Oil Cooler - 2001 xj600s leaking oil cooler line

[psa666]

Hi, I have read several posts from people with this same problem, one of my oil cooler lines is leaking from the middle at the connection to the small rubber hose. I would like to know if it would be ok to cut the metal pipe either side of the rubber hose and then fit a slightly longer rubber hose secured with a jubilee clip at either end. If you think this would be ok does anyone know the size of the hose needed to connect to the oil pipe? Also i have read threads of people doing away with the oil cooler is this possible with a 2001 xj600s? Thanks Paul:(

[Padster]

It would be fine to do as you suggest as the oil isn't under great pressure. I only did the repair on my 900 so you would have to measure the distance you need on your bike. The internal diameter needed for the hose on my 900 was 10mm. Braided hose is cheap enough to make it worth doing yourself. You can get some quite smart jubilee clip fixing end pieces.

[reborn]

Been there.



Not pretty. Then again neither is the rest of the bike.

[psa666]

Thanks Reborn, your photos show exactly what i plan to do, just a couple of questions before i tackle the job, do you know the size of the hose i will need? and is it possible to do it without removing the down pipes? Sorry bit of a novice but am very grateful for any advice i can get. Thanks Paul

[reborn]

As padster said the internal diameter needs to be 10mm. ( I tried with 8mm first )

My headers aren't standard but I can't see it being necessary to remove yours.
Do each pipe seperately. I would recommend taking the complete pipe off, finding the leak and as long as it isn't too close to the bottom fixing, cut the pipe leaving a good sized stub at the bottom and then above the flexible section. From the pic, you can see I cut them in such a way as the pipe goes naturally into the centre away from the exhaust pipes.
When you do the left pipe, have the bike on the side stand then on main to do the right one. That should minimise oil loss. (Don't forget to put down a drip tray) Take out the one 5mm bolt holding the flexible sections. The bottom fixings are a little fiddly but should come off with a little patience (make sure you tap the allen key well into the head of the bolt to stop rounding)
Then remove the banjo bolt on the cooler. Do the cutting and fix a length of pipe to the bottom piece. Refit both end pieces. Cut the new hose to right length to fit onto the top piece of pipe. Do the same on the other side. Put back the retaining clamp and bolt in the middle and the jobs a carrot.



Just an after thought.... buy enough hose to easily do both. Even if you only do the one thats leaking now, I can guarantee the other one wont be far behind.

[bobh]

DEFINITELY remove the pipe to go the job. It must be thoroughly cleaned out after cutting, otherwise you risk getting nasty bits of steel in your bearings.

[teejayexc]

And make sure you have a tight hold of the nut on top of the cooler whilst you undo the banjo bolt...they have a nasty habit of cracking around where the nut is affixed to the cooler

[psa666]

Hi Guys, Just to let you know i did the repair to my oil lines today and it worked a treat, did both while i was at it even though only one was leaking. Thanks for all your advice it saved me a bundle by doing the job myself.

[pilgrim]

Good result, well done.

I'll look to do that with mine if the problem arises.

;D

[humphreysj1]

This morning I took my 1995 XJ 900 diversion to Pirtek in Milton Keynes and had them refurb both oil lines, this was done quickly and did not cost an arm and a leg. Very pleasant and efficient people, I recommend Pirtek for this type of repair to everyone. Just google for your nearest repair centre.

[shu2b]

Went to Pirtek cost £20 to £30 per pipe a lot cheaper than new pipes
that's for sure

But not as cheap as the illistration above done by Reborn.

That's the way I went total cost for pipe and clips £8.00 "easy" Thanks for tip reborn

[bobbertandsammy]

Just wanted to say Hi and thanks for this thread, just saved me a fortune.

[m40man]

Excellent - welcome aboard :-)

[andymanhole780]

Hi

I have this problem too. Does mine look bad enough to do the mod? It is only in the joining bit. Nowhere else. The radiator is in very good condition and under the bike is too. It's just the joining bit as shown in the picture.


I'm not loosing oil but it must have in the past as there is dirty dusty oil sediment on it.

Can they be welded?

Attachments:

[eliminator]

There's a lot to be said for preventive maintenance. I painted these bits with black hammerite a couple of years ago.

Hmm, must go and do my FJ sooner rather than later, the set up is the same.

[columbus]

Hi, Thanks for taking the time to post this very useful and money saving thread. I also have a leak on my 600 Diversion and have just ordered some braided hose and jubilee clips. Cheers, Andy