Oil leakage, from the cooler lines?

[Mudflaps]

Just picked up a bike (03 800S) and looks like its leaking oil from the oil cooler lines. Just wondering if there is anything that the manufacturer recommends for sealing the fittings where it feeds into the motor. Oil was leaking pretty bad, getting on the back tire. Im assuming it came from the lines (looks to be the culprit), but I figure Ill re-seal these and then look elsewhere.

Thanks in advance.

[ducpainter]

The cooler fittings are AN style and have a sealing washer between the fitting and the case.  The seal to the line is a flare and shouldn't require any sealer.

First thing you should do is to clean the area and let it dry. Spray with aerosol foot powder and it will pinpoint the leak.

Then we'll know what to suggest.

[ducpainter]

Older bikes, like my '97 M900, definitely used AN6 fittings that are used with aluminum sealing washers.

I believe that the newer bikes, perhaps including his '03 bike, have a different style fitting that are sealed with a small o-ring.

If the threads on the fitting or the O-ring has been damaged, that might account for the leak.

I checked on the fiche and you're right.

His bike uses a sealing washer between the fitting and the case and each line has 2 orings at each end, similar to an AC line...part number 886.5.015.1A O-Ring...total of 8/bike.

To the OP...if you tighten the lines at the cooler make sure to use 2 wrenches or you'll twist the fitting off the cooler itself.

[avizpls]

dont we have a good picture of what happens when you DONT do that here somewhere?

[BK_856er]

dont we have a good picture of what happens when you DONT do that here somewhere?

Yep, that would be me.  Don't do like I did.  It's not pretty.  

BK

(found the pic in my folder of shame...)

[BK_856er]

Back to cooler line fitting leaks...I was sure I had one immediately after retrofitting my monster with an oil cooler...turns out by coincidence a leak started from the layshaft seal.  The footpowder trick revealed the true source.  Oil would leak down and collect around the fitting, when I thought the wind was blowing it upward at speed.

BK

After some miles:


And some miles later:

[BK_856er]

And to fill out the answers to the original quesiton, in addition to the sealing (crush) washer and little o-rings, the manual calls for medium-strength heat/oil resistant thread compound on the adapter piece that screws into the block.  The fitting that screws into that part, and the o-rings, only get a smear of oil.  Be very careful not to tear the little o-rings when inserting the line.

Verify the source of your leak before you go taking things apart.  One member cracked his block unscrewing the cooler fitting.  That will spoil your day for sure, and how ironic it would be if the leak was actually elsewhere.

BK

[uclabiker06]

for what its worth I thought my oil cooler was leaking but it turned out to be the anti dirt gunk that I sprayed into the air filter (which is foam).  I sprayed a lot in there so it leaked down to my oil cooler.  So if you have foam filter that might be it .

[Mudflaps]

Well, as a response, I took the bike to the dealer. It was indeed leaking from one of the oil cooler lines. They replaced crush washers on both lines. Additionally, there was leakage from the drivers side (left side if you are sitting on the bike), it was leaking from an o ring under that side of the engine cover. The oring was simply not even there.

[ducpainter]

Last guy to service the bike left the inspection cover o-ring out.   

Hope it wasn't you.

[Mudflaps]

Was not me, Ive owned it for about, ummm, 7 days?