GS1000 Rear master leaky banjo bolt ?

[srsupertrap]

I have a persisent small brake fluid leak were the brake fluid bolt connects the Russell brake line to the master cylinder. I discovered this leak a while back and I replaced the two old crush washers with suzuki oem parts and didn't give it another thought. Today while assembling body parts I noticied some brake fluid were my lovely finger is pointing. I already torqued it down pretty good.

Any suggestions or has someone had the same problem?

[hikermikem]

Are there crush washers on both sides of that banjo bolt?? Can't really see the bottom one...

I've been using the 3/8" copper crush washers from Z1. They come in a 10 pack & they're pretty cheap.

They are a little bigger than OEM & seal well. Perhaps the face of the offending banjo has a small nick on it??

[srsupertrap]

You are right the pics isn't too good but yes there are crush washers on both sides of that banjo bolt. I think the leak is occurring at the bottom washer. Are the Z-1 copper crush washers softer or do they compress easier?

[hikermikem]

I wouldn't say they're softer, just have a larger OD so maybe it covers more of the banjo face. The OEM ones are copper too I believe, just with a coating/plating.

I would think you could get replacement crush washers at a hose shop - the 3/8" ones fit the 10mm bolts just fine.

I see you're from Westminster, my wife is from Lousiville, right next door.

[srsupertrap]

I wouldn't say they're softer, just have a larger OD so maybe it covers more of the banjo face. The OEM ones are copper too I believe, just with a coating/plating.

I would think you could get replacement crush washers at a hose shop - the 3/8" ones fit the 10mm bolts just fine.

I see you're from Westminster, my wife is from Lousiville, right next door.

I am just trying to ensure which ever crush washer I buy cures the leak because this is the second time I have this leak now in less than 6 months. I looked at the bag of suzuki crush washers and I see one side of the crush washer is flat while the other is slightly crowned. Perhaps I have them orientated wrong?

I like Colorado been here a decade so far. I think Money Magazine recently stated Louisville, CO. was one of the 2009 top ten US cities to live in.

[hikermikem]

I am just trying to ensure which ever crush washer I buy cures the leak because this is the second time I have this leak now in less than 6 months. I looked at the bag of suzuki crush washers and I see one side of the crush washer is flat while the other is slightly crowned. Perhaps I have them orientated wrong?

I was going to suggest that as well, take it apart & flip the washer around, but give the face of the banjo a good look for any nicks or dings first. Check the top of the M/C too, it's aluminum & maybe there's a small burr keeping the washer from sealing.

I like Colorado been here a decade so far. I think Money Magazine recently stated Louisville, CO. was one of the 2009 top ten US cities to live in.

I remember Louisville BEFORE the Wal-Mart & the cinema & the Home Depot, etc...

Is the Blue Parrot still there on Main?