Oil Leak on 2023 RTL caused by oil filter cap O-ring...

[Jetfixer]

A friend brought over his 2023 RTL to have me look for the source of his oil leak. He had noticed some oil drops on his garage floor. What with him riding the Spyder, and oil covering a lot of the engine and lower side of the bike, I knew it wouldn't be easy. I started by removing all of the right side bodywork. Then proceeded to wipe up the many small puddles of oil, and finally after cleaning the whole right side of the engine, I let it sit for 2 hours. No oil, so it's not a static leak. I started the engine, and within 30 seconds had a small puddle forming under the engine. It took a mirror and flashlight to find that the oil was leaking out of the oil filter cap and running down. After wiping it all down again, I removed the oil filter cap. The large o-ring was fine, however, the bottom o-ring on the filter cap stick was cut and rolled up and half out of it's groove. A simple o-ring replacement and no more oil leak! The owner had done his own oil change. I believe he got the o-rings mixed up because the damaged one was thicker than the correct one. Also, he said he'd had trouble getting the stick and filter cap to line up and go in. I believe he went in crooked and forced it, thereby cutting and rolling the o-ring. A word of advice, if you're going to do your own oil change, pay attention when you swap out the o-rings and match up the correct new one as you go. Do not force the filter cap assembly. It can be tricky to get it lined up right, but when you do it should drop right down to the top threaded area. If you have to force it, it's not right.

 

[Snowbelt Spyder]

Well, if he used a non-BRP/XPS oil change kit, where all of the O-rings in his were black and he got them mixed up, then there's also an incorrect one on the Engine Drain Plug. The thin one that was supposed to be on the filter stick. One that's too thin for the drain plug.

 

[JayBros]

FWIW, when I do my oil changes I have a document at hand that I put together from the parts manual and a picture of the canister and its three O-rings along with the wrench sizes and torque specs for everything that must be removed and reinstalled, crank case and clutch cover plugs included. One at a time on the oil filter canister and cap assembly I replace those two small O-rings on the lower cap staff after verifying the part numbers from the manual with those on the plastic bags containing the respective O-rings. Additionally, I lubricate all three O-rings with fresh oil before installing them.

 

[TheMariner]

Hmmmm... Unless the rolled-up o-ring on the bottom of the stem prevented the oil filter cap from being screwed down all the way, the large o-ring under the cap should have prevented oil escaping. Did you notice if the oil filter cap was down tight before you removed it?

 

[Mrmikey]

I don't like tightening the cap, I'm always scared of cracking the housing yet don't want to have a leak. To me it feels like a very chintzy design.
Having a thought here, anyone think there'd be an advantage to putting a hose clamp around the top of the housing to add a bit of support to the circumference of it? And no, I don't use a 24" power bar to tighten it.

 

[blacklightning]

I used to get in trouble all the time when working on my cars, trucks, etc. as a youth. My uncle used to laugh and say I was too "cock strong". Since then I have purchased many tools, and the go to ones for me are the short handle ratchets and wrenches. I hardly ever use a torque wrench, I just use the short tools and remember what my uncle used to tell me.

 

[jjc54]

I always lube the threads of the cap with white lithium grease as plastic threads tend to grab when dry. I then torque at half torque first and check with the thinnest feeler gauge to make sure the mating surfaces are touching. I then torque to the low end of the specs. I then run it before I button it backup to check for seeping.

 

[Mikey]

I just did my first oil change on the 2025 and I can say you have to pay close attention to the O-rings and their different sizes in the same areas, it would be easy to get them mixed up! And of course, in my book, a little oil before you install would go a long way!!