front brakes 1981 GS850G leaking

[Guest]

I have rebuilt the calipers and the front master cylinder with a ton of help with the guys on this site, thank you. I am using HEL SS lines and the brakes are working well except that they leak at the crossover. I have used all new crush washers, tried Teflon tape, replaced the HEL bolts with brand new OEM bolts. Should I try aluminum washers ? I have checked all the surfaces and they do not appear to have any pitting etc. Do I need to use a thicker washer as the HEL line ends seem a little narrower than the OEM ends. I did use the "search" function and did find some helpful stuff, but any help would be appreciated. I really want to get this bike on the road.

[Nessism]

You need a crush washer on each side of the banjo, and obviously, the crush washer needs to be the correct diameter for the parts you are using. I don't think washer thickness is the issue but rather how they interface with the parts you are using.

[Zook]

Ensure the banjo bolt isn't bottoming out or it will never seal.
Correct washers-and amount-should do the trick.

[ardbeglily]

thanks

Thanks guys for the replies. I am using copper washers from my local Suzuki dealer. I am uncertain of alternate size washers that might fit better. I will have a look at Z1 etc.

[Nessism]

Thanks guys for the replies. I am using copper washers from my local Suzuki dealer. I am uncertain of alternate size washers that might fit better. I will have a look at Z1 etc.

The washers need to fit tightly on the banjo bolt; the ID of the washer need to nightly match the OD of the banjo bolt. Sounds like you have the wrong washers. The factory crush washers are bright plated copper, not plain copper. Maybe they gave you the wrong ones?