My 12 year old Bandit 1200, despite having only 11k miles on the clock, has developed some small oil leaks in the factory oil lines, both on the cam feed, and on the cooler lines. The leaks happened in the factory crimped seal, which were lose and actually swiveled.
Since new OEM lines cost an arm and a leg, I decided to make my own, with Russell Performance AN braided hose and fittings. Unfortunately, Suzuki uses odd fittings on the valve covers and on the cooler. I had two options:
Have a machine shop make me some new fittings tapped for the AN, or tap the existing fittings.
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| OEM lines with crimped seals |
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| Hard lines cut off at fittings |
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| Fittings with line drilled out. Hole drilled at 27/64 for a 12mm tap |
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| Tapped valve cover connector |
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| Tapped sump connector |
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| I also drilled and tapped the cooler, so I can run AN hose there |
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| Replacing OEM banjos with Russell 16mm x 1.5 to AN-6 adapters |
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| 12mm x 1.5 to AN-6 adapter in the cooler |
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| Adapters and hose ends in the OEM fittings |
I plan to use thread sealant and copper (or aluminum) crush washers under the adapters. Next, I'll be finishing this setup and making four hoses to connect everything. That will be part 2.
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