Oil leak.. HELP!

allstar1ny

Member
[/URL][/IMG] 20160724_215000.jpg My 03 Mastiff is leaking quite a bit at this plug where the ignition module wires enter the block... It almost looks like the plug should be deeper into the block just from the shape of it. There is no movement in the plug either to push in or it will not easily pull out. Thoughts? I have a ride this upcoming weekend and I need this ride shiney and safe. Don't make me ride Momma on the Busa! She likes low and slow. Actually not too slow! Damn image is turned 90 degrees.. sorry guys. Thanks for the help.
 

ground pounder

Active Member
The little allen head bolt holds the plug in place i believe. Do you have a manual? You could try tightening it or back it out a little and see if the plug will go down. That bolt is a pain because it is behind the covers!!!
 

FrankBDPS

Well-Known Member
Jon, that plug is where you're voltage regulator plugs into the wires coming from you're stator windings. It is not for you're ignition. On my 2000 mine started leaking also. What happened to mine was the rubber has become oil soaked and went bad to the point that the electrical connections worked apart and the system quit charging. The only fix is to replace the stator itself. If it is still charging and not pouring oil out I would check the primary oil level and finish out the summer on it. Good luck!
 

BadDawg Bill

Well-Known Member
The little allen head bolt holds the plug in place i believe. Do you have a manual? You could try tightening it or back it out a little and see if the plug will go down. That bolt is a pain because it is behind the covers!!!
If that doesn't work get some high heat gasket silicone sealer and put a ring around the plug on to the casing. It may work for the summer. Good luck.
 

allstar1ny

Member
I tried multiple allen wrenches but there doesn't seem to be a set screw within the hole where there should be one.. Maybe it came out? Any idea on size of this rascal. Also if the set screw is gone.. shouldn't then the plug be easily pushed back in? It will not budge!
 

BadDawg Bill

Well-Known Member
I tried multiple allen wrenches but there doesn't seem to be a set screw within the hole where there should be one.. Maybe it came out? Any idea on size of this rascal. Also if the set screw is gone.. shouldn't then the plug be easily pushed back in? It will not budge!
If you put a small allen wrench in the hole and tap it do you hear metal or rubber? If it's rubber then the set screw is gone and by tapping the rubber plug you mat loosen it up.
 

FrankBDPS

Well-Known Member
Don't keep pushing it in. It is installed from the inside out. If you push it back thru you will be screwed. It is where it is supposed to be.
 

BadDawg Bill

Well-Known Member
Don't keep pushing it in. It is installed from the inside out. If you push it back thru you will be screwed. It is where it is supposed to be.
You are 100% right. I don't know what I was thinking. I guess other than replace the stator the silicone seal may work.
 

BadDawg Bill

Well-Known Member
The only other thing here is if the set screw is gone the plug may have slipped down and it's not sealing. Pulling it up and putting in a set screw may help.
 
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