Found Last Year's Oil Leak!

[IronMick]

Last year my iron had an oil leak. Looked like it was coming from behind the gearcase cover. It was getting onto the chain and making a mess of the back wheel and rear sprocket area. You may recall i posted pics of the oil pump - maybe it was on the old forum.

I removed the gearcase cover. It was a filthy mess in there. I cleaned up everything, removed and partially dismanted the oil pump; everything looked good so i never did find the origin of the leak. I have been hoping that whatever it was i have fixed.

So now i figured it out. Did you see my post about the generator bolt? The generator was not properly sealed against the case, oil leaked down right to the oil pressure sensor and oil pump. From there it picked up lots of road dirt etc, migrated to the chain, and made that mess all over the back of the bike.

Yea! My IronHead does not leak oil!

[Moved On]

Yea! My IronHead does not leak oil!Sounds like you made yourself an EVO there Mick ;)

I'm glad you found that. I know how that stuff can drive you crazy for a long time when you can't quite figure it out. :clap

Gazza

[Fisherman]

Yeh. I know how that goes. I tried for a long time to find my high crankcase leak before I figured out it was a crack under the mounting bracket on the oil tank..... I guess it's a weakness in design...

[tprJJ49707]

Hey Fish, I think you just diagnosed my "high case leak."

While tearing down the top end I was able to figure it was somewhere on the bottom of the oil tank...did you require new tank or did you weld it?

[Fisherman]

I just bought a new chrome tank for about $100. As I understand it, the vibration 'crystalizes' the metal making it brittle. So if you try to weld or braze it, it just cracks again almost immediately. I thought about 'lining' the tank with the same tank liner I used on the gas tank. But on further consideration, I remembered hearing about from time to time, the lining material cloging the fuel filter. NOT a good thing in the oil system. SO, a new oil tank for me. One thing I did do, I noticed that there was quite a bit on tension on the 'isolating' rummer mounts. So, I made a plate to space the the oil tank a little bit away from the battery box mount to relieve the 'tension' so the oil tank 'floats' a little better. This relieves the 'pull & flex' on the mounting straps on the back of the oil tank...

[IronMick]

... i guess it is a good idea to not tighten the oil tank mounting bolts to tightly on those rubber isolation mounts, eh?

[Fisherman]

What I did was to mount the rubber isolaters on the bike. Then slide the oil tank onto the studs. The ones that didn't bottom out on the isolaters without having to push on the oil tank I spacered 'till they did. So the oil tank brackets weren't in a bind or wanting to tweek one way or the other.

[xraydave]

Mick, I'm gonna have to check this out. As you know I have quite a leak down there. Sounds a lot like what you were going through. It's throwing oil all over the back of mine. I'm surprised I don't get dirty looks from bikers behind me with all that oil flying!

[IronMick]

Mick, I'm gonna have to check this out. As you know I have quite a leak down there. Sounds a lot like what you were going through. It's throwing oil all over the back of mine. I'm surprised I don't get dirty looks from bikers behind me with all that oil flying!

What i would do is remove the generator, clean up both mounting surfaces, apply some Permatex Ultra Blue gasket maker [a thin layer], and re-install. Clean up the whole thing with degreaser [Simple Green Automotive is good and safe], then see.

[mordak]

<SNIP>

Yea! My IronHead does not leak oil!
For now anyway!!! ;) :D :p :laugh

[GSB_77_XL]

Hell that may be where one of mine is coming from. I have noticed the gasket between the generator and the case is sticking up a bit. Ill check it when it gets and stays cold along with the rocker box gaskets (I know they are bad my chaps prove it), oil pressure sensor, and oil tank.

Congrats Mick

[IronMick]

Hell that may be where one of mine is coming from. I have noticed the gasket between the generator and the case is sticking up a bit. Ill check it when it gets and stays cold along with the rocker box gaskets (I know they are bad my chaps prove it), oil pressure sensor, and oil tank.

Congrats Mick

Last time i put it together i discarded the gasket and just used the Permatex. Works just fine. 1 less gasket to have to buy.