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This is a combination of two posts from Phaedrus' website on FEED LINES and RETURN LINES.

Re-posted by permission. ~Joe

Installing the Cylinder Head Oil Cooling Return Lines

One of the main differences between the XR1200 and other Sportsters (or Harleys for that matter) is the oil cooling lines to the heads. These oil lines run up to the heads on the right (throttle body) side of the engine, and exit from the heads on the left (spark plug) side of the heads. The oil return lines need to be inserted into the heads as the heads are being lowered into place on the cylinders. The oil feed lines are installed after the head is torgued down. (And, it is easier to install the throttle body before the oil feed lines are attached.)


Prepping the Fittings



The fittings for the oil return lines have o-rings inserted in a groove within the fittings. The o-rings are hard to see without a light, but they can be removed with a scribe or pointed tool, and replaced using a small pair of needle nosed pliers. I replaced these rings to help prevent later oil leaks at these fittings. These o-rings should be liberally oiled to let the oil lines slip into them without distorting or tearing them.


Replacing Oil O-Ring


Here is the front oil return line. The front line is a metal tube. In order to install (and remove) the head, there is a nut at the base of the V of the cylinders that needs to be removed. Once this is unbolted, the tube can be eased slightly out to the side of the engine to let the tube be flexed as it is inserted or removed from the head.


Front Hard Line


The rear return oil line is a little easier to work with. It is rubber and can be flexed. While it still needs to be inserted before the head is lowered into place, it can be a little easier to align. Obviously, the hose end and fitting need to be oiled to let it insert easily.

Rear Return Line



Once the return oil lines are inserted into the heads and the heads positioned, one can move on to torquing down the heads.


The feed lines for the cooling oil to the heads enters each head just in front of the throttle body flanges. The oil feed lines are connected after the heads are torqued down and the intake manifold is installed.


With the heads torqued down, it can be easier to install the throttle body before installing the rockers arms. The extra clearance is pretty nice to have.




Installing the Oil Feed Lines for the Head Cooling


The feed lines for the cooling oil to the heads enter each head just in front of the throttle body flanges. The feed lines are connected after the heads are torqued down and the intake manifold is installed.




These fittings screw into the heads and then a compression fitting on each hose attaches to them. HD only calls for an o-ring on each fitting. I replaced the o-rings, but also added a layer of teflon tape to the fittings. The o-rings get oiled lightly to keep them from distorting as the fittings are torqued down.

Installing the Oil Fitting


And then the compression fittings on each braided oil line are tightened onto the fittings in the heads. Spec is 13-17 ft-lbs.


Lines in Place




As you can see in the above picture, in order to be able to position the intake manifold against the heads, the cooling oil feed lines to the heads should be installed after the heads are torqued and the throttle body is bolted in place.



 
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