Leaking alternator cover

[Tom Herold]

The factory original gasket for your bike was metal impregnated for longevity and durability.

After market and current manufacturer gaskets are 'paper' type without the metal and are just as good, and just as durable.

While it's not 'normal' to have oil around the stator because it's supposed to be a dry area, on some 955i engines oil seeps in. It's under mass speculation at this time if the oil combined with the heat from the engine is what's killing the stators prematurely.

Most mechanics I've spoken to regarding the oil issue don't seem concerned about it since it's such a minimal amount.  If you're getting more than a cup (240ml) out of that area, then something needs to be addressed. Most likely it's the pressed in oil seal and small, flat, washer type gasket you'll see in the stator cover. The small and flat gasket should go between the pressed oil seal and the engine casing.

There's discussion about the factory coating on the stator windings and an experiment with a marine grade coating currently undergoing testing on a few members bikes, mine included. I've noticed the winding coating on the factory and stators coming from Ricks Motorsports having turned clear after exposure to the oil inside the casing. This new coating a few of us are trying out hasn't passed the test of time yet, but so far I haven't had any problems and my voltage is staying in the 14.5 range above 2500 rpm without any accessories running.

In reality, there aren't many Tiger's experiencing the stator and rectifier problem when you look at the numbers produced. Obviously there are a few of us who are, and our posts attract alot of attention because it's a major issue to have your machine break down. There are fixes out there, and we're all contributing to finding them. The 995i engine is solid, stout, and relatively easy to work on. It's a time proven design and very respected in the motorcycling world.  A few quirks among thousands of engines isn't anything to cause alarm, we'll get them worked out.

[mittens]

thank you for your indepth reply.
 I have now finished repairs on the alt. cover and buttoned it all back up again. It's ran fine during a short test ride.
Im due to have a service in about 1200k's, Ill have another look inside then and see how much, if any oil has collected by then.

[mittens]

Here are some before and after pics. I used "Permatex Cold Weld"
And then Hi gloss engine enamel.
The "after" one is a little blurry as I had to go manual exposure cause the auto focus couldnt read it, it was too shiny :)
It does have a small bubble in it, but I wasnt going to do it a third time :lol:

[Tom Herold]

Since the cover isn't under pressure, your 'fix' should work out for you.  It looks good, keep us informed on how it's working out and holding up!!

[Stretch]

Now install some crash bars.

[mittens]

working on it, surely I wouldnt drop it again! :oops:
Anyone know of any good ones to be had in aus? Or will I have to send away overseas for them?

[EvilBetty]

might start with these guys.  If they don't have them, they might be able to direct you to someone local that can supply them.

http://www.aussiebiker.com.au/catalog.p ... e%20Guards (http://www.aussiebiker.com.au/catalog.php?category=5%20Crashbars%20and%20Engine%20Guards)

[Stretch]

Thunderbike is based in New Zealand.  Close enough, perhaps?

http://www.theshop.co.nz/shopn/SP/71596 ... sg=,co=TIG (http://www.theshop.co.nz/shopn/SP/715965373.5291/pv=TBIKE,pg=35270,sg=,co=TIG)