Sportster Oil Leak
Big Kahuna HDF Member
Joined: Feb 2006
Posts: 23,881
Likes: 34
From: USA
RE: Sportster Oil Leak
ORIGINAL: yarplyXL1200C
I am new here and just recently bought my first Harley, a 2006 XL1200C and am having the same problem. Oil was low, barely above the low fill mark so added just enough to bring it comfortably above low mark yet below mid way. Started leaking at cap. When I checked the oil when hot it was still below the full mark, yet after inspecting and cleaning cap, o-ring and other areas I was still getting "blow by" around the O-ring.
My solution was to get a larger "metric" sized o-ring and replace the original with it. Barely leaks at all now but am worried that back pressure may cause some other problems. Can any here give an opinion on solution or potential problems? Is the cap supposed to be completely sealed or is it designed to "breath" a little?
I am new here and just recently bought my first Harley, a 2006 XL1200C and am having the same problem. Oil was low, barely above the low fill mark so added just enough to bring it comfortably above low mark yet below mid way. Started leaking at cap. When I checked the oil when hot it was still below the full mark, yet after inspecting and cleaning cap, o-ring and other areas I was still getting "blow by" around the O-ring.
My solution was to get a larger "metric" sized o-ring and replace the original with it. Barely leaks at all now but am worried that back pressure may cause some other problems. Can any here give an opinion on solution or potential problems? Is the cap supposed to be completely sealed or is it designed to "breath" a little?
1. Check the oil hot at full operating temp allowing about 4-5 minutes for the oil to return to the tank. If it is overfilled suck some out with a fluid extractor or turkey baster.
2. If that's not it, pull the cover off the oil tank and check the connections on the hoses to the tank (see my explanation of what the hoses are forearlier in this post) make sure they are tight and not leaking.
3. Check each hose to make sure it is not bent or crimped in any way that would obstruct it's flow. Follow each hose all the way to its other end.
If you are still stuck then PM me your email address as I have a service manual for the 2005 XL on CD and can email it to you in .pdf files. It should be pretty much the same as the 2006. Hope this helps. KB
Same Issue
Stage II
Joined: Apr 2013
Posts: 2
Likes: 0
From: mich
tore bike down tank popped at seam poor design new tank has a prv on top thats how it should of been designed in the first place no more oil leak oh common problem from 04 to 06 srotsters
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