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#146528 - 12/02/19 10:08 PM 03 XT225 Oil Leak
quaziau Offline
Junior Member

Registered: 12/02/19
Posts: 7
Loc: GA
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

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#146531 - 12/03/19 11:49 AM Re: 03 XT225 Oil Leak [Re: quaziau]
#brer15 Offline
Bronze Member
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Registered: 10/03/16
Posts: 595
Loc: Atlanta,GA
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.

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#146532 - 12/03/19 11:59 AM Re: 03 XT225 Oil Leak [Re: quaziau]
#brer15 Offline
Bronze Member
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Registered: 10/03/16
Posts: 595
Loc: Atlanta,GA
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.


Edited by #brer15 (12/03/19 11:59 AM)
_________________________
2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.

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#146533 - 12/03/19 12:16 PM Re: 03 XT225 Oil Leak [Re: quaziau]
Paul49 Offline
Platinum Member
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Registered: 07/22/11
Posts: 1768
Loc: High Peak, UK
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.

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#146534 - 12/03/19 02:03 PM Re: 03 XT225 Oil Leak [Re: quaziau]
Az4x4 Offline
Platinum Member
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Registered: 08/18/08
Posts: 4351
Loc: Heber/Overgaard, AZ

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..
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Lovin' life in Arizona's Mogollon Rim Mountain Country!!

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#146535 - 12/03/19 02:18 PM Re: 03 XT225 Oil Leak [Re: Paul49]
quaziau Offline
Junior Member

Registered: 12/02/19
Posts: 7
Loc: GA
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

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#146536 - 12/03/19 02:42 PM Re: 03 XT225 Oil Leak [Re: quaziau]
Paul49 Offline
Platinum Member
*****

Registered: 07/22/11
Posts: 1768
Loc: High Peak, UK
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.

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#146537 - 12/03/19 03:00 PM Re: 03 XT225 Oil Leak [Re: quaziau]
quaziau Offline
Junior Member

Registered: 12/02/19
Posts: 7
Loc: GA
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?
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2003 XT225

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#146538 - 12/03/19 03:21 PM Re: 03 XT225 Oil Leak [Re: quaziau]
Muniac Offline


Platinum Member
*****

Registered: 01/16/04
Posts: 5848
Loc: Montrose, CO
There are three bolts on that cover. One passes through an O-ring in the engine case. Which two did you break off?
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Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#146539 - 12/03/19 03:27 PM Re: 03 XT225 Oil Leak [Re: quaziau]
quaziau Offline
Junior Member

Registered: 12/02/19
Posts: 7
Loc: GA
The two on top
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2003 XT225

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