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Discussion Starter #1
I am trying to repair a leaky oil level sensor and wanted to check with the collective as to what product might work best for this particular application.

a picture to show the damage:



I tried JB weld on the first try but must have done a poor job of cleaning as it leaked again after a few rides.



Bought a second hand one off of fleebay, was kind of promising for a few days but has developped a leak at the same exact spot.

The sensor sits under the scoot and is exposed to the elements:



The wire seems to be encased in a clear glass type material that solidifies after being poured!

I thought about maybe first applying a gasket sealant first to fill up in and around the wire and then apply JB weld on top of that?

A new one is about $100.00, would rather not spent that much on a perfectly working sensor but might come to that.

Any recommendations about what might work best to seal the leak and keep it at bay.

thanks for your thoughts.
 

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Boy they are proud of that switch based on the price of a new one, ouch!

SWITCH ASSY,ENG
37990-10G00 1 $116.65 $94.49
 

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I'm gonna guess that the 'glassy' looking stuff
is fiberglass resin...commonly used to 'pot'
electronics.
 

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Duster said:
I'm gonna guess that the 'glassy' looking stuff
is fiberglass resin...commonly used to 'pot'
electronics.
Sounds about right as long as it's temperature rated for the engine.
 

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I guess my question would be why they keep developing leaks. Is it possible the wire leading to the sensor is pulled to tight causing stress that is cracking the seal when the engine moves in the rubber motor mounts.
 

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Buffalo said:
I guess my question would be why they keep developing leaks. Is it possible the wire leading to the sensor is pulled to tight causing stress that is cracking the seal when the engine moves in the rubber motor mounts.
I think he said he hit it with something though it looks fairly well protected.
 

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MJR said:
I think he said he hit it with something though it looks fairly well protected.
Seems I remember something like that from the original thread when he repaired it with the epoxy. But then that started leaking and the one he bought of E-bay started leaking at the same place. I don't remember any one else every having posted of a problem with these leaking so it makes me wonder what the root cause of his problem is.
 

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Buffalo said:
Seems I remember something like that from the original thread when he repaired it with the epoxy. But then that started leaking and the one he bought of E-bay started leaking at the same place. I don't remember any one else every having posted of a problem with these leaking so it makes me wonder what the root cause of his problem is.
Guess I missed the buy. Interesting then.
 

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Discussion Starter #9
My original sensor got hit by road debris during a wind storm.

The location of the senor with the wire hanging loose is less than ideal.

I took a chance on the 2nd one off of fleebay for just $15.00. But ad luck
would have it was damaged at the same exact spot. I put some gasket
maker on it hoping it wouldn't leak, short lived joy, only lasted two weeks.

There is nothing wrong with the sensors, doesn't make sense to
replace it with a new one.
There had got to be a product that works for this type of repair.

Duster said:
I'm gonna guess that the 'glassy' looking stuff
is fiberglass resin...commonly used to 'pot' electronics.
Thanks for the tip, I have used a similar product in the pass to encase
electrical boards, was hoping someone would know of an equivalent
product for the auto industry.
 

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In a PM I suggested to clean it very well with degreaser then try the JB Weld again. Jb Weld is just two part epoxy with fine ground steel mixed in. I would maybe Dremel it out some, roughen up the alumumn and the wires sheath and repack it with original JB Weld, not the quick stuff. Oil/wax/gasket maker may keep the JB Weld from bonding to the wire sheath and metal.
 

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Or you could stop by a Electronics Wholeseller and get Potting Compound. Potting Compound is what we used in the Marines for that kind of repair. We also used it at G.E. when we were fabbing anything like that. I suspect that is what is there already. I use black or red RTV here at the house as a Potting Compound. You can get the RTV at any auto parts store. You will need to clean (degrease) and roughen the area you are going to apply it to as it won't stick unless you do.

Oh, and btw... The red RTV is for high temp use.
 

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Discussion Starter #14
I have been reading online about possible products to use for this application, and one avenue that is often referenced is marine type potting material.

Going to contact a few marine shops to see what they stock or recommend.

thanks again for your inputs.
 

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LeDude said:
I have been reading online about possible products to use for this application, and one avenue that is often referenced is marine type potting material.

Going to contact a few marine shops to see what they stock or recommend.

thanks again for your inputs.
I would clean it well and clean it well again using alcohol. Lightly scuff the area using a Scotch Brite Pad. Clean again using alcohol. Let dry and apply a liberal amount of black Silicone that is oil resistant and let it cure for 24 hours. That should stop the leaking since it is not under much if any pressure
 
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