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Title: XL250SA Casting flaw?
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bsamat
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From: United Kingdom
Registered: 02/15/2009
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(Date Posted:11/02/2009 04:59:21)

My recently acquired 1980 XL250SA had a persistent oil leak from the cylinder head. On investigation, it seems the oil is coming from the front right of the head, from the tunnel that the long cylinder head bolt goes down. There appears to be a large gap in this tunnel which connects directly with the atmosphere... tell me this can't be right?! Is this a casting flaw, or is there a sleeve or something missing? You can see a DPO has tried to bodge up something before; the bolt has been shortened and the thread re-cut. I can't find a spare head, so repair seems to be the answer. Has anyone ever had this problem before?

many thanks,

Mat

English Phil
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From: United Kingdom
Registered:05/16/2007
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RE:XL250SA Casting flaw?
(Date Posted:11/02/2009 07:34:44)

Sorry, not familier with the xl250sa, but have a look at http://www.cmsnl.com/honda-xl250s-81-us_model7692/partslist/  The diagrams may shed some light on your problem.
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bsamat
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From: United Kingdom
Registered:02/15/2009
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RE:XL250SA Casting flaw?
(Date Posted:11/03/2009 00:43:22)

What a brilliant link thank you very much. I think I may see if I can get the bolt tunnel sleeved... it just can't be right as it is.
350s
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Re:XL250SA Casting flaw?
(Date Posted:11/03/2009 21:02:52)

Check the threads in case. Maybe the bolt was/is loose. There should be no hole going inside so shouldn't be oil to get out. Washer has to seal under bolt head. I'm not sure but I'm thinking some of those did have a hole to outside and would get packed with fine dirt. With my memory, it could be the "old" 250's that had that flaw. Pat Orman. 
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