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Discussion Starter #1
I have a quick question for you guys, has anyone else had oil leaks out of their XR's. I only ask because I am now on my second time of it doing this. The first time it wasn't such a huge deal it was only the thermostat and and some of the lines out of the tank, now its those lines again the right side where that engine and tranny meet and the rear cylinder rocker box. I just wondering if anybody else has had any similar problems?
 

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A few roos short in the front paddock
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88 Posts
Oil Leak

I had a severe oil leak from new. Lost more than a litre during the 500-mile ride from the dealership. The leak continued whenever the engine was warmed on longer or hard rides.
As per usual it is often hard to identify exactly where the leak is coming from. It ended up being a kinked vent hose. An easy fix. I received this info from HD Australia.


XR 1200 Transmission Vent Hose Routing
Some early 2009 XR 1200 models could have a kinked transmission vent hose
under the starter motor.
If this line is restricted in any way, it is possible for oil to be forced out of the
primary area at the clutch cable adjuster as the air from inside the transmission /
primary case expands with temperature.
To correct this, simply direct the end of the hose downward between the starter
motor and primary case. It may be necessary to rotate the hose and clamp on
the transmission vent fitting to ensure that the hose does not contact the rear
cylinder cooling fins.


It could be it. All the best.
marx
 

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Super Moderator
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18,659 Posts
Mine has been leaking from day 1 on the right side under the cam cover. At the dealer now and they had to order parts so we'll see what all they replace.
 
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Discussion Starter #6
I already had the bike at the dealer to fix the leaks I had from the rocker covers.
Well the rear on is ok now but the front one leaked again..and now it's getting worse...the pics are after a hot 150km ride...
I think they just changed the gaskets but that's not enough to solve the prob...maybe there is some powdercoating left on the sealing surfaces...I'm still thinking about it as if I should do it myself or give them the bike again...after all it's still under warranty...

sure thing it's a freakin mess:


 

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My giant goes with me wherever I go.
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14,911 Posts
oh oh

I already had the bike at the dealer to fix the leaks I had from the rocker covers.
Well the rear on is ok now but the front one leaked again..and now it's getting worse...the pics are after a hot 150km ride...
I think they just changed the gaskets but that's not enough to solve the prob...maybe there is some powdercoating left on the sealing surfaces...I'm still thinking about it as if I should do it myself or give them the bike again...after all it's still under warranty...

sure thing it's a freakin mess:


Benny, it looks like (in addition to rocker box leaks) you have a blown head gasket on your front cylinder....could just be the photo though....
 
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Discussion Starter #8
No, the oil runs down from the rocker covers.
When I wash it down, I can watch it the more km's I drive...it just got worse now than before...crap...
 

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Warning! Fat people are harder to kidnap.
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1,373 Posts
I checked and my oil leaks are on back order. I changed my zip code on the order so I hope they won't arrive. Oil leaks are :001_9898:! :censored: Later,
 
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Discussion Starter #10
the silver engine likes the black color on my bike so it's pouring out some oil to get a little more black :1eye:
 

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Warning! Fat people are harder to kidnap.
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1,373 Posts
Naalb

Sorry Dude but mine is leak free ORANGE. I guess it doesn't want to mar that fast color. I'll make no comments on your color because I don't want any hassle from the NAALB. Thats National Association Against Leaking Bikes. LOL I guess it's best to be politically correct. :innocent: Later,
 
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Discussion Starter #12
Should of got back to guys sooner but I have been enjoying the weather that MN is getting so far this year after being without my bike for a week and a half. So the break down got just about every seal, it was a a long list of warrantied items, replaced along with the thermostat at the dealership. So far about 200 miles or 361.88 km leak free. And less oil = less weight which = faster right?
 
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Discussion Starter #13
I have oil streaking across my derby cover, and around the cylinder head bolts on the spark plug side.
 

