Leaky Front Banjo

[hampshirehog]

The sealing washers are plenty soft to begin with and should not be heated.

I disagree - I haven't seen decent copper on just about anything for 20 years. Proper copper (excuse the rhyming) should be real soft and go green (cuprous) on contact with air moisture in no time. The only green copper you see now is on old cathedrals or gents urinals.

What passes as copper nowadays is full of impurities and has lost a lot of its physical properties. That bit of heat can make a world of difference.

[Nessism]

I disagree - I haven't seen decent copper on just about anything for 20 years. Proper copper (excuse the rhyming) should be real soft and go green (cuprous) on contact with air moisture in no time. The only green copper you see now is on old cathedrals or gents urinals.

What passes as copper nowadays is full of impurities and has lost a lot of its physical properties. That bit of heat can make a world of difference.

Banjo washers are often times aluminum, and the copper ones are typically plated so they don't turn green. I haven't looked closely at the stock Suzuki washers but I know they are silver colored thus are not pure copper.

[anikmankar]

Washers

The washers I have are from Bikebandit. They are silver in color and pretty soft to begin with. Let me try the annealing process and see if it works.

any comments on the washers with o-rings...

http://www.truechoice.com/prodinfo.asp?number=ERL 1781

Before these I tried using the Aluminium washers they also worked...Have these on the other side - no leaks. I have run out of those hence using the bike bandit ones.

[KTA]

The amount of effort you've needed to exert to fix this problem seems very over characteristic. If I was you I would stop messing around with my existing parts which must be damaged in some way. I would go on ebay and find a nice replacement unit. Bolt on the new caliper and hose and be done with it. Save your existing setup for parts.