincase lubricant. Replace the inspection cover gasket and re-install the inspection plate.

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1 Answer

1994 fatboy. why is there oil in voltage regulator plug?


There is oil in the primary case and that's the same place that the alternator is located. It too runs in an oil bath. Not that it needs oil for the alternator to run, just that this place is a good place to put the alternator. The plug is made up of synthetic rubber moulded around the two wires from the stator. Over the years, heat and oil exposure have deteriorated the rubber in the plug and it doesn't fit as tightly as it used to. The only way to stop the oil leak reliably is to replace the stator with a new one with a new plug. I always put some RTV sealant on the new plug as well. The oil leakage won't hurt anything other than make a mess. The alternator will still continue to work until something else goes wrong with it. If the leak is bad, keep a check on your primary oil level until such time as you replace the stator.

Good Luck
Steve

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1 Answer

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The stator is on the left side of the bike while you are sitting on it.

It is underneath the primary cover, the largest one on that side. It can be reached by removing the primary cover, primary chain, clutch basket and the sprocket on the end of the crankshaft. I myself would not tackle a job like this at home. Gaskets are another issue on reassembly. The stator is a coil like winding of copper wire around which rotates a heavy round metal flywheel type piece that has magnets afixed inside of it, as the flywheel rotates around the stator, it creates the electricity, just like a hydroelectric generator you have seen on TV only on a smaller scale.

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