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Registered
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23 Posts
Since the day I got it I had a leak from the shift shaft and from the right side where the oil cooler line goes up into the engine. Took it in, they fixed the shift shaft, didn't have the right tools for the right side fittings?. Took it back in a month or so later, they said the o-ring in the line had been kinked on original installation, and the o-rings listed in the computer do not match what is on the bike-thought they found the right one. Got it back, took it for 100 mile ride and it leaked like a sieve from the lines at the bottom of the oil cooler on the left side, but not on the right anymore. In frustration they pulled the whole cooler assembly from one of their new bikes and installed it. I am taking it on a 200+ mile ride today, and hopefully it is fixed. I love the bike, but I am not impressed with the leaks. 1st H-D, and likely my last if any more issues.
 

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Joe Mama!
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10 Posts
My fast orange bike leaks like it has the e-bola virus with a side of malaria. Both rockers, cooler lines and now a leak where the starter meets the engine. 2800 miles, goes to the hospital Wednesday.

Back when I was a BMW bike tech, I used to tell people, "Harley's don't leak oil, BMW's leak oil." Looks like I won't be using that line again. :whistling:

At least, unlike a BMW, I can see the oil leak. The first indication of the leak on the BMW usually came when the rear main oiled up the dry clutch while you were on a road trip.
 

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Super Moderator
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12,518 Posts
I already had the bike at the dealer to fix the leaks I had from the rocker covers.
Well the rear on is ok now but the front one leaked again..and now it's getting worse...the pics are after a hot 150km ride...
I think they just changed the gaskets but that's not enough to solve the prob...maybe there is some powdercoating left on the sealing surfaces...I'm still thinking about it as if I should do it myself or give them the bike again...after all it's still under warranty...

sure thing it's a freakin mess:


My leaks look about the same as Benny's. I have not taken it in for repairs, kinda scared it might come back worse.
 
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Discussion Starter #17
i had oil leak coming from the clutch,it turned out something had been put on upside down at the factory.shes ok now and done5000 miles since
 
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Discussion Starter #18
Mine has been leaking from day 1 on the right side under the cam cover. At the dealer now and they had to order parts so we'll see what all they replace.
< color="black">Have a 2010 with 220 miles. Been leaking since day one from the lower, right side. I thought it was the rear oil line 1" fitting at the bottom of the motor, near the transmission. Took it to the dealer, at first, they were thinking possibly clutch. Now, they are replacing the oil pump. Seems like they are "throwing darts and parts" at the leak. Once I know, I'll let you know.
 

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< color="black">Have a 2010 with 220 miles. Been leaking since day one from the lower, right side. I thought it was the rear oil line 1" fitting at the bottom of the motor, near the transmission. Took it to the dealer, at first, they were thinking possibly clutch. Now, they are replacing the oil pump. Seems like they are "throwing darts and parts" at the leak. Once I know, I'll let you know.
mine still leaked after they changed oil cooler assemblies for a brand new one. I took it back in, got politely agitated, and said I will be seeking a refund under the state lemon law if it isn't fixed when
I pick it up in a week. Lo and behold, they finally decided to dig deeper, and the engine plate? that the oil pump bolts to/is housed in had a pinhole flaw in the casting, and at highway speeds it would build enough pressure to pump oil out. They replaced that assembly, and it has been leak free since last fall. They said they had never seen anything like that happen before. Out in the Rockies right now, rode it up to Mt
Evans(14,000+ feet), ran like a champ except for down on power due to thin air.
 

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So what's the deal with all the leaks? Is this something that's not uncommon with the Evo engines? I ask because I've owned 8 TC Harleys and not one of them ever leaked. Does Harley utilize less skilled labor for their Sportster assembly line?

Between these reports of leaks and the gas tanks getting hard-ons, I'm getting nervous pulling the trigger on an XR. (I have until August 24 before I have to commit a deposit to get an order placed for Nov. delivery.)
 
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