"let the oil set u free" banjo upgrade - 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 61 Old 04-21-2020, 09:11 PM
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Many thanks to PD and Tom. I just couldn’t get it through my noggin. If someone told me to drill through the first hole and keep going through the other side I would have understood. I know cross drilled is a simple term to most and much easier than the other two terms you mentioned.

I looked at the inter webs and only saw pictures of 4 holes 90 degrees to another. However I thought it best to ask the experts on this forum. Thanks for not being condescending in your answers. You guys are the best!
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post #42 of 61 Old 04-22-2020, 06:16 AM Thread Starter
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my apologies as some have been confused by my pictures. i should have said i was doing the complete banjo replacement not the drill mod. thanx guys for stepping in and clarifying. i will get better or be corrected. (one or the other)soon to come will oil filter cap control orifice mod
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post #43 of 61 Old 04-23-2020, 10:38 PM
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Location: TX Hill Country
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So I just completed a ride today that has put almost 500 miles on since I drilled the banjos. Before I ride, I always fill to the top of the sight glass. Picture is no oil added after 500. Rpm range was mostly between 5-6k. 2 up for a chunk of it. This is a big win in my book. Seriously appreciate the parties that figured this out!

I would have had to top it off twice before, this bike being the typical over 4k oil burn. I'm keeping track of the miles till it hits the normal fill line.

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Sounds like a lawnmower, Rides like a paint shaker!

I got 99 problems but fuel injection, 6th gear or a 2nd cylinder ain't 1!

My wife: "I didn't know if that was you coming home, or a neighbor mowing"
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post #44 of 61 Old 04-24-2020, 09:36 AM Thread Starter
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cool beans
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post #45 of 61 Old 04-27-2020, 06:59 PM
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Location: Victoria, Australia
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I did the Banjo's on the weekend. Just waiting for the exhaust gasket so I can put it back together.
Installed the T-handle mixture screw while I had the starter out, saved having to rotate the carb as far.
Somehow even reading this thread several times it did not register in my head until I took the first banjo out that the std banjo's are radially drilled not cross drilled.
Thanks Maveric for the write-up.
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post #46 of 61 Old 05-15-2020, 10:44 PM
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Location: TX Hill Country
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Just a follow up, I've put about 800 miles since the mod and some of that at upper limits of speed (75-90mph +/- 200 miles). I've put maybe 3.5 ounces of oil to top it back to my original starting level - top of sight glass window.

Sounds like a lawnmower, Rides like a paint shaker!

I got 99 problems but fuel injection, 6th gear or a 2nd cylinder ain't 1!

My wife: "I didn't know if that was you coming home, or a neighbor mowing"
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post #47 of 61 Old 05-16-2020, 12:52 AM
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Join Date: Jul 2018
Location: Carlton OR
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I also finished the second part of the oil mods, with the 3 banjo bolts and the brass orifice in the oil port of the right case done. The bike is running, doesn't leak, all parts are back where they belong, didn't break off the tap in the oil passage, and no chips got away, so I am happy.

My oil burn was fine before, so it was mostly a case of tinkeritis.

That said, this was my first time looking behind the clutch cover. Found the missing part of the doohickey coil spring in the oil screen, but no other metal in there. I also found a compromised water pump oil seal, where the coil spring was partially dislodged. This might explain why the oil analysis a while ago was a bit high on sodium. However, despite the compromised seal, I had no noticeable loss of fluids.
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2006 KLR650 - 40,000+ miles

Last edited by chrider; 05-16-2020 at 04:47 PM. Reason: better terminology :)
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post #48 of 61 Old 05-16-2020, 11:52 AM
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Location: Lander, Wyoming
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Quote:
Originally Posted by chrider View Post
I also finished the second part of the oil mods, with the 3 banjo bolts and the brass plug in the oil port of the right case done. The bike is running, doesn't leak, all parts are back where they belong, didn't break off the tap in the oil passage, and no chips got away, so I am happy.

My oil burn was fine before, so it was mostly a case of tinkeritis.

That said, this was my first time looking behind the clutch cover. Found the missing part of the doohickey coil spring in the oil screen, but no other metal in there. I also found a compromised water pump oil seal, where the coil spring was partially dislodged. This might explain why the oil analysis a while ago was a bit high on sodium. However, despite the compromised seal, I had no noticeable loss of fluids.
I really hate to hear the crankshaft oil control Orifice to be referred to as a 'plug'. You really should use proper terminology to reduce the possible confusion of future readers. (Could you edit? "Brass Orifice")

As to the water pump shaft oil seal, it keeps the oil in the engine. The mechanical water seal keeps the coolant in the cooling system.
There is a passageway (weep hole) between the outer mechanical coolant seal and the inner oil seal to ALLOW either fluid to leak onto the skid plate to get the owners attention and keep the two fluids from being able to contaminate each other.

A few less knowledgeable owners over the years have sealed the weep holes with epoxy glue, thinking they might stop a leak. But that is one of the few things that can cause the two fluids to mix.

Some engine oils simply have more sodium in them. Did you refill the engine oil with the same brand?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #49 of 61 Old 05-16-2020, 05:18 PM
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Thanks for pointing out the bad choice of words. It's corrected now, referring to the orifice instead.

The weep hole was not obstructed, and I've never seen oil come out of there, so the compromised oil seal must have still been doing its job of keeping oil contained.
As to engine oil, I've been using the same oil for oil changes and topping off in-between.
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2006 KLR650 - 40,000+ miles
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post #50 of 61 Old 05-21-2020, 08:14 AM
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Join Date: Jul 2017
Location: Chesapeake, VA
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Does anyone know the donor motorcycle for the replacement banjo bolts? I'm trying to order from Rocky Mountain but I can only look up parts by motorcycle, not part number. I can find them by part number on partszilla but I'm already ordering other stuff from RMAVTMC so I'm trying to save on shipping.

Thanks,
Jeff
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