Alternator wire seal

[hannibal smith]

1979 GS1000E-

The alternator wire seal that is typically molded over the wires that seals the passage from the alternator/starter gear compartment into the secondary cavity on my bike is missing.

It looks like the PO just inserted some thick rubber "sleeve" if you will, but by the nature of this seal, it's not going to stop all the oil and keep it contained within the first cavity that the alternator is housed in.

I am assuming that I need it completely sealed. I checked, but can only source the complete alternator with the seal attached and not separately. My current original alternator is working fine, and would like to be able to just source this grommet/seal. Any sources? Or is there a "fix" that can be constructed?

I hope that I explained it correctly!

[salty_monk]

You're talking about the stator seal. Seen in this picture.

From memory that area is not covered in oil (no pressure) & is only splashed by oil flinging from the rotor (more so during a hard left) so you can likely make your own seal with something like RTV I would say.

[salty_monk]

I don't think it would hurt if you filled all of that small area with RTV if you cleaned it up really well to make sure it stuck... I think I'd rather have a "big lump" in there than just a small bit. Less likely to get dislodged & cause problems.

If you can get one of the rubber ones on an old stator you can carefully split them with a blade & put them around the new wires.

[hannibal smith]

Thanks! That's the part! So I need to refer to it as the stator. Ok, I will fashion something. I can see that some oil did get past, and was pooled a little in the second cavity. Don't want a head scratcher oil drip once I get it running again.

[Grimly]

I had success in re-using an old seal by mixing up some silicone and bicarbonate of soda, and wedging the seal in place around the wires and into the casing, leaving it overnight to cure and trimming as necessary before fitting. Never leaked a drop.

[salty_monk]

Yep, I’ve done similar with RTV. What’s with the bicarbonate? I’m all ears for a new trick!

[Grimly]

Yep, I’ve done similar with RTV. What’s with the bicarbonate? I’m all ears for a new trick!

If you google Sugru, that's basically all it is. A quick-setting silicone rubber. The bicarb in the mix carries humidity with it and causes the curing reaction to happen much quicker, uniformly throughout instead of slowly from the surface in.

https://www.pinterest.ie/pin/82894449364214272/

[Big T]

A rubber grommet from Ace Hardware and some silicone to fill the gap