Every time I tinker with Zed it leaks a little less. This session I tackled the alternator wire oil leak. Zed’s alternator runs wet, a popular thing to do way back when motorcycles were made of steel and riders were flesh and blood. Where the wire harness exits the stator housing a rubber grommet is supposed to keep oil from seeping out. Someone had stuffed electrical tape down in there and Zed’s grommet wasn’t doing its job because the harness dripped oil.
The problem with replacing the grommet is that the stator harness plug needs to be dismantled to get the wire ends through the grommet. Dismantling the 45 year old stator plug is an iffy proposition. You’ll break the brittle plastic for sure. I guess you could eliminate the plug, cut the wire ends off and butt splice the mess back together. It would probably be better from an electrical standpoint.
The job also requires removing the stator housing to gain access to the grommet. That means a new cover gasket and more work. Instead, I took ExhaustNotes.us reader, Honda 919’s advice: After removing the tape and gunk in the grommet area I flushed the void with carb cleaner and mopped it out with a rag. Once I got the void nice and clean I packed in black, RTV silicone until it was flush with the stator housing. Then I let it dry over night. No more stator leak…at least for now.
The black rubber, half-circle cam end plugs were the next problem. Oil seeped out of these with the engine running and at high speeds the oil would blow back onto the plug wire and whatever pants you happened to be wearing that day. The plugs are more than just rubber though, they have an aluminum core to help hold their shape. Zed’s were dry and hard from years of service so I bought new ones.
The old cam plugs were glued in with silicone. I’m not sure it’s a factory process but I used a tiny bit of RTV black on the head semi-circle to help seal the plugs. All went well until I started tightening the valve cover and the rubber plugs started to squirt out the side of the head. Maybe the silicone was making the plugs slippery. I used a rubber mallet to tap the rubber plugs back into the head but when I did that the valve cover gasket pulled in towards the head.
I decided to let the silicone set up and walked away. The next day I loosened the valve cover, set the valve cover gasket back into position and buttoned the thing up. Hopefully for good.
Somewhere in all these road tests the high/low beam knob fell off leaving a broken bit of plastic stalk to control the lights. The parts to fix the high/low switch cost nearly as much as an entire new switch cluster! Having had about enough parts ordering I heated and curved a bit of black plastic, drilled a hole in the thing and RTV silicone glued it onto the protruding bit of the switch stalk. It looks horrible but at least it’s ugly.
I set an ambitious goal for Zed’s 4th test run: 200 miles across the Sacramento Mountains to eastern New Mexico and back. I was only 15 miles into the test run when I smelled oil. The damn valve cover was leaking. Still! The two forward cam ends had a light sheen of oil so I aborted the big ride and took a shorter route. After 36 miles of riding the oil leak seemed to be gone. After 60 miles of riding the cams were nice and dry and there was no oil smell. After 90 miles of riding, not a drop of oil anywhere: the engine was dry. Maybe the earlier oil leak was pre-existing oil blowing around the front of the engine? Back home I checked Zed and could not find any leaks.
I believe the test runs are over for Zed. It runs great and it doesn’t leak. There will be more repairs in Zed’s future but I feel pretty confident in the old motorcycle getting me where I need to go. That is, if the gas tank doesn’t leak.