Oil Line from Crank Case to Cylinder Head - Kawasaki KLR 650 Forum
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  • 2 Post By Bluehighways
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post #1 of 6 Old 06-02-2017, 08:32 PM Thread Starter
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Oil Line from Crank Case to Cylinder Head

Hi All,

New to this forum and looking for some help with my 2008 klr.

Theres a steel line that goes from the crank case to the cylinder head connected at both ends with banjo bolts. Yesterday I started the bike and oil shot out of the top of the line through a pin hole right below the banjo at the top of the line. The line looks like its in great shape otherwise which leads me to believe this hole is supposed to be there but probably covered up. I can't find any diagram in any manual that shows the line with any sort of clip or cover on it so I'm not really sure.

Anyone have this issue or any ideas on parts?

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post #2 of 6 Old 06-02-2017, 10:50 PM
2nd Gear
Join Date: Mar 2017
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It sounds like the weld (braze more likely) has a defect. You might see if there is a shop local to you that can re-braze it for you.

Also, really, really, really closely check both the inside and the outside copper washers that seal the Banjo Bolt and the Oil Line to the Cylinder Head. Sometimes leaks like this can be very deceiving in their origin. A pin hole can be squirting an extremely thin stream that when it hits something nearby it spatters. The spattering doesn't have to be dramatic, it's just what is most visible. The thin stream can be very difficult to see all by its lonesome. Furthermore it can easily be obscured by the spattering. The result is that it (falsely), looks like the leak, is where the spattering is occurring. If you can clean the area spotless with brake clean, carburetor cleaner, etc. and (this is actually quite important) while you are watching it intently with a bright light (even in daylight), have someone else start the bike.

If these are not options that are available to you; I've got a good Oil Line you can have for $10 + Shipping.

Last edited by Bluehighways; 06-03-2017 at 04:32 PM.
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post #3 of 6 Old 06-03-2017, 11:35 AM
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I am with Bluehighways on this. A leak at the crush washers is more likely. Try cleaning and inspecting. An eighth turn on the bolt might help. Don't force it. Just snug. New crush washers might help.

If you determine it is in the line, a muffler or radiator shop should be able to fix it easily.
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post #4 of 6 Old 06-03-2017, 05:50 PM Thread Starter
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Thanks, its actually just coming right out of the line, the leak is about an inch or so below the banjo bolt. I can see it clearly.

Think theres any harm in a quick JB weld?
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post #5 of 6 Old 06-03-2017, 05:58 PM
3rd Gear
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It might hold if absolutely clean and scuffed to roughen the surface to get a good bond but I wouldn't trust it more than a few miles from home. The engines life blood is under pressure in that line.
I'd take the prior offer for $10 plus shipping.

2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
1983 GL1100 Goldwing
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post #6 of 6 Old 06-03-2017, 06:21 PM
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Do an eBay search for <KLR 650 Oil Line> and then sort low price to high. There's lots of them available for between $10 and $15 with free shipping and they include the three Banjo Bolts. That is how I wound up with an extra Oil Line. I bought a set just for the Bolts. I wanted to modify the oil flow to the Head and the Transmission by doing the Bolt Modification/Drilling that many recommend. I also wanted to keep the original Banjo Bolts in case I didn't like the results. This modification, by the way, works like a charm. But I'll still keep the original Banjo Bolts. LOL

I'd definitely NOT try and use JB Weld or similar on that Oil Line. I'd be concerned that enough might just find its way through the hole in the line and partially block the oil supply to the Head. Do that and the repair to the damage to the Camshaft Bearings from oil starvation can get extremely expensive!
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Last edited by Bluehighways; 06-03-2017 at 06:26 PM.
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