PDWestman oil mods to my 08 burner testing - Page 5 - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #41 of 51 Old 01-06-2020, 12:58 AM Thread Starter
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post #42 of 51 Old 01-06-2020, 09:12 AM
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if ive done the 692 kit and oil burning is gone. should i still do the banjo and oil filter oil mods also?
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post #43 of 51 Old 01-06-2020, 11:29 AM
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Originally Posted by maverick9611 View Post
if ive done the 692 kit and oil burning is gone. should i still do the banjo and oil filter oil mods also?
I'd say no. Those mods are designed to move oil from the crank/conrod/piston, where it can't be controlled by the poor OEM rings and the two few/too small oil return holes in the OEM piston, over to the transmission/cams. The idea is that there is more than enough oil thrown up onto the piston and cylinder to do the job, so stealing some and sending it over to the trans/cams leaves enough oil behind on the cylinder walls to do the job, but it is an amount of oil that the OEM rings/piston can handle.

If your 692's rings are controlling the oil well then there is no reason to get after any mods to help them control the oil that they are already controlling well.

Well, that was a mouthful.

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post #44 of 51 Old 01-06-2020, 11:32 AM
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thanx tom
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post #45 of 51 Old 01-06-2020, 12:27 PM Thread Starter
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I know I’m going to leave the mods in place after the 685.
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post #46 of 51 Old 01-06-2020, 01:12 PM
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if ive done the 692 kit and oil burning is gone. should i still do the banjo and oil filter oil mods also?
maverick9611,
I'll suggest that you may perform all or part of the oil control mods. Specifically the 1st banjo bolt by the starter motor.
Better yet, the 1st banjo bolt & the cylinder head banjo bolt. Or even better yet, all 3 banjo bolts.

IMO, the more oil flow thru the others parts of the KLR engine the better. Kawasaki did it themselves, on the KLX250's / 300's & 650's. The only Kawasaki models to ever us the tiny holed banjo bolts were the KLR250, 600 & 650 plus the KSF250 atv which was based on the KLR250 engine.

Or 3 banjo bolts & a #40 / 2.49mm / .098inch crankshaft oil control orifice in the oil Filter cap, for simplicity.
I've tested clear down to #46 / 2.06mm / .081inch crankshaft oil control orifice. (My 3000 mile oil change [BSL #4] wear metals were still less ppm per 1k traveled than the Blackstone UA's with 2100 mile average oil changes.)


How tight is the case around the outer steel end cap of your oil filter cavity? Maybe reduce the height of that ledge from the oil inlet port at 5:00 upto the 2:00 area by about 1mm?

Or if you are up to it the 100% oil filtration is pretty simple to do if the clutch cover is ever off.

And at least lapping the cold oil Pressure Relief Valve is not hard to do. One can simply use the existing spring, like Kawasaki still does in the KLX series. up thru 2013 at least (16130-1001)
I see a new part number for the newer 2104+ KLX250's, part #16130-0002. I wonder if it has a lower set point or better sealing?

Thanks for the vote of confidence, PT-13Pilot. KLRChris also used the 4 basic oil control mods on his 60HP 685 engine.

pdwestman
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Last edited by pdwestman; 01-06-2020 at 01:20 PM. Reason: thru 2013 KLX250 series
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post #47 of 51 Old 01-06-2020, 01:15 PM
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what are the banjo part #'s again?
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post #48 of 51 Old 01-06-2020, 01:17 PM
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drats, i recently had clutch cover off recently doing upgraded clutch springs
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post #49 of 51 Old 01-06-2020, 01:24 PM
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The best write up is on souperdoo.com. https://www.souperdoo.com/stuff%20th...ht-oil-burning

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Modify at "YOUR OWN RISK"!

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post #50 of 51 Old 01-06-2020, 01:25 PM
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The best write up is on souperdoo.com. https://www.souperdoo.com/stuff%20th...ht-oil-burning
yup readin it right now😎
i have banjo part #'s

Last edited by maverick9611; 01-06-2020 at 01:51 PM.
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