2003 XL1200C

Pulled the bike out for the first time this year and did the standard oil/filter change. Nothing different in amount of oil drained from the previous 2 year oil changes. After putting 3 quarts and running about 1 minute, the oil tank built pressure causing the oil cap to fly about 5 feet. The oil tank was suddenly filled to the rim. Drained about 1 quart and started bike and ran for about 30 seconds. I would still need to drain about ˝ quart oil according to dip stick.

Suggestions?

Thanks

 

Check all 3 hoses (feed/return/vent) for a restriction or kink. Then check pressure release check valve, then check oil filter. My guess: you have a blocked or kinked hose. Then check to see if you have an air locked hose. Then check your breather valves in the heads.

From the 05XL SM

ENGINE LUBRICATION SYSTEM 3.6
GENERAL
NOTE
The following paragraph numbers correspond with the numbered
callouts in the Lubrication Diagram foldout.
1. Oil is gravity-fed from the oil tank to the gerotor-style oil
pump through a
feed hose.
Oil enters the
feed section
and fills a cavity located under the feed pump.
NOTE
A complete explanation of the gerotor pump is given under
OIL PUMP, which follows.
2. The feed pump transfers oil from the inlet cavity through
the
feed hose
to the oil filter mount.
3. Oil flows through the
filter mount cavity
to the oil filter.
4. Oil enters the peripheral cavity of the
oil filter,
passes
through the filtering medium into the central cavity of the
oil filter, and flows into the filter adapter (fitting which
connects filter to filter mount).
5. Adequate oil pressure in the filter mount cavity activates
the
oil pressure indicator lamp switch
and shuts off
the oil pressure indicator lamp.
6. Oil flowing from the filter adapter opens the
check ball.
The check ball opens at 4-6 psi (28-41 kN/m
2
) oil pressure.
7. With the check ball open, oil flows into the
crankcase
feed galley.
8. Oil flows through the feed galley in the crankcase to the
tappet blocks and hydraulic lifters.
Cross-drilled passages
intersect the main feed galley and carry oil to
each hydraulic lifter. From this cavity, oil is also fed to the
piston jets.
9. Oil also enters an
intersecting passage
in the gearcase
cover. Oil flow is then routed to the crankshaft area.
10. Oil enters a hole in the end of the
pinion gear shaft
and
travels to the right flywheel where it is routed through the
flywheel to the
crank pin.
Oil is forced through the crank
pin to properly lubricate the rod bearing assembly.
11. Oil flows up passages in the
push rods
to the rocker arm
shafts and bushings.
12. The valve stems are lubricated by oil supplied through
drilled oil holes in the
rocker arms.
13. Oil collected in the push rod areas of the cylinder heads
flows down the
push rod covers,
through drain holes in
the
tappet blocks
and into the gearcase. After providing
lubrication to the gearcase components the oil flows to
the return side of the oil pump.
14. Feed oil to the rocker area is returned to the gearcase
through a
passage
in the head, cylinder and crankcase.
15. Oil collected in the
sump
is splash-fed to the pistons, cylinder
walls and flywheel components.
16. Oil collected in the sump area returns to the scavenge
section of the oil pump through a
passage
located in the
rear section of the sump. Oil flow to the pump is accomplished
by the scavenging effect of the pump and by the
pressure created by the downward stroke of the pistons.
17. Return oil fills a
cavity
above the pump's return gears.
The return gears pump oil back to the oil tank.
18. A small amount of oil flows from the feed galley in the
right crankcase half through a
restricted orifice,
which
sprays the oil onto the rear intake cam gear in the gearcase.
Oil is transferred to the teeth of all the cam gears
through the gear meshing action.
OIL PUMP
See Figure 3-1. The oil pump consists of two gerotor gear
sets, feed and scavenge (return), housed in one pump body.
The feed pump distributes oil to the engine, the scavenge
pump returns oil to the tank.
A gerotor-type gear set has two parts — an inner and an
outer gerotor. The inner gerotor has one less tooth than the
outer gerotor. Both gerotors have fixed centers which are offset
to each other.
In a gerotor gear set, oil is transferred from inlet to outlet as it
is trapped between the rotating inner and outer gerotors. The
illustration shows the principle of gerotor operation:
●
During the first 180 degrees of rotation, the cavity
between inner and outer gerotors gradually increases in
size until it reaches its maximum size, equivalent to the
full volume of the “missing tooth.” The gradually enlarging
cavity creates a vacuum into which oil flows from the
inlet.
●
During the next 180 degrees of rotation, the size of the
cavity decreases forcing oil into the outlet. See Figure 3-
2. Gravity-fed oil from the oil tank enters the pump
through fitting (5). It is forced by gerotor set (6) through a
hose to the oil filter.
Return oil from the flywheel compartment is drawn back
into the pump. Returning oil from the gearcase compartment
drains directly into the pump and is forced by gerotor
set (8) back to the oil tank.
See Lubrication Diagram foldout for oil passages within the

 

There is a 2005 XL service manual on pdf here

http://www.sendspace.com/file/h952ae