| PART NUMBER | TOOL NAME |
| HD-41675 | OIL PRESSURE SENDING UNIT WRENCH |
| HD-96921-125 | OIL PRESSURE GAUGE ADAPTER |
| HD-96921-52D | OIL PRESSURE TEST GAUGE KIT |
| HD-96925-58 | OIL PRESSURE GAUGE ADAPTER |
1. Fill oil tank to proper level. See 1.6 ENGINE OIL AND FILTER.
2. Slide a catch pan under the motorcycle.
3. Obtain OIL PRESSURE TEST GAUGE KIT (Part # HD-96921-52D).
Connecting gauge: XL models
1. See Figure 3-2. Detach wiring from oil pressure indicator lamp switch (2).
Figure 3-2. Oil pressure indicator switch: 1. Oil filter; 2. Indicator switch; 3. Switch connector [120]
2. Using OIL PRESSURE SENDING UNIT WRENCH (Part # HD-41675), remove oil pressure switch.
3. See Figure 3-3. Install OIL PRESSURE GAUGE ADAPTER (Part # HD-96925-58) (2) in oil pressure indicator lamp switch mounting hole. Tighten adapter snugly. DO NOT OVER-TIGHTEN.
Figure 3-3. Oil pressure test gauge set: 1. Gauge; 2. Adapter, pressure switch hole (XL models); 3. Adapter, oil cooler line (XR 1200X); 4. Banjo bolt; 5. Washers (2)
Connecting gauge: XR 1200X
1. See Figure 3-5. Disconnect the quick connect fitting from the inlet side of the oil cooler (4). See 3.12 PRECISION COOLING SYSTEM: XR 1200X, General.
2. Connect OIL PRESSURE GAUGE ADAPTER (Part # HD-96921-125) (5) to the oil hose (6).
3. Connect the other end of the adapter to the oil cooler fitting (4).
Testing pressure
1. See Figure 3-4 or Figure 3-5. Assemble banjo bolt (2), washer (3), OIL PRESSURE GAUGE banjo fitting (1) and second washer onto adapter and tighten snugly.
Figure 3-4. Oil pressure test connections: 1. Oil pressure gauge banjo fitting; 2. Banjo bolt; 3. Washer (2); 4. Adapter; 5. Oil pressure gauge hose
Figure 3-5. Oil pressure test connections: XR 1200X: 1. Oil pressure gauge banjo fitting; 2. Banjo bolt; 3. Washer (2); 4. Oil cooler connector; 5. Adapter; 6. Oil cooler hose fitting
Note. For an accurate reading, engine oil should be at normal operating temperature: 230°F (110°C).
2. Temporarily secure oil pressure gauge and hose to motorcycle frame with cable straps. Verify gauge and hose assembly do not interfere with normal operation. Ride motorcycle until engine reaches normal operating temperature.
3. Check and record the pressure readings at normal idle (approximately 1000 rpm) and again at 2500 rpm. Refer to Table 3-21.
Table 3-21. Oil pressure: at operating temperature
| rpm | XL MODELS* | XR1200X** | ||
| psi | kPa | psi | kPa | |
| 1000 | 7-12 | 43.3-82.7 | 16-20 | 110.3-137.9 |
| 2500 | 10-17 | 68.9-117 | 40-44 | 275.8-303.4 |
* Pressure reading taken at oil pressure switch fitting.
** Pressure reading taken at oil cooler inlet.
Removing gauge: XL models
1. Stop engine. Remove OIL PRESSURE GAUGE assembly from oil pressure indicator lamp switch mounting hole in crankcase. Cut cable straps securing gauge and hose. Remove banjo bolt, gauge assembly, washers and adapter from vehicle.
2. See Figure 3-2. Coat threads of oil pressure switch (2) with LOCTITE 565 PIPE SEALANT with TEFLON. Replace the oil pressure switch. Using OIL PRESSURE SENDING UNIT WRENCH, tighten switch snugly. DO NOT OVERTIGHTEN.
3. Plug in connector [120] (3) by pushing elbow connector straight up onto stud on oil pressure switch.
Removing gauge: XR 1200X
1. Stop engine. Cut cable straps securing gauge and hose. Remove banjo bolt, gauge assembly, washers and adapter from vehicle.
2. Connect oil hose to oil cooler fitting, making sure it is securely latched.
Finalize test
Note. If an appreciable amount of oil leaked out when oil pressure switch was removed, replace with fresh oil.
1. Check oil level in oil tank. See 1.6 ENGINE OIL AND FILTER. Top off oil level if necessary.
2. Start engine. Test oil pressure switch for proper operation. Check for oil leaks.