Search

GREAT RIDES & STAYS!
Fab Ads
Previous Thread
Next Thread
Print Thread
Rate Thread
Page 1 of 3 1 2 3
03 XT225 Oil Leak #146528 12/02/19 10:08 PM
Joined: Dec 2019
Posts: 39
Q
quaziau Offline OP
Junior Member
OP Offline
Junior Member
Q
Joined: Dec 2019
Posts: 39
I picked up the bike just over a week ago and have been playing triage ever since for a repair list/order.

I am leaking fuel from the carb, so the carb rebuild is on top of the list.
At the same time, the petcock needs to be replaced as the lever was broken off at some point and the prior owner used vice grips to shut the fuel off.

Meanwhile, I have a pretty interesting oil leak. It only leaks when the oil/bike is hot. Best I can tell, its leaking around bolts in a couple places. I've read that there are a handful of O rings on this bike that just...fail, and I'm hoping its that easy. Any idea what may cause leaks at the bolts in these pictures?








2003 XT225
Re: 03 XT225 Oil Leak [Re: quaziau] #146531 12/03/19 11:49 AM
Joined: Oct 2016
Posts: 619
#brer15 Offline
Silver Member
*****
Offline
Silver Member
*****
Joined: Oct 2016
Posts: 619
It's generally easiest to trace the source of an oil leak by cleaning everything up, then riding (or sometimes just idling) the bike as normal. Then inspecting for leaks early on.
parts fince
But in this case I think it is almost certain you will just need to replace part# 93210-25711-00 (ref.#3 in the diagram). Almost certainly where the oil is coming from in the first pic, but also a good chance it is responsible for all the oil your seeing.

On another note I would suggest not doing any work on the bike until (or unless you have) acquired a service manual.


2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.
Re: 03 XT225 Oil Leak [Re: quaziau] #146532 12/03/19 11:59 AM
Joined: Oct 2016
Posts: 619
#brer15 Offline
Silver Member
*****
Offline
Silver Member
*****
Joined: Oct 2016
Posts: 619
Also on the petcock issue. The plastic knob can be replaced by it's self, if that is the part that broke. And if it doesn't go on due to tool damage from the vice grips, you should be able to file the damage out, so the knob would fit.

Last edited by #brer15; 12/03/19 11:59 AM.

2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.
Re: 03 XT225 Oil Leak [Re: quaziau] #146533 12/03/19 12:16 PM
Joined: Jul 2011
Posts: 1,814
Paul49 Offline
Platinum Member
*****
Offline
Platinum Member
*****
Joined: Jul 2011
Posts: 1,814
By 'eck worra orribull filthy bike. Poor wee thing needs some love.

Like brer says, when it's clean be able to see where the oil leaks from without all that crud soaking it up.


1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, Tiger 800 XRx.
Re: 03 XT225 Oil Leak [Re: quaziau] #146534 12/03/19 02:03 PM
Joined: Aug 2008
Posts: 4,421
Az4x4 Offline
Platinum Member
*****
Offline
Platinum Member
*****
Joined: Aug 2008
Posts: 4,421

Originally Posted By: quaziau
.....Meanwhile, I have a pretty interesting oil leak. It only leaks when the oil/bike is hot. Best I can tell, its leaking around bolts in a couple places...

Like the guys said, you need to clean the bike thoroughly to accurately locate the source of the leak. Brer is likely right with his suggestion for where the leak is and how to remedy it. Get the bike up on a stand and power wash it clean. That'll give you a more accurate view of what you're dealing with..


"Never let your sense of morals get in the way of doing what's right." Isaac Asimov
Re: 03 XT225 Oil Leak [Re: Paul49] #146535 12/03/19 02:18 PM
Joined: Dec 2019
Posts: 39
Q
quaziau Offline OP
Junior Member
OP Offline
Junior Member
Q
Joined: Dec 2019
Posts: 39
Originally Posted By: #brer15
Also on the petcock issue. The plastic knob can be replaced by it's self, if that is the part that broke. And if it doesn't go on due to tool damage from the vice grips, you should be able to file the damage out, so the knob would fit.

Thats about the best possible news I could hope for. I do not have a service manual and have had some trouble finding one. I've already learned (and am still in the process of learning) an extremely difficult lesson about the dangers of over torqueing the bolts on the oil filter cap.

The petcock has been so abused over time that it rotates 360 degrees. It was a cheap enough part that simply replacing it is probably a good idea in general.

