"let the oil set u free" banjo upgrade - 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 #1 of 61 Old 03-16-2020, 04:25 PM Thread Starter
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being a student of souperdoo and paul, i wanted to contribute my 2 cents. anything to make the klr more efficient is always in my wheelhouse. the studies, experiments that tom and paul have done are amazing. these guys have gone way above the call of duty in making the klr a true, economical winner. so my banjo fitting upgrade comes right from souper doo and pauls playbook. i tweak it with pictures. you can modify stock banjos ( 3 ea) or do the no brainer and get the replacement with the larger holes. i chose the later. here is the part numbers you will need(got mine from revzilla)

1. remove side panels, seat, and tank,/shrouds.(ims guys remove tank)
should look this

2. disconnect battery

3. remove header pipe

4. loosen carb clamps and tilt so starter will clear.
5. remove + and - wires from starter. use a air lance and blow out and dirt below starter.
6. remove starter holddown bolts (2 ea)
7. pull, wiggle starter out of housing and pull straight back
should look like this

(inspect pinion gear for trash/wear)

Last edited by maverick9611; 03-16-2020 at 05:04 PM.
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post #2 of 61 Old 03-16-2020, 04:37 PM Thread Starter
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part duex
stuff a clean rag paper towel into starter housing. clean case of all the nasty dirt that your starter was hiding.
clean, stuff a rag in here

clean case

once clean, remove your first bango that was blocked by starter (14 mm)
im reusing my banjo washers
notice difference in holes

reinstall with 12mm socket
tighten to 15 ft ftbs/180 in/lbs. dont forget washer on new banjo.
here is locations and part numbers to use/locate
*note* these are replacement kawi banjos
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Last edited by maverick9611; 03-16-2020 at 06:00 PM.
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post #3 of 61 Old 03-16-2020, 04:47 PM Thread Starter
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part 3
next location is up top

word of caution! this banjo is vertical! put rags underneath to catch inner washer when you pull banjo out it will fall. this is why you shoved a rag in the starter housing!
reinstall same as b4 12mm socket, 15 ft ftbs or 180 inlbs.
remove front sprocket cover
clean it, since you have it off.

follow oil tube and you will find banjo. remove and replace. this banjo uses a 14mm socket! same torque

Last edited by maverick9611; 03-16-2020 at 05:00 PM.
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post #4 of 61 Old 03-16-2020, 04:55 PM Thread Starter
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part 4

leave front sprocket cover off so ya can check for oil leaks.
reinstall starter. i use a touch of vaseline on the oring. once seated , bolt it back up 78inlbs.
install your starter +& - cables.
straighten carb and tighten clamps.
reinstall header pipe
reconnect battery
install tank and or shrouds for stock peeps
install seat/sidepanels
start up bike and check for leaks (use a flashlight)
if good, reinstall sprocket cover.
job done. bout 3 hours 😎
your top end just thanked you!
my source
https://www.souperdoo.com/stuff%20th...ht-oil-burning
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post #5 of 61 Old 03-16-2020, 05:40 PM
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Nicely done and documented!

Thanks!

Tom [email protected]

“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #6 of 61 Old 03-16-2020, 05:51 PM Thread Starter
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no thank you for doing all the legwork 👏
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post #7 of 61 Old 03-16-2020, 11:05 PM
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Thanks for posting this. Now I have no excuse anymore not to do this. Should I anticipate any problems removing an exhaust header that hasn't been touched in 14 years? And will I need new exhaust gaskets?

-------------------------------
2006 KLR650 - 40,000+ miles
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post #8 of 61 Old 03-17-2020, 01:11 AM Thread Starter
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its tight, i run a leo vince muffler,so i cannot say if you have to remove stock muffler. i left the leo in place and just loosened the midpipe clamp. it came out with some wiggles. i would get a new header gasket if its that old. good luck😎
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post #9 of 61 Old 03-17-2020, 10:19 AM
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Quote:
Originally Posted by chrider View Post
Thanks for posting this. Now I have no excuse anymore not to do this. Should I anticipate any problems removing an exhaust header that hasn't been touched in 14 years? And will I need new exhaust gaskets?
The oval exhaust head pipe gasket is intended to be a 'One Time Use' gasket. Use a smear of grease on the flat side to hold it in place & put a little anti-sieze grease on the stud threads.
And one should re-torque the mounting flange nuts after the second ride & cool down cycle.

Maverick did not mention whether or not he annealed the copper banjo bolt gaskets? They really should be annealed to re-soften & clean the copper for an oil tight seal.
I suspend all 6 on a wire and heat with propane torch till red and jiggle them off the wire individually into a cup of water. I'm frugal and 6 New copper gaskets are pricey for their size.
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 61 Old 03-17-2020, 10:27 AM Thread Starter
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unfortunately i did not do this. thanx for bringing it up. i should have known😭
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