What a day...

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Feb 4, 2012 | 03:34 PM

FL-kruzen

Thread Starter

Road Master

Joined: Oct 2011

Posts: 1,221

Likes: 17

From: West Palm Beach, FL

What a day...

When I changed my lower fork tubes a couple of weeks ago, I noted the front forks wouldn't hold air. So I changed the "O" seals on the Banjo fittings on top of the forks. It still didn't hold air. So today, I take the banjo bolts out and take it to my local HD stealer and they don't sale replacements. It comes in a kit...that includes the two banjo fitting the 3-way connector and new air hose for $72.00! So I get new hose line and when I get home, I freaken lost the banjo bolt! How can this happen!

I said the hell with it and went to Ace hardware and bought two 71/6 x 1" stainless bolts and just plugged the holes. Oh, while I was at it I replaced the front brake pads. Got new brake pads from ebay for $ 18.00 for all four in Kevlar. Harley wanted $42.00 a pair. I least I did get an hour ride in this afternoon. It's always something. Does anyone have one of those banjo bolts laying around they might want to part with?

Mar 31, 2012 | 01:02 AM

C.H.L.

Road Warrior

Joined: Feb 2010

Posts: 1,953

Likes: 28

From: Houston, TX

Banjo Bolts just suck - haha

Hope you turned out ok. I installed a stage 1 screamin eagle air filter kit on my road king today, and I miss read the instructions. It says tighten the banjo head bolts to 120 inch pounds..... I set up my torque wrench on foot pounds. - pulled the head threads out with the bolt.... jeez!!!!!

Like you, i put a 3/8 longer bolt in and said to heck with it. I really don't see the point in the banjo bolt for my application anyway.... check out the video I made, I just don't see what it is doing.

http://www.youtube.com/watch?v=MuKVexRoM9E

Mar 31, 2012 | 01:08 AM

mkguitar

Extreme HDF Member

Joined: Sep 2010

Posts: 14,744

Likes: 402

From: Phoenix '53, '88, '09 Big Twins

Quote:

Originally Posted by C.H.L.

i put a 3/8 longer bolt in and said to heck with it. I really don't see the point in the banjo bolt for my application anyway....

...to release breather pressure from the heads.

you are asking for trouble if you try running your bike like this.

looking at your video:

from the area between the 2 seals, is a passage running toward the throttle body throat ( by your left thumb at the beginning of the video, and on the backside you can see the casting where the passage runs)

so the piston goes down into the case-either on the intake or power stroke, as it goes down it pushes air and oil up to the heads.

there is an umbrella valve ( one way valve) in the heads which helps to separate most of the oil from the mist, but the air mist that exits the valve, goes into that banjo bolt, then thru the backplate to the intake where it is burned.

If a solid bolt is put in the head the pressure will find a way out, maybe pushing a gasket or seal out in front of it

-----------

you gotta fix it right, maybe a helicoil in the head

-----------------

a torque wrench that goes past 40 ft pounds is not going to be used often on your bike--- and with experience, you will notice that steel bolts into aluminum are not torqued very tightly.

Mike

Last edited by mkguitar; Mar 31, 2012 at 02:15 AM.

Mar 31, 2012 | 02:02 AM

DOMAPOI

Stellar HDF Member

Joined: Feb 2011

Posts: 3,335

Likes: 27

From: San Diego, CA

Definitely got to fix it! Yes, a helicoil is the answer or replace that part of the head that the threads were ripped out of. Your head has to breath or that pressure will go back into the case and up the other head which will probably cause it to blow more oil from the head that is still vented. Either that or if you know someone that has good machining skills he can turn that new longer bold into a banjo bolt.

Mar 31, 2012 | 07:28 AM

C.H.L.

Road Warrior

Joined: Feb 2010

Posts: 1,953

Likes: 28

From: Houston, TX

Thanks guys. Looks like I'll try to get a half inch longer banjo bolt to just go into the threads that are back there. But if not, I will do a helicoil.

Thanks!!!!!!!!!!!

Mar 31, 2012 | 08:09 AM

C.H.L.

Road Warrior

Joined: Feb 2010

Posts: 1,953

Likes: 28

From: Houston, TX

Ok Guys,

I'm going to use a helicoil today. That is also what my father-in-law suggested, right off the bat.

One last question, I have this stock black bracket over the head threads.... I've seen it removed on some applications..... Should I remove my black bracket for the regular Stage One Screaming Eagle Air Kit I'm putting on????

THANKS GUYS!!!!!!!!!!!!!!!!!!!

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