I have oil leakage problems on my 2000 model XT600e and I hope somebody can help to find the source and suggest a way to fix them. I can share the following information:

Oil temperature
The air temperature is high 30's and while riding the bike, the oil sits between 120 & 130 degrees. At 135 degrees I stop riding and let the bike cool down. I tested the temperature gauge in boiling water at boiling point and beyond, the gauge reads 100 degrees. I'm not sure if the high oil temperate has anything to do with the oil leaks.

Oil pressure
Oil flows out at a steady rate when the bolt at the top of the oil filter housing is removed and the bike is running, so I believe the oil pressure is good.

Oil level
The oil is filled as discussed in the forum here: http://www.horizonsunlimited.com/hub...il-level-26197. At 40 degrees the oil level sits at the ‘empty’ mark. At 60 degrees it sits between ‘empty’ and ‘full’. At 80 degrees the oil level reads ‘full’. A very small amount of oil is pushed to the air box and there is no oil in the plastic resivour tube at the back of the airbox.

Oil leak
When I put the bike on the side-stand after riding, oil drips from the bike. The oil covers everything on the 'intake' side of the motor from top to bottom (carb, starter motor, coil, etc.) So I believe the source of the problem could be somewhere at the top. I attach some photos with this.

I cannot see any oil leaking from the frame / tank running over the top of the motor so believe the oil must be pushed out by the motor.
I replaced the O-ring in the tappet cover and put liquid gasket around the outside. I've also put liquid gasket on the seam where the two sections of cylinder head meet.

Can anybody help please?

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With that much leak i think its the gasket seal of the head cover, check the O rings in the front and back.


http://www.horizonsunlimited.com/hub...-problem-71852

You mention a bit of oil in the air cleaner. Have you checked the vent line from atop the engine? Maybe it is split and oil leaking from that. An over full condition may cause this or crankcase pressure from worn rings pushing out oil.

Thank you for the suggestions.
I thought the vent line from the motor to the air filter box was part of the problem so I checked it this afternoon for blockages / wear but it's good. There's no problem with that line.

Be sure to let us know what you figure out, and you will!!

Why don't you degrease the engine & dry it off.
Fit a longer temporary fuel hose to the fuel tank so you can sit the fuel tank on the frame where the seat normally goes(on top of the air box).
With the bike on the side stand run the engine and adjust the idle speed to approx 3000 rpm.
Then look to see where the oil starts to appear from.

Bob

__________________
Remember that Assumption is the mother of all f**k-ups.

Thanks for the tips and suggestions. Oil leak problems were a worn o-ring at the starter motor and a missing bolt at the engine head.
All replaced now and running perfectly without any oil leaks.