where does it go - Kawasaki KLR 650 Forum
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Old 03-02-2017, 04:12 PM Thread Starter
1st Gear
 
Join Date: Feb 2017
Location: Round Rock, TX
Posts: 55
where does it go

I am wrapping up a project and discovered one very important looking bolt left over. It is a 12 mm bolt that is hollow in the center and has a hole on one side near the top. It is the type of bolt you find anchoring the oil pipe in a banjo fitting. The only such bolt I can recall removing was the one that attaches the oil pipe to the back side of the head, and it is there. I have had the cover off that exposes the doohickey. I have had the head and the cylinder off. Those are the places I have been. I can see nothing in my Clymers manual that seems to indicate such a bolt in any of these places. Can anybody tell where this bold might have come from?
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Old 03-02-2017, 04:19 PM
2nd Gear
 
Join Date: Aug 2016
Location: Reno, NV
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Called a Banjo bolt I believe. It is for one of your hard oil lines.
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Old 03-02-2017, 04:20 PM
2nd Gear
 
Join Date: Aug 2016
Location: Reno, NV
Posts: 118
VERY IMPORTANT that you didn't use a standard bolt in it's place on an oil line. DO NOT START YOUR BIKE UNTIL YOU FIND OUT!!!!!!!!!!!!!!!
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Old 03-02-2017, 04:24 PM
2nd Gear
 
Join Date: Aug 2016
Location: Reno, NV
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I didn't read your whole message.... Guess you already knew it was a Banjo bolt. My bad..

I think that there's one around the rear of the side cover that's over the doohickey. It's right around the chain drive sprocket.
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Old 03-02-2017, 04:27 PM
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Location: Kelowna, B.C.
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Also used on the brake systems.....

Dave
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Old 03-02-2017, 07:56 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,702
madmotorcyclist,
There are 3 identical banjo bolts used on the KLR650 oil pipe.
1st one by the starter motor, oil inlet to the pipe.
2nd one to the cylinder head, to feed the cams.
3rd one is above the engine sprocket, under the plastic sprocket cover.

They are 'black'ish, 14mm head size, 10 x 1.25p and have a single tiny little 1/16th inch diameter feed hole.
Which I will strongly urge you to drill to a full 1/8th inch. Especially the inlet banjo by the starter motor, drill 1/8th inch clear thru both sides. Let some oil into that pipe!
One can also drill 1/8th inch clear thru both sides for the cams.
I personally only drill one side of the banjo bolt for the transmission.

One can read about the PDW oil mods over here,
http://www.klrforum.com/1987-2007-wr...mportance.html


So did you have the oil pipe completely off of the bike?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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Old 03-02-2017, 08:26 PM Thread Starter
1st Gear
 
Join Date: Feb 2017
Location: Round Rock, TX
Posts: 55
No, I never had the oil pipe off the bike. I had the bolt out of the one on the back side of the head. I just checked and all the three banjo bolts you mention are in place. The bolt I am referring to is only a 12 mm. I don't recall any banjo bolts in the interior of the engine, at least not where I was working. And, it is not one of the three you mention related to the oil pipe. Any other suggestions?
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Old 03-02-2017, 08:36 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,702
Do you mean 12mm bolt size or 12mm hex head size?
Is it black anodized or shiney?
What is the hole size thru the side? 1 hole or 2?
Did you purchase a basket case or did you take it apart?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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Old 03-02-2017, 08:48 PM Thread Starter
1st Gear
 
Join Date: Feb 2017
Location: Round Rock, TX
Posts: 55
The hex head size is 12mm. I am not astute enough to tell you the size of the hole, I just know that one hole goes a little beyond the length of the threads. There is a space from the threads to the collar of the bolt and there is a hole near the top side that intersects it. I have no way of measuring the size of the holes. And no, the bike was not a basket case. I am simply adding one of Eagle Mikes oversize pistons. A wire the size of a coat hanger slips in and out of both holes easily.
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Old 03-02-2017, 08:50 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,702
Quote:
Originally Posted by madmotorcyclist View Post
No, I never had the oil pipe off the bike. I had the bolt out of the one on the back side of the head. I just checked and all the three banjo bolts you mention are in place. The bolt I am referring to is only a 12 mm. I don't recall any banjo bolts in the interior of the engine, at least not where I was working. And, it is not one of the three you mention related to the oil pipe. Any other suggestions?
I looked at your earlier postings, found that you took it apart.

Is there any chance that you ordered one of the KLX650 or KLF300 banjo bolts that I have suggested be used in my oil flow modifications? 12mm head size, 10mm x 1.25p thread size.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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