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  #1  
Old 26th March 2012
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Smile Fixing a leaky top end... with pics!

My '05 XL1200C has this annoying oil leak, which I've been ignoring for the second half of last season, but it's making a mess of my bike, and I've got at least another month to kill before I get my medical suspension lifted and I can ride my Sporty again, so... time to dig out the tools and start turnin' wrenches!

I got some great answers and ideas from this thread and have a .030 Cometic gasket kit on order from Hammer Performance (thanks Dan) so I began surgery yesterday.

Here's the ugly leak at the front cylinder, the rocker boxes look dry, as do the fins above the head gasket. Looks like a base leak here also.



The base of the rear jug is even uglier

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  #2  
Old 26th March 2012
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Off with the seat, AC, heat shields and let's get down to business



Disconnect the fuel lines, unbolt and pull the tank... a handy 'tank holder' to avoid damaging the petcock



...but wait a minute, what's this? Looks like a CHIP IN THE CLEARCOAT!!

Proof positive that no matter how long I've been wrenching, I'm still a rank amateur

Don't be a lazy dipshyte like me, drain the tank to make it easier to handle and put some padding between the tank and the SPEEDOMETER HOUSING!

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  #3  
Old 26th March 2012
AsSeenOnTV AsSeenOnTV is offline
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Sorry to hear about the tank chip John.

Looking forward to seeing this thread progress.
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  #4  
Old 26th March 2012
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Awright... on with the show, soak the exhaust nuts with some Liquid Wrench while I work on other stuff, else I'll be calling sportsterpaul for advice on how to remove busted studs



Pull the carb and intake manifold



Carb is relatively clean, spray with carb cleaner and wipe off some of the grunge and set aside

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  #5  
Old 26th March 2012
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Good start John, I'm not that far so if you have to "McGyver" something give me a shout!
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  #6  
Old 26th March 2012
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Pull the mufflers off... looky here, we have a crossover leak! Good thing I picked up a couple gaskets at the parts counter during the last visit.



A few good douses of carb cleaner and ten minutes with a shop rag and this muffler is as clean as it's going to get in my lifetime. Damb... now I have to do the other one.

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Old 26th March 2012
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is the one that was all dirty the rear muffler? could just be from the front one. mine is like that
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Old 26th March 2012
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Remove horn and bracket from other side



Remove head pipes. When I put the nuts on last year (after I lost a couple) I used high temp copper anti-seize, torqued to spec (10 ft/lbs) and checked they were not loose before each ride. They stayed put even with the anti-seize, and it sure made them come off easy now. In the exhaust port you can see the SE gaskets, I'm not too happy with the way they seal on the stock pipes ...just around the edge instead of on the taper. They are in good shape but I will replace them anyway with the standard gaskets. Also clear in this pic is the oil leakage which is the primary goal of this exercise



A quick peak inside the front intake port shows a pleasant surprise: no oil



The rear intake is just as clean. After spending a few nights reading the oil consumption threads I was prepared for a nasty sight.



The exhausts had a fair layer of carbon, but were dry also. This I'm happy with. I have been experiencing some more oil coming out of the AC than when I got the bike, but consumption seems to be negligible. I do tend to dump 3 quarts in when I do the oil change, which is more than the recommended 2.8 so that may account for the breather oil.
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Old 26th March 2012
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Quote:
Originally Posted by aemsee View Post
is the one that was all dirty the rear muffler? could just be from the front one. mine is like that
Yes it was, I was thinking the same thing and you're probably correct. The last time I had the exhaust off, it didn't look like the crossovers were sealing very well, so I bought a couple new seals for the next occasion. There are a few leaks in my exhaust system that I'll have to take some care with this time, but I've not noticed any leak induced anomalies like pops etc.
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Old 26th March 2012
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Quote:
Originally Posted by AsSeenOnTV View Post
Sorry to hear about the tank chip John.

Looking forward to seeing this thread progress.
Thanks, it's one of those nagging 'oops' that no one will notice, but it will bug me to no end

Quote:
Originally Posted by sportsterpaul View Post
Good start John, I'm not that far so if you have to "McGyver" something give me a shout!
Appreciate the offer and will keep it in mind
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