Originally Posted By: Paul49
By 'eck worra orribull filthy bike. Poor wee thing needs some love.

Yes it does. Its in pretty bad shape. It only has 5,000 miles on it, but looks like 10-12 times that. I swapped the air filter and changed the oil, and I've never seen filthier filters before in my life.
This is my todo list so far:
- Rebuild carb (fuel leaking from Pilot screw)
- Replace starter motor O Ring (as per this post)
- Replace broken (cracked open)speedo with Vapor Speedo/Tach
- Replace petcock
- Replace/rewire taillight (green wire is not connected, all wires to light are electrical taped together)
- Retrofit a lower profile replacement for the rear light/plate holder (existing one is snapped in half just below the light and the housing is dangerously loose)
- Replace blinkers w/ LED and resistors(both on right side are cracked open)
- Replace headlight (light itself is cracked and the bulb is not at all bright enough)
- Replace front brake lever (existing lever is broken and 80% of the lever is MIA)
- Replace clutch lever and clutch pearl
- Swap stock handlebar for high rise bars
- Replace mirrors
- New plastics
- DMO oversized pegs


2003 XT225
Re: 03 XT225 Oil Leak [Re: quaziau] #146536 12/03/19 02:42 PM
Joined: Jul 2011
Posts: 1,814
Paul49 Offline
Platinum Member
*****
Offline
Platinum Member
*****
Joined: Jul 2011
Posts: 1,814
Crickey. bit of graft to do there, keep ya going over the winter months. Be like a new'n come summer. Great guys on here if ya need any help. Best tip I've found is, run it dry after every ride, it always starts fine next time then.

We have to take care with them filter screws or it's a big repair job aint it. My way is a 4" driver to tighten, then I know they'll always come undone with a 10" driver. Torque reaction I call it, long screwdrivers undo tight stuff.


1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, Tiger 800 XRx.
Re: 03 XT225 Oil Leak [Re: quaziau] #146537 12/03/19 03:00 PM
Joined: Dec 2019
Posts: 39
Q
quaziau Offline OP
Junior Member
OP Offline
Junior Member
Q
Joined: Dec 2019
Posts: 39
I actually broke both of the bolts while torqueing them down. Any tips on removing broken bolts, one of which is so deep you can't even see it?


2003 XT225
Re: 03 XT225 Oil Leak [Re: quaziau] #146538 12/03/19 03:21 PM
Joined: Jan 2004
Posts: 5,887
Muniac Offline
Platinum Member
*****
Offline
Platinum Member
*****
Joined: Jan 2004
Posts: 5,887
There are three bolts on that cover. One passes through an O-ring in the engine case. Which two did you break off?


Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video
Re: 03 XT225 Oil Leak [Re: quaziau] #146539 12/03/19 03:27 PM
Joined: Dec 2019
Posts: 39
Q
quaziau Offline OP
Junior Member
OP Offline
Junior Member
Q
Joined: Dec 2019
Posts: 39
The two on top


2003 XT225
Page 1 of 3 1 2 3

Web & Site Search
Google
 
Custom TO Customer
Specialty Resource
Fab Ads
Boardcaster Updates

Board Upgrade: Board upgrade to V7.7.3 has been completed on Monday Feb 3rd 2020. Ride safely. Enjoy the new software!

Who's Online Now
0 registered members (), 47 guests, and 3 spiders.
Key: Admin, Global Mod, Mod
ShoutChat Box
Comment Guidelines: Do post respectful and insightful comments. Don't flame, hate, spam.
Top Posters(All Time)
Reggie 11,645
alexd 5,915
Muniac 5,887
Moto Psycho 4,684
Az4x4 4,421
peejman 3,336
kris 2,366
Paul49 1,814
Doc250 1,643
JerryH 1,522
Forum Statistics
Forums38
Topics16,003
Posts143,492
Members5,376
Most Online279
Dec 6th, 2019
Newest Members
NoBs, indigoer, Woodythedon, Peter UK, type918
5376 Registered Users
February
S M T W T F S
1
2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26 27 28 29
Powered by UBB.threads™ PHP Forum Software 7.7.3
(Release build 20190728)
PHP: 7.3.14 Page Time: 0.014s Queries: 16 (0.004s) Memory: 2.9043 MB (Peak: 3.0970 MB) Data Comp: Off Server Time: 2020-02-17 12:21:01 UTC
Valid HTML 5 and Valid CSS