Stripped threads top oil banjo

[Bjorn]

" one step forward, two steps back"

The saying is real, the bike that keeps on giving lol.

I was finally rebuilding the bike after some ignition failure, i noticed the top banjo of the oil feed line was wheeping a bit so I decided to replace the copper rings.

Placed new rings, pulled out the torque wrench but never made it to "the click"....... Pulled the aluminium threads right out of the head (great).

How it looks now...

How it should look


Hopefully I can repair this in the frame. Really don't want to pull the engine.

 

[Its been a long time]

Looks like maybe a longer banjo bolt might fix it?

 

[Bjorn]

yeah there is like 5mm of thread left. But i dont know if that is sufficient. Ill look into finding longer banjo bolts. Have also ordered a Helicoil set.

 

[Its been a long time]

yeah there is like 5mm of thread left. But i dont know if that is sufficient. Ill look into finding longer banjo bolts. Have also ordered a Helicoil set.

OK. Only 5mm. That's not really enough on a 8mm (10mm?) banjo bolt. What a shame that happened.

 

[Signal]

I dont think you have anything to loose by trying a longer bolt. If you get through the summer riding its a win, and you can carry out a proper fix if needed over the winter.

 

[Bjorn]

Thanks signal, i can sometimes get lost in doing it perfect. I looked into this option and found an longer banjo bolt in the "parts bin". I reduced the overal length so it would engage every bit of thread left in the head without protruding so much it won't seal the banjo.

I got smaller diameter copper rings to increase the surface load and hopefully seal at a lower torque. Also annealed them to make them even softer.

Mounting worked without stripping the last threads! Hopefully it's oil tight.