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Oil pressure sensor

12K views 26 replies 4 participants last post by  slowindown  
#1 ·
Hey, everyone! I'm in the process of doing a full service on a machine with the 2015 800 motor. I was having some issues with oil pressure light coming on at idle after it's warmed up and also a leak near the sensor. I replaced the sensor and still had the leak. I just now discovered that it's actually leaking at the grommet where the stator wires exit the case. After doing a bunch of reading on here it seems that is a well known issue. I think I'm going to try the permatex or rtv fix first and see what it does. Unless someone recommends I don't! Now, for my actual question. During my trial and error search for this leak, I saw a set screw above the oil pressure sensor. I backed it off and cleaned up around it. Then when I put my sensor back in I realized the sensor wouldn't snug tight. So I threaded it in as far as it would go and then tightened down the set screw pretty tight and then I was able to snug up the sensor. Does anyone know what that set screw is all about? I've never seen a single person mention it in any video I watch or post I read. I just want to make sure I don't mess anything up! I really appreciate the help!
 
#4 ·
It's referred to as a plug in the parts fiche. Probably an accommodation in the crankcase design for another oil sensor, or a spot that was cross-drilled to accommodate the sensor that's there, then tapped and plugged. I'm guessing there was nothing under it?
 
#8 ·
I ended up putting some teflon on the sensor when I put it back in, just for some added precaution. That was before I realized my leak was coming from the stator wiring grommet. I may pull that plug and sensor out and see what I can discover. I did a valve adjustment on it last week and it was the first time I'd ever adjusted valves on anything. I made sure the marks on the gear were parallel with the top of the jug on the low side and not on top, and that the corresponding cylinder number was lined up in the crank sensor hole. When I checked them, I couldn't get the feeler gauge in them until I loosened the lock nut and backed them off. So I adjusted all of them to the middle of the spec range. Now I can hear some valve chatter, but I'm not sure what is normal. I know these things aren't whisper quiet. I only put about 10 minutes on it before I went through and did a full service. I just bought it and wanted to make sure I was starting with all new fluids and filters and an all around tune up. It starts up and runs great throughout the power band, but I'm just a little paranoid I guess. I've also been wondering about the engine temp. I went ahead and replaced the thermostat and water pump impeller and flushed the system. After it gets up to temp it repeatedly raises to 195 and the fan kicks on and drops it down to 160-165ish and the process repeats, even while running down the road in fairly mild conditions. At risk of getting banned from the forum, I guess I should also mention that it's not actually a Defender. It's a 2016 Intimidator 800 Crew. After doing some research I discovered that they used the same motor as the Defender from Rotax. Unfortunately I haven't been able to find many resources for the Intimidator, so I've been poaching information off the Can-Am forum. I've got so many questions that I'm trying to figure out. I love to learn and get in there and do things. So, I apologize for the long post(s) but all of the help is appreciated beyond words!
 
#10 ·
What about the valve chatter? Do these motors have a unique sound to them? I'm just trying to figure out if I should double check my adjustments, even though I double checked each one after tightening the lock nut. I guess one other thing of note, when I did the valves, the valve train in cylinder 2 was a dark color. Almost like it was covered in soot or carbon. Cylinder one was nice and clean metal. I figured that wasn't normal.
 
#14 ·
Tonight I will be putting it all back together and I will do some experimenting to determine what, if any, effect one has on the other. I took the sensor off to give myself some room to seal up the grommet for the stator wiring that was leaking. It will be good to go tonight, so I'll report back tomorrow with additional findings.
 
#15 ·
Well, I've still got that pesky oil leak. It has to be coming from the oil pressure sensor. I sealed up the grommet for the stator wiring quite well and it looks good. There is no leak when it sits cold. But, if I take it out for a ride and bring it back and park it, there's a 6" diameter oil stain on the concrete. When I put the new sensor in I gave it a few wraps with Teflon tape in hopes that might help me out. Apparently that didn't do the trick either. I'm open to any tips, tricks, or suggestions! Thanks!
 
#17 ·
Well, I decided to go with Permatex Ultra Black RTV, for better or worse. I tried to keep it on the last few threads closest to the base and then on the flat spot of the base. I was a little worried about getting too much deep in the threads on the case. I was going to use the Permatex thread sealer, but I already had some of the Ultra Black on hand and it's supposed to be able to withstand the heat and oil. I'll come back with results as I have them. Again, I appreciate the insight!
 
#18 ·
I'm back again. After putting the RTV on the op sensor and running it, I'm back to believing the leak is coming from around the grommet where the stator wires exit the case. I also applied RTV on that as best I could, but it looks like oil has still found a path up through it. There was some oil in the nook's and crannies of the RTV. So, now I have a coat of rtv on there that isn't going to do the trick apparently. Do I take off the magneto cover and try to clean up the RTV I already applied and then replace the gasket? Or use rtv instead of a new gasket? Or use a new gasket and add some RTV around the grommet? I'm also worried that maybe the oil is coming up through the middle of the grommet where the wires travel. If that's the case, I can't just replace the wires or grommet. It's the whole kit and kaboodle. Again, I appreciate all of the advice. I'm ready to keep on plugging away at this thing.
 
#20 ·
Well, it sounds like that is just a silicone based gasket maker. I may try some of that rtv dissolver that Permatex offers to clean some of it up. Then I'll get a new gasket and use the sealant around the grommet like is recommended. But I'm definitely open to suggestions! Has anyone heard of the grommet itself leaking? Like where the wires run up through it? That would be the only other place I could come up with that could be leaking. Thanks!
 
#21 ·
So, I've come to the conclusion that I'm going to replace the stator and the gasket. I was wondering if anyone had this part of the service manual handy? I was wondering about the torque specs of the bolts on the cover and the particular pattern to tighten them, if any. I was also wondering if it is recommended to use some RTV type of product around the grommet for the wiring. If so, only on the sides that directly touch the case or all the way around, including where the grommet touches the gasket? Thanks again for all of the help!
 
#24 ·
On page 85, it does show to apply a sealant on the grommet as shown in the referenced picture. The arrow in the picture is pointing at the flat side where it meets the gasket. I'm wondering if they're just pointing out the grommet, or specifically stating to apply it on that flat spot where it meets the gasket and nowhere else. Has anyone ever replaced the stator, and if so, did you use sealant only on the flat side of the grommet, or all the way around it?
 
#25 ·
Alright, let's close out this post once and for all...Hopefully...I installed a new stator and gasket and that seems to have solved the issue. I didn't have any of the silicone recommended in the manual, but I did use some Ultra Black Permatex around the grommet. The oil pressure light still does come on after the engine is hot and comes down to an idle. But with the slightest bit of throttle it goes off. So, I have to believe it's just barely getting too low. I will probably just let it be unless someone has another recommendation. I thought about running some 30 weight through it instead of the recommended 40 weight. Either way, I really appreciate all of the help I got on this issue! It truly is appreciated.