Brake issues (Not the FJR)

[Canadian FJR]

After completely rebuilding the brakes on my TL I installed new steel braided brake lines. I cannot get

master cylinder banjo bolt to seal properly. I tried three different types of new washers and it still

leaks.

The only thing different from the original set-up is that I now have a two line race set-up so a double

banjo at the master cylinder.

At wits end over this, any suggestions would be greatly appreciated.

Canadian FJR

 

[BkerChuck]

You are using washer/brake line/washer/brake line/washer? I've seen folks try to run the 2 brake lines next to each other without the sealing washer between them. Not trying to insult your intelligence.

On the banjo bolt, is it steel or aluminum? I've seen a few aluminum banjo bolts over-tightened. I know some of the race kits come with them.You mention trying different washers have you tried a different banjo bolt?

 

[Fred W]

^ this is what came to my mind as well.. Need a soft washer between the two brake lines, as well as at each end.

 

[Canadian FJR]

Yep

MC washer banjo washer banjo washer bolt

As mentioned, I tried three different types of washers.

I think that my problem is I need a longer bolt. It is a double banjo bolt but I can only get around 4 threads and am nervous to tighten too much with risk of stripping the threads. I need 36 mm long.

Canadian FJR

 

[ionbeam]

...I think that my problem is I need a longer bolt. It is a double banjo bolt but I can only get around 4 threads and am nervous to tighten too much with risk of stripping the threads...

And there is the rest of the story. Low torque = leak.

 

[rickysnickers]

Nice to see another TL rider around,

 

[BkerChuck]

Insufficient torque it's definitely gonna leak! Most folks don't realize the amount of pressure a mc generates with that small volume we're dealing with.

 

[Canadian FJR]

"Nice to see another TL rider around"

Yep, I picked up a 97 S model as a winter project to sell this spring but things kinda got out of hand. I ended up liking it too much and spent way too much money on it. It makes a great play bike.

Canadian FJR

 

[rickysnickers]

"Nice to see another TL rider around"
Yep, I picked up a 97 S model as a winter project to sell this spring but things kinda got out of hand. I ended up liking it too much and spent way too much money on it. It makes a great play bike.

Canadian FJR

If you haven't already, check out TL Planet and TL Zone. Lots of good info there.