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hose, leak, manual, oil, routing

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  #1  
Old 1st March 2016
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kneeco kneeco is offline
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Default Oily Hell

I bought this 1999 XLH 1200 knowing it had a problem leaking oil from somewhere. It had sat for a long time so oil is in everything. The guy I picked it up from said he couldn't find the leak because when it heats up oil appears everywhere. I've cleaned it up, replaced the crank seal, all oil lines and clamps. It appears all clamps were factory but very loose. I don't know that this was the leak yet. I know oil, yes oil, was coming out of the primary vent as well. I've hooked up all the oil lines back like they were when I pulled them off, but decided to check the manual. The routing seems to be different from what the manual says it should be. Can someone please look at my mock up and tell me if which is right? The manual doesn't show enough detail to where I feel comfortable changing the routing. The guy I bought it from said he picked it up from a guy who complained about the oil leak but he couldn't figure where or why it was happening. Could this be it? The wrong routing of hoses causing an oil avalanche.

My mock up


Manual Image

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  #2  
Old 1st March 2016
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"A" looks right to me. "A" IS what is in the manual. Be careful of the feed line in that FSM diagram. It is mis-leading. Feed comes off the oil pump, under the engine, tees to drain, up to tank. The oil pump scavenger (return) is on the top of the oil pump.
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  #3  
Old 1st March 2016
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Thanks for the confirmation! Much appreciated!
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Old 1st March 2016
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Here is some food for thought. Especially the 'oil puking out the breather section' regarding 'wet sumping' http://sportsterpedia.com/doku.php/h...h:start#engine
Edit: http://sportsterpedia.com/doku.php/h..._foo_foo_valve

Last edited by Hippysmack; 1st March 2016 at 04:10..
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  #5  
Old 1st March 2016
Martin G Martin G is offline
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"A" looks right to me.

I've spent too much time this winter chasing down an oil leak on mine.

At first I thought it was one of the lines connected to the oil pump, so I replaced or fettled all of those.

Then I decided it was the oil pump gasket, so I replaced that. Twice, thinking I'd damaged it the first time.

Finally, I replaced the timing cover gasket and that *seems* to have fixed it.

The leak was from the sealing face of the timing cover just above the oil pump; oil was dripping out and onto the pump, running all round the pump then onto the oil lines and then finally onto the rest of the bike. It only leaked when the bike was running and was upright; no leak when the engine was stopped, and no leak when it was running on the sidestand - that should have been a clue. When the bike was upright oil was draining back to the pump past the failure point in the gasket (and so leaking out) whereas when it was on the sidestand the oil was staying at the 'back' of the timing chest and so avoiding the leaky area.
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Old 1st March 2016
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On the tank, the feed is the big nipple (1/2") on the back side, return is 3/8", and vent is 1/4". The return/vent are on side of the tank facing the front of the bike.
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Old 1st March 2016
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Default

Thanks for the information Martin G, I'll definitely check that as well. I've replaced all oil lines, clamps, oil pump gasket and oring, crank seal and the primary case gasket. Honestly, I'm starting to think the oil leaked down into primary by way of crank seal, the previous owner saw the low level and just kept adding more oil. When I pulled the primary drain plug damn near two gallons of oil came out. It also smelled like gas. I've drained and cleaned out everything. Currently the primary cover is off with oil loaded in the tank. Today I'm dropping some mystery oil in the spark plug holes and cranking the engine around, by hand, to prime the oil pump. Then tearing into the carburetor and petcock to figure out how so much gas drained down.
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  #8  
Old 1st March 2016
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Make sure you do not over fill the primary. It doesn't take a full quart like the newer bikes, you need to cut back to 24 or 26 OZ. If you don't the transmission breather will puke all over the bike.
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  #9  
Old 1st March 2016
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wedge, thanks for the heads up! I was already prepared to just dump the whole quart.
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Old 1st March 2016
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Quote:
Originally Posted by kneeco View Post
wedge, thanks for the heads up! I was already prepared to just dump the whole quart.
If you remove the derby and add oil to the bottom of the ring gear like it says in the manual, then see how much you put in to do that, then you will have that level as a future reference on how many ounces it is.

I found this out with a friend of mine here as we swapped the crank seal twice thinking that it was putting pressure into the primary, just to find out that the level was the entire problem.
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