Blacktopper and I put in a new stator and fixed the stator plug leak in his K9 primary. But his is a 2016 Big Dog with the Harley-style primary. I think much of what I say applies here.
Drain and remove outer primary. Then remove the primary drive chain. We didn’t remove the inner primary, but there sure would be more room if you did—-your call. Get two bolts and screw them into threaded holes in the stator—work it off the spline (do not drop or strike it (EVER). They have strong magnets and I hate screwing with them—once you get them moving a little, they’ll loosen up. Inspect the teeth in the rotor that fit in the spline—the teeth can can get flattened, especially on a high output engine.
To get the rubber plug out out, back out the little Allen—dig the permatex out of the little hole— (oughta call it the clit bcs it’s so hard to find), and use a small flat tip screwdriver to gently free up the little rubber skirt around the base of the wiring plug in the primary—-take your time and don’t damage it. What we did was to then (again using the small flat tip) work around the skirt, pushing it down into the hole. Then we loosened the blob of permatex inside the engine case and pushed the plug down into the case from the outside (flat-nose punch) and pulled the wires (gently) from the inside. A little silicone or WD might help.
Then we really cleaned the hole for the plug. Obsessively….spotless clean aluminum, then scrubbed with a green scotch rite, then cleaned several times with with brake cleaner. Then coated the plug (not globs, but a good coating) with a high quality Permatex. Install from inside the primary, paying attention to not pull it through too far.
Problems will come from the inside, so pay attention to the permatex that was scraped off the plug as you installed it. Leave it in place and smooth any visible gaps. How that plug is sealed INSIDE the engine case determines if it’ll leak or not. Be careful not to pull the plug too far through the hole in the inner primary case, bcs then you’ll have to push it back down to seat that plug’s rubber skirt back down on the primary case. Avoid moving the plug any more than necessary to get the rubber skirt seated on the engine housing. If you screw it up—no worries—push it back through, wipe it off and do it again—the $12 tube of Permatex will harden before you use it all up anyhow!! The worst thing is you’ll be several days getting that black crap from around your fingernails-haha.
Re-install tiny Allen screw-or leave it out as Jwooky says—be sure to clean and seal the hole w/Permatex.
Then—let’s say you were thinking ahead and just snipped the tip off the Permatex tube—you can lay a thin bead around the skirt and smooth it with a finger for a finished look.
Replace outer primary and add oil (I’m using 20 oz. of ATF these days)—DO NOT start the bike!! Leave it to cure for 24 hours